Method for manufacturing a container for consumer goods and container for consumer goods

Abstract

The present invention relates to a method for manufacturing a container for consumer goods, the method comprising: forming a first multilayer (100), the first multilayer comprising a first cellulose-based layer (30) and a first polymer layer (31); folding the first multilayer (100) to form a package (10) comprising a lid portion and a box portion, the box portion and the lid portion being separated by an opening line, the lid portion being hinged to the box portion, the package defining an outer shell for the consumer goods, wherein the first multilayer is folded such that the first polymer layer is provided on the outside of the first cellulose-based layer; forming an outer wrapper (101), the outer wrapper comprising a second cellulose-based layer (40 ) and a second polymer layer (41); - wherein one of the first polymer layer (31) and the second polymer layer (41) is a moisture barrier layer and the other of the first polymer layer (31) and the second polymer layer (41) is a heat sealable layer; - wrapping the package with the outer wrapper (101), the outer wrapper at least partially covering the opening line, wherein the wrapping is performed such that the second polymer layer (41) is provided on the inner side of the second cellulose-based layer (40); - heating the package and the outer wrapper (101) to seal the outer wrapper to the package (10), thereby forming the container.

Description

[0001] The present invention relates to a method of manufacturing a container and a container for consumer products. The container is preferably used to hold elongated objects such as aerosol-generating articles.

[0002] It is known to package cigarettes, and more generally aerosol-generating articles, in cardboard boxes which are overwrapped with a biaxially oriented polypropylene film (BOPP film), in other words, a plastic film. This solution has been the industry standard for decades.

[0003] However, plastic packaging can be harmful to the environment due to the potential for littering, as well as the use of non-renewable resources and potential impact on global warming.

[0004] Therefore, it is desirable to have packaging solutions that contain less plastic than available packaging solutions. At the same time, packaging solutions for aerosol-generating articles preferably provide product protection to prevent moisture absorption or loss. Indeed, excessive or insufficient moisture in an aerosol-generating article may alter the user's smoking experience.

[0005] Furthermore, packaging for aerosol-generating articles is preferably "tamper-evident", ie it is preferably obvious whether the packaging has been opened.

[0006] Therefore, there is a need for a method of manufacturing a container and a container for consumer products, the container being suitable for containing, in particular, an aerosol-generating article, having a reduced plastic content relative to prior art containers. There is also a need for a method of manufacturing a container and a container for consumer products, the container being suitable for containing, in particular, an aerosol-generating article, wherein it is apparent whether the container has been opened.

[0007] According to one aspect, the present invention relates to a method of manufacturing a container for a consumer product. The method may include forming a first multilayer, the first multilayer including a first cellulose-based layer and a first polymer layer. The method may include folding the first multilayer to form a package, the package defining an enclosure for the consumer product, wherein the first multilayer is folded such that the first polymer layer is provided on an outer side of the first cellulose-based layer. The method may include forming an overwrap, the overwrap including a second cellulose-based layer and a second polymer layer. The method may include one of the first polymer layer and the second polymer layer being a moisture barrier layer and the other of the first polymer layer and the second polymer layer being a heat sealable layer. The method may include wrapping the package with the overwrap, wherein the wrapping is performed such that the second polymer layer is provided on an inner side of the second cellulose-based layer. The method may include heating the overwrap to seal the overwrap to the package. In this way, the container is formed.

[0008] To form a container according to the present invention, a first multilayer is formed. The first multilayer comprises a first cellulose-based layer and a first polymer layer. The first cellulose-based layer is a layer comprising a cellulose material. Preferably, the first cellulose-based layer is a paper layer or a paperboard layer, i.e., a layer made of paper or paperboard.

[0009] The first polymer layer is a moisture barrier layer or a heat sealant layer or both.

[0010] For the purposes of the present invention, a moisture barrier layer is a layer having a water vapor or moisture transmission rate (VWTR) of 20 g / (m²) or less per 24 hours at 38 degrees Celsius and 90% relative humidity when measured according to ISO 2528:1995 or ASTM F3299. Preferably, the moisture barrier layer of the container of the present invention has a WVTR of less than 10 g / (m²) per 24 hours at 38 degrees Celsius and 90% relative humidity.

[0011] A heat sealable layer is a layer that can be fused and bonded by a conventional indirect heating device that generates enough heat on at least one film contact surface to conduct to adjacent film contact surfaces and form a bonding interface between the surfaces without losing film integrity. The bonding interface between adjacent layers preferably has sufficient physical strength to withstand the packaging process and subsequent disposal. Heat sealable layers can be designed to meet different expected use conditions, and various heat sealable layer formulations are known in the art and can be used in conjunction with the present invention.

[0012] If the first polymer layer is a sealable layer, it is preferably also a heat sealable layer optimized for bonding to the second polymer layer. If the first polymer material has heat sealant properties, it is preferred that the properties of the first polymer material are such that its heat sealable properties are optimized for bonding to the second polymer layer.

[0013] The heat sealable layer preferably has a melting point of less than 100 degrees Celsius as measured by differential scanning calorimetry (DSC). More preferably, the heat sealable layer preferably has a melting point of less than 80 degrees Celsius as measured by DSC.

[0014] The first polymer layer and the first cellulose-based layer are attached to each other to form the first multilayer. Any technique can be used to attach the first cellulose-based layer and the first polymer layer together, preferably permanently. The first polymer layer can be glued to the surface of the first cellulose-based layer. The first polymer layer can be coated on the surface of the first cellulose-based layer. Preferably, the first polymer layer and the first cellulose-based layer cover the same area. Preferably, the first polymer layer and the first cellulose-based layer have the same dimensions. Preferably, the first polymer layer and the first cellulose-based layer are consistent.

[0015] The first cellulose-based layer and the first polymer layer are preferably permanently attached to each other and they essentially form a “blank.” The blank preferably has a shape that is standard in the industry, for example it forms a rectangular sheet of multilayer material.

[0016] The first multiple layers, such as the blank, are then folded to create the package. The method of folding the blank depends on the desired geometry of the package. For example, the package typically has a parallelepipedal form. Preferably, the blank is folded so that the package is closed, i.e., it defines a completely enclosed interior volume that is isolated from the surrounding environment. The interior volume defined by the package is preferably completely isolated from the exterior. The consumer goods are preferably stored in the interior volume.

[0017] Furthermore, the blank is folded in such a manner that a surface of the first cellulose-based layer defines an inner surface of the package and a surface of the first polymer layer defines an outer surface of the package. Other layers may cover the first cellulose layer or the first polymer layer, but in any case, the first cellulose-based layer is located inner relative to the first polymer layer.

[0018] When closed to form a package defining an internal volume, the first multilayer can control the relative humidity within the internal volume. This occurs when the first polymer layer is a moisture barrier layer. Preferably, the box can be opened and closed, as described in detail below. Preferably, the relative humidity in the internal volume is within a given desired range. The desired range is the optimal relative humidity range for the consumer goods stored in the internal volume. When the package is opened to obtain one or more consumer goods stored in the internal volume, the relative humidity of the internal volume will begin to balance with the external environment and may cause the relative humidity of the internal volume to deviate from the desired range. If the box is closed, the moisture barrier layer can help restore the desired humidity level to within the desired range. This is particularly advantageous when one or more consumer goods remain in the package after opening and closing.

[0019] Preferably, the package comprises a package front wall, a package left side wall, a package right side wall, a package rear wall, a package top wall and a package bottom wall.The package defines an inner surface and an outer surface.

[0020] Preferably, the first cellulose-based layer comprises the inner surface of the package. Preferably, the first polymer layer comprises the outer surface of the package. Preferably, the inner surface of the package is the free surface of the first cellulose-based layer. Preferably, the outer surface of the package is the free surface of the first polymer layer.

[0021] A second multilayer layer is formed that functions as an outer wrapper. The outer wrapper comprises a second cellulose-based layer and a second polymer layer. The second cellulose-based layer is defined in the same way as the first cellulose-based layer, i.e., a layer comprising a cellulose material. Preferably, the second cellulose-based layer is a paper layer or a paperboard layer, i.e., a layer made of paper or paperboard.

[0022] The second polymer layer is a moisture barrier layer or a heat-sealable layer, or both. If the first polymer layer is a moisture barrier layer, the second polymer layer is a heat-sealable layer, or the second polymer layer is both a heat-sealable layer and a moisture barrier layer. If the first polymer layer is a heat-sealable layer, the second polymer layer is a moisture barrier layer, or the second polymer layer is both a moisture barrier layer and a heat-sealable layer. If the first polymer layer is both a heat-sealable layer and a moisture barrier layer, the second polymer layer is a moisture barrier layer or a heat-sealable layer, or both.

[0023] The definitions of the heat sealable layer and the moisture barrier layer are the same as used with respect to the first polymeric layer.

[0024] If the second polymer layer is a heat sealable layer, it is preferably also a heat sealable layer optimized for bonding to the first polymer layer.If the second polymer layer has heat sealant properties, the properties of the second polymer layer are such that the heat sealable properties are optimized for bonding to the first polymer layer.

[0025] The heat sealable layer preferably has a melting point of less than 100 degrees Celsius as measured by differential scanning calorimetry (DSC). More preferably, the heat sealable layer preferably has a melting point of less than 80 degrees Celsius as measured by DSC.

[0026] The second cellulose-based layer and the second polymer layer are permanently attached to each other. They preferably essentially form a "blank." The blank preferably has a standard shape in the industry, for example, it forms a rectangular sheet of multilayer material.

[0027] The second polymer layer and the second cellulose-based layer are attached to each other to form a second multilayer, referred to as an overwrap. Any technique can be used to attach the second cellulose-based layer and the second polymer layer, preferably permanently. The second polymer layer can be glued to the surface of the second cellulose-based layer. The second polymer layer can be coated on the surface of the second cellulose-based layer. Preferably, the second polymer layer and the second cellulose-based layer cover the same area. Preferably, the second polymer layer and the second cellulose-based layer have the same geometric dimensions. Preferably, the second polymer layer and the second cellulose-based layer are identical.

[0028] The second multilayer wraps around the outer surface of the package. Preferably, the second multilayer wrap completely covers the outer surface of the package. Preferably, when the package is wrapped in the outer wrap, no portion of the outer surface of the package is visible from the outside. The wrapping is performed such that the second polymer material is on the inside relative to the second cellulose-based layer, and the second cellulose-based layer is on the outside relative to the second polymer layer. Thus, the second cellulose layer can define an inner surface and an outer surface. The outer surface is preferably free, while the inner surface is covered by the second polymer layer.

[0029] In this way, a wrapped package is formed. Wrapping is preferably performed by folding the outer wrap blank around the package so that the outer wrap covers the entire outer surface of the package. The resulting geometry of the wrapped package is substantially the same as, or very similar to, the geometry of the package. The outer wrap is folded around the package in a manner that creates contact between the walls of the package and the outer wrap. Preferably, the outer wrap contacts all walls of the package. Preferably, the outer wrap contacts the front wall, left side wall, right side wall, rear wall, top wall, and bottom wall of the package.

[0030] Heat is then applied to the package wrapped with the second multilayer. Preferably, the heat is applied from the outside of the wrapped package. Preferably, both heat and pressure are applied to the wrapped package. The heat, pressure, or both seal the second polymer layer to the outer surface of the package, for example, to the first polymer layer. Preferably, the heat applied to the overwrap causes the first or second polymer layer to reach a temperature below 100 degrees Celsius, more preferably below 80 degrees Celsius. Preferably, the pressure applied to the overwrap is between 1 kPa and 100 kPa.

[0031] The material of the second polymer layer or the first polymer layer or both partially melts to seal itself to the package or overwrap.

[0032] After applying heat or pressure or both, a container according to the present invention is formed.The container is a wrapped package after applying heat or pressure or both, so that the outer wrapper is permanently attached to the package.

[0033] After the application of heat or pressure, or both, the overwrap becomes permanently attached to the package and cannot be removed without deforming or damaging the container.

[0034] Preferably, the container includes a front wall, a left side wall, a right side wall, a rear wall, a top wall, and a bottom wall. These walls correspond to the front wall, left side wall, right side wall, rear wall, top wall, and bottom wall of the wrapped package, respectively. The container has an inner surface and an outer surface. The inner surface of the container is the inner surface of the package.

[0035] Preferably, the first cellulose-based layer comprises the inner surface of the container. Preferably, the second cellulose-based layer comprises the outer surface. Preferably, the inner surface of the container is the free surface of the first cellulose-based layer. Preferably, the outer surface of the container is the free surface of the second cellulose-based layer.

[0036] The first polymer layer and the second polymer layer may be formed of the same polymer material. For example, the first polymer layer and the second polymer layer may be formed of a polymer material having both heat-sealing properties and moisture barrier properties.

[0037] The first polymer layer and the second polymer layer can be formed from two different polymer materials. In this way, the heat sealability or moisture barrier properties can be optimized for each layer.

[0038] The first cellulose-based layer and the second cellulose-based layer may be formed of the same cellulose-based material.

[0039] Once wrapped, the outer surface of the container implemented according to the present invention can be printed, embossed, debossed or otherwise decorated with manufacturer or brand logos, trademarks, slogans and other consumer information and indicia. The outer surface of the container is made of a cellulose-based material; printing thereon is easy and can be accomplished according to standard techniques in the art.

[0040] Additionally, other components may be part of a container formed according to the methods of the present invention. For example, the container may include inner packaging for a consumer product, such as an aerosol-generating article. The inner packaging may be located within the packaging. Preferably, the inner packaging is formed from metal foil or metallized paper. The inner packaging material may be formed as a laminate of metallized polyethylene film and a lining material.

[0041] The container according to the present invention has a recyclability that is equal to or better than that of current packaging solutions. Compared to cellulose-based containers wrapped in transparent plastic film, the container of the present invention uses an equal or less amount of plastic and an equal or greater amount of cellulose-based material.

[0042] At the same time, because the second cellulose-based layer substantially forms the outer surface of the container, consumers perceive the container as having increased eco-friendliness. Furthermore, if any markings, such as registered trademarks, are to be provided on the outer surface of the second cellulose-based layer, these markings can still be easily formed according to standard procedures.

[0043] The presence of a layer with moisture barrier properties allows the consumer product to be protected from excessively high or low moisture levels.

[0044] The container according to the present invention is easy to manufacture and does not require any large-scale modification of existing packaging equipment. Specifically, there is essentially no need to modify the folding process for forming a package using the first multi-layer blank or the format of the packaging machine that handles the blank.

[0045] According to another aspect, the present invention relates to a container for consumer goods. The container comprises a package comprising a box portion and a lid portion, the package defining an outer shell for the consumer goods, the lid portion being hinged to the box portion by a hinge line, the box portion and the lid portion being separated by an opening line outside the hinge line, the box portion and the lid portion being formed by folding a first multilayer blank. The first multilayer blank preferably comprises: a first cellulose-based layer. The first multilayer blank preferably comprises: a first polymer layer provided on the outside of the first cellulose-based layer. The container further preferably comprises an outer wrapper wrapped around and sealed on the package and at least partially covering the opening line. The outer wrapper preferably comprises: a second cellulose-based layer. The outer wrapper preferably comprises: a second polymer layer provided on the inside of the second cellulose-based layer. Preferably, one of the first polymer layer and the second polymer layer is a moisture barrier layer and the other of the first polymer layer and the second polymer layer is a heat-sealable layer.

[0046] Preferably, a container for consumer goods includes a lid for easy access to the consumer goods contained within the container. The lid is movable between a closed position and an open position. When the lid is in the closed position, the container defines a closed enclosure for the consumer goods. Furthermore, when the lid is in the open position, the enclosure containing the consumer goods is accessible.

[0047] In known solutions, containers with lids may not provide tamper evidence; in other words, it is difficult to assess when the container was first opened. According to the present invention, the container is formed as detailed in the first aspect of the invention and has the advantages already outlined in the previous aspects. Furthermore, the container of the present invention is tamper-resistant because the outer wrapping must be destroyed in order to open the lid.

[0048] The package is formed by folding a first multi-layer blank. The first multi-layer blank may include an opening line and a hinge line, and is configured such that when the blank is folded to form the package, the package is separated into a lid portion and a box portion by the opening line and the hinge line. Preferably, the hinge line and the opening line are adjacent. Preferably, the opening line and the hinge line form a closed loop on the outer surface of the package. Preferably, the opening line includes a first end and a second end. Preferably, the hinge line includes a first end and a second end. Preferably, the first end of the hinge line contacts (is in contact with) the first end of the opening line. Preferably, the second end of the hinge line contacts the second end of the opening line.

[0049] The opening line can be an opening cut or a first weakening line. The opening cut can be formed by the edge of the cover portion that is enclosed on the box portion. Due to the existence of the outer wrapper that makes the cover portion remain enclosed on the box portion, the cover portion remains tightly closed against the box portion.

[0050] The first line of weakness may be continuous or discontinuous (eg, perforated). Furthermore, the first line of weakness may be formed using any suitable technique or combination of techniques, such as laser cutting or mechanical cutting (eg, die cutting or kiss cutting).

[0051] Preferably, the first multilayer has a total thickness defined by the sum of the thicknesses of the first polymer layer and the first cellulose-based layer. The first line of weakness can have any suitable depth in a direction transverse to the inner and outer surfaces of the first cellulose-based layer and the first polymer layer. Preferably, the first line of weakness has a depth of at least about 90% of the total thickness of the first multilayer. More preferably, the first line of weakness has a depth of about 100% of the total thickness of the first multilayer, i.e., it is a cut. Any suitable percentage of material can remain along the first line of weakness.

[0052] Preferably, the cover portion comprises a cover front wall, a cover left side wall, a cover right side wall, a cover rear wall and a cover top wall. The cover portion has an inner surface and an outer surface.

[0053] Preferably, the box portion comprises a box front wall, a box left wall, a box right wall, a box rear wall and a box top wall. The box portion has an inner surface and an outer surface.

[0054] Preferably, the hinge line is realized on the rear wall of the package. The hinge line divides the rear wall of the package into two parts: the rear wall of the lid portion and the rear wall of the box portion. Preferably, the hinge line is formed parallel to the bottom wall of the package.

[0055] The front wall of the package also preferably comprises a section of an opening line. The opening line divides the front wall of the package into two parts: the front wall of the cover portion and the front wall of the box portion. Preferably, the section of the opening line is realized parallel to the bottom wall of the package.

[0056] The left and right side walls of the package also preferably each include a section of an opening line. Preferably, each opening line section on a side wall connects the hinge line on the rear wall to the opening line section on the front wall of the package. The opening line divides each side wall of the package into two parts: the left (right) side wall of the lid portion and the left (right) side wall of the box portion.

[0057] The opening line on the side wall may form an angle different from 90 degrees with the rear wall. The opening line sections on the right and left side walls of the package are therefore preferably not parallel to the bottom wall of the package. Preferably, the height of the hinge line is different from the height of the opening line section on the front wall of the package.

[0058] When the package is wrapped with an overwrap, which is then heated and sealed to the package, the overwrap becomes an integral part of the package, thereby forming a container of the present invention. The overwrap cannot be separated from the package without damaging the overwrap and the package.

[0059] The outer wrapper at least partially covers the opening line. Preferably, the outer wrapper completely covers the opening line. The outer wrapper preferably covers both the opening line and the hinge line. Therefore, in order to open the lid portion from the box portion and access the consumer goods stored in the enclosure defined by the package, the outer wrapper must be broken because it at least partially covers the opening line. Breaking the outer wrapper is necessary to allow the lid portion to move from the closed position to the open position. The opening line is the edge of the lid portion.

[0060] If the opening line comprises a first line of weakness, upon opening the container both the first line of weakness and the outer wrapper are preferably torn or broken.

[0061] If force is applied to separate the box portion from the lid portion, the outer wrapper is most likely to break near the opening line. The package opens at the opening line. When the outer wrapper is broken, the lid portion can rotate about the hinge line, thereby opening the package. At the beginning of this movement, the lid portion breaks the outer wrapper that at least partially covers the opening line.

[0062] The damage to the outer wrapper will not conceal the fact that the container has been opened at least once since manufacture. Furthermore, the outer wrapper cannot be replaced because it is permanently sealed to the packaging. Thus, a user purchasing a container according to the present invention can be assured that the container has never been opened if they observe that the outer wrapper is intact. Thus, the user can be certain that no one has tampered with the consumer goods contained therein after they were inserted into the packaging.

[0063] Hereinafter, the lid portion which is wrapped by the outer wrapper after being torn open, i.e., after being "opened for the first time", is referred to as the lid of the container, and the box portion which is wrapped by the outer wrapper after being torn open, i.e., after being "opened for the first time", is referred to as the box of the container.

[0064] Preferably, the step of heating the package and the overwrap comprises heating the package and the overwrap while applying pressure to seal the overwrap to the package. Preferably, in order to properly seal the overwrap to the package, both heat and pressure are applied such that the first polymer layer and the second polymer layer bond together.

[0065] Preferably, the method comprises folding the first multilayer to form a package comprising a lid portion and a box portion, the box portion and lid portion being separated by an opening line, the lid portion being hingedly connected to the box portion. Preferably, the method comprises wrapping the box portion and lid portion with an outer wrapper, the outer wrapper at least partially covering the opening line. Preferably, the method comprises heating the wrapped outer wrapper to seal the outer wrapper to the package. Preferably, a package comprising a lid portion and a box portion is achieved, wherein the lid portion and the box portion are separated by an opening line. The advantages of this configuration have been summarized with reference to one aspect of the present invention and will not be repeated here.

[0066] Preferably, the line of opening comprises a first line of weakness.

[0067] Preferably, the method includes the step of completely covering the opening line with an overwrap. The overwrap covers the opening line in all directions of its extension. For example, the opening line extends along the front wall and the left and right sides of the package. The overwrap thus wraps around the package, covering its front wall and the left and right sides. Preferably, the overwrap covers the entire outer surface of the package. This provides better control over the moisture content and structural integrity of the resulting container. Preferably, the step of forming the overwrap includes the step of forming the overwrap to include a third polymer layer.

[0068] More preferably, the first cellulose-based layer defines an inner surface and an outer surface. Preferably, the step of forming the first multilayer comprises: coating the outer surface of the first cellulose-based layer with the first polymer layer. More preferably, the method comprises the step of coating the entire outer surface of the first cellulose-based layer with the first polymer layer. Among the possible techniques for forming a multilayer, wherein the individual layers of the multilayer form a whole, coating is the preferred technique due to its reliability and relative ease of execution. Due to the tensile strength of the first polymer layer, the blank formed from the first multilayer can contain less cellulose-based material than blanks for cigarette packs realized according to the prior art.

[0069] During the coating of the first cellulose-based layer with the material forming the first polymer layer, care is preferably taken to prevent the formation of pinholes and other defects that could adversely affect the moisture barrier properties or heat-sealing properties of the coated material. Defect formation can be minimized by careful selection of the application technique, drying conditions, and the rheology of the applied polymer dispersion. In particular, techniques such as rod coating, slot die coating, and curtain coating allow for the preparation of polymer layers with reduced defects and, therefore, enhanced barrier properties. However, satisfactory coatings can also be applied using printing techniques such as flexographic printing or gravure coating. In the case of the latter technique, the coating is preferably applied in multiple layers until the desired thickness of the first polymer layer is achieved. Indeed, each subsequent layer or step in the printing process allows for the filling of pinhole defects left behind during the previous coating step. The coating made of the first polymer material can be cast from a molten state onto the first cellulose-based layer, such as a paper or paperboard sheet, using techniques well known in the art, such as hot melt coating or extrusion coating. Detailed information on these processes can be found, for example, in “The Definitive Processing Guide and Handbook” Plastics Design Library Editor, 2014, pages 551-554 (https: / / doi.org / 10.1016 / B978-1-4377-3481-2.00047-8).

[0070] Preferably, the step of forming the overwrap includes forming the overwrap including a third polymer layer. Preferably, if the second polymer layer is a heat-sealable layer, the third polymer layer is a moisture barrier layer. Alternatively, if the second polymer layer is a moisture barrier layer, the third polymer layer is a heat-sealable layer. In this way, the moisture barrier properties or attachment between the overwrap and the package are improved because the provision of more than one layer allows for enhanced moisture barrier or sealing properties, or both, by using specialized compositions in each layer between the second and third polymer layers (e.g., one layer between the second and third polymer layers serves as an optimal moisture barrier layer, while another layer between the second and third polymer layers is selected for optimal sealing).

[0071] Preferably, the second cellulose-based layer defines an inner surface and an outer surface, and wherein the first polymer layer is a heat-sealable layer, and forming the overwrap comprises coating the inner surface of the second cellulose-based layer with the second polymer layer. Preferably, forming the overwrap further comprises coating the inner surface of the second polymer layer with a third polymer layer. Thus, when the overwrap is wrapped around the package, the two heat-sealable layers (the third polymer layer and the first polymer layer) are in contact. This optimizes the sealing of the overwrap to the package. Preferably, the coating of the second cellulose-based layer by the second polymer layer is performed according to the preferred characteristics described in conjunction with the coating of the first cellulose-based layer by the first polymer layer.

[0072] Preferably, the method includes folding the first plurality of layers to form a package comprising a lid and a box portion, the box and lid being separated by an opening line, the lid being hingedly connected to the box portion. Preferably, the method includes wrapping the box and lid with an outer wrapper, the outer wrapper at least partially covering the opening line. Preferably, the method includes forming a second line of weakness on a portion of the outer wrapper covering the opening line. More preferably, the method includes opening the lid by tearing or breaking the second line of weakness. To properly open the lid and access the consumer goods stored in the package, the package preferably has an easy opening, allowing the user to open the package without exerting excessive force. Furthermore, since the outer wrapper at least partially covers the opening line, it is preferred that the required tearing or breaking of the outer wrapper is somewhat controlled. To this end, the second line of weakness is formed on the outer wrapper. Preferably, the second line of weakness is formed on the outer surface of the outer wrapper. Preferably, the second line of weakness follows the extension of the opening line. In a front view, the second line of weakness is positioned at the same height as the opening line. In both the left and right views, the second line of weakness is positioned at the same height as the opening line. Thus, when force is applied to the container to open the lid, the force required to break or tear the outer wrapper at the second line of weakness is lower than the force required to break or tear the outer wrapper in the absence of the second line of weakness. Furthermore, the outer wrapper is torn or broken in a controlled manner, improving the aesthetics of the opened container.

[0073] Preferably, the opening line comprises a first line of weakness. More preferably, the method comprises opening the lid by tearing or breaking the opening line and the second line of weakness. If the opening line is a line of weakness, the user breaks or tears both the first line of weakness and the second line of weakness in the same movement.

[0074] Preferably, the second line of weakness can be produced by any suitable partial cutting process of the second cellulose-based layer (i.e., the cutting process cuts less than 100% of the thickness of the second cellulose-based layer or the cutting process cuts less than 100% of the width of the second cellulose-based layer when in the unfolded state). After the partial cutting, the second polymer layer is applied to the second cellulose-based layer.

[0075] This second line of weakness may preferably be produced on the overwrap before the overwrap is wrapped around the package.

[0076] Preferably, the second line of weakness is formed on the second cellulose-based layer before the second cellulose-based layer is coated with the second polymer layer or the third polymer layer. Alternatively, the second line of weakness is formed on the second cellulose-based layer when the second cellulose-based layer has been coated with the second polymer layer or the third polymer layer or both.

[0077] Preferably, the method comprises printing a label relating to the consumer product or the manufacturer of the consumer product on the second cellulose-based layer. More preferably, the method comprises printing a label relating to the consumer product or the manufacturer of the consumer product on the outer surface of the second cellulose-based layer. Preferably, the container defines the outer surface. Preferably, the outer surface of the container is formed by the outer surface of the second cellulose-based layer. Preferably, the outer surface of the container is made of paper or cardboard. Therefore, any label can be printed on this outer surface using standard printing techniques. The printing cannot be easily removed and remains essentially unchanged for a long period of time. This allows, for example, the printing of health warnings on the container without the risk of them being easily removed (the outer wrapper cannot be removed from the packaging after sealing).

[0078] Preferably, the step of forming the first multilayer or forming the overwrap comprises forming a moisture barrier layer from an emulsion or dispersion of a copolymer of styrene and an acrylate and a wax. Preferably, the step of forming the first multilayer or forming the overwrap comprises forming a moisture barrier layer from an emulsion or dispersion of a copolymer of styrene and butadiene and a wax. Preferably, the step of forming the first multilayer or forming the overwrap comprises forming a moisture barrier layer from an emulsion or dispersion of a copolymer of ethylene and vinyl acetate and a wax. Preferably, the step of forming the first multilayer or forming the overwrap comprises forming a moisture barrier layer from an emulsion or dispersion of a copolymer of ethylene and acrylic acid or methacrylic acid and a wax. Preferably, the step of forming the first multilayer or forming the overwrap comprises forming a moisture barrier layer from an emulsion or dispersion of a polymer or copolymer of ethylene and propylene, 1-butene, isobutylene, 1-octene, 1-hexene, norbornene and a wax. Preferably, forming the first multilayer or forming the outer wrapper comprises forming a moisture barrier layer from an emulsion or dispersion of a wax and two or more of the following: a copolymer of styrene and acrylate, a copolymer of styrene and butadiene, a copolymer of ethylene and vinyl acetate, a copolymer of ethylene and acrylic acid or methacrylic acid, a polymer or copolymer of ethylene and propylene, 1-butene, isobutylene, 1-octene, 1-hexene, or norbornene. Preferred waxes are paraffin wax, microcrystalline wax, or hydrocarbon wax. Adding a certain amount of wax to one or more of the polymers or copolymers listed above will reduce the moisture permeability of the polymer or copolymer. This is described in detail, for example, in US 4117199. Examples of these possible compositions can be found, for example, in US 2580050, US 2595911, US 2945398, or EP 0688793.

[0079] Preferably, the wax content is between 5% and 15% by weight relative to the polymer or copolymer. In this way, suitable moisture barrier properties are obtained and a good emulsion is achieved.

[0080] In the case of an extrusion coating method, in which a cellulose-based layer (a first cellulose-based layer, a second cellulose-based layer, or both) is coated with a polymer layer (a first polymer layer, a second polymer layer, or a third polymer layer), a polymer such as low-density polyethylene (LDPE), medium-density polyethylene (MDPE), or high-density polyethylene (HDPE) is preferably used as the material forming the first polymer layer, the second polymer layer, or the third polymer layer. To achieve an overwrap having an acceptable compromise between moisture barrier and heat-sealing properties, the overwrap preferably comprises a multilayer coating comprising layers of LDPE and layers of HDPE. For example, for moisture barrier purposes, a multilayer coating made of 5 grams per square meter (gsm) of LDPE, 10 gsm of HDPE, and 5 gsm of ethylene acrylic acid copolymer as the sealable layer is used to coat the second cellulose-based layer.

[0081] Furthermore, the moisture barrier properties of the HDPE, MDPE or LDPE layer can be increased by blending it with hydrocarbon waxes obtained from gasoline refining.

[0082] As used herein, the definitions of LDPE, MDPE, and HDPE are those according to ASTM D0883-20B (Standard Terminology Relating to Plastics) and are as follows: The density of LDPE is between 0.910 grams per cubic centimeter (g / cm 3 ) to 0.925 grams per cubic centimeter (g / cm 3 ); the density of HDPE is greater than or equal to 0.941 grams per cubic centimeter (g / cm 3 ) or greater; the density of MDPE is between 0.926 grams per cubic centimeter (g / cm 3 ) to 0.940 grams per cubic centimeter (g / cm 3 )between.

[0083] Preferably, the step of forming the first multilayer or forming the outer wrapper comprises forming a heat-sealable layer from an emulsion or dispersion of a copolymer of ethylene. Preferably, the step of forming the first multilayer or forming the outer wrapper comprises forming a heat-sealable layer from an emulsion or dispersion of a copolymer of methacrylic acid. Preferably, the step of forming the first multilayer or forming the outer wrapper comprises forming a heat-sealable layer from an emulsion or dispersion of a copolymer of an ester of acrylic acid or methacrylic acid. Preferably, the step of forming the first multilayer or forming the outer wrapper comprises forming a heat-sealable layer from an emulsion or dispersion of two or more selected from the following: a copolymer of ethylene, a copolymer of methacrylic acid, a copolymer of an ester of acrylic acid or methacrylic acid. Preferred examples of polymers for making the heat-sealable layer include copolymers based on ethylene, such as, but not limited to, copolymers of ethylene with acrylic acid or methacrylic acid or its esters, such as methyl, ethyl, butyl, or ethylhexyl ester of acrylic acid or methacrylic acid. These polymers have desired heat-sealability at the temperature of interest. These polymers are also preferred because they may have high fluidity in a molten state. The flowability of a material can be expressed as the MFI (melt flow index) at 190 degrees Celsius (°C) and an applied force of 2.16 kilograms (kg) (ASTM D1238). Preferred heat-sealable layers have an MFI of 100 g / min or more, more preferably 200 g / min or more. The MFI can indicate the rheological properties of the heat-sealable layer. The higher the MFI, the higher the flowability at a reduced shear rate (in this case, the shear rate is the pressure applied during sealing). This means that in order to achieve a good seal of the overwrap on the package at relatively low pressure, a high MFI is preferred. The lower the applied pressure, the higher the MFI is preferred.

[0084] Preferably, the outer wrapper includes a third polymer layer. More preferably, one of the second and third polymer layers is a heat-sealable layer and the other of the second and third polymer layers is a moisture barrier layer. In this way, each layer between the second and third polymer layers can optimize its properties (e.g., heat sealability or moisture barrier).

[0085] Preferably, the third polymer layer is located on the inside of the second polymer layer. This configuration is preferred when the third polymer layer is a heat-sealable layer and the second polymer layer is a moisture barrier layer. Thus, the two heat-sealable layers: the first polymer layer and the third polymer layer are in contact with each other and a good seal can be achieved when heat, pressure, or both are applied to the outer wrap of the wrapped package.

[0086] Preferably, the overwrap comprises a second line of weakness formed on a portion of the overwrap covering the line of opening.Preferably, the second line of weakness is formed on an outer surface of the overwrap.

[0087] Preferably, the second cellulose-based layer has a first thickness, and the second line of weakness comprises an etch line having a depth no greater than 80% of the first thickness. Preferably, the second line of weakness is implemented only in the second cellulose-based layer. Preferably, the depth of the second line of weakness is not sufficient to also form an etch in the second or third polymer layer. This is particularly relevant if the second or third polymer layer has heat-sealable properties, allowing for a substantially uniform seal upon application of heat. If the second or third polymer layer has moisture barrier properties, the etching may result in areas where moisture exchange may be impossible. Preferably, the first thickness of the second cellulose-based layer is between 30 and 60 microns. Preferably, the depth of the second line of weakness is at least 50% of the first thickness. Preferably, the depth of the second line of weakness is between 50 and 80% of the thickness of the second cellulose-based layer. This allows for easy opening of the container without interfering with the properties of the second polymer layer.

[0088] Preferably, the thickness of the first cellulose-based layer is between 200 and 400 microns.

[0089] Preferably, the thickness of the first polymer layer is less than 10 microns, more preferably less than 5 microns.

[0090] Preferably, the second line of weakness is formed on the second cellulose-based layer before coating the second cellulose-based layer with the second polymer layer.Preferably, the second line of weakness is formed on the overwrap before wrapping the package with the overwrap.

[0091] Preferably, the moisture barrier layer comprises a copolymer of styrene and acrylate and wax. Preferably, the moisture barrier layer comprises a copolymer of styrene and butadiene and wax. Preferably, the moisture barrier layer comprises a copolymer of ethylene and vinyl acetate and wax. Preferably, the moisture barrier layer comprises a copolymer of ethylene and acrylic acid or methacrylic acid and wax. Preferably, the moisture barrier layer comprises a polymer or copolymer of ethylene and propylene, 1-butene, isobutylene, 1-octene, 1-hexene, or norbornene, and wax. Preferably, the moisture barrier layer comprises a wax and two or more of the following: a copolymer of styrene and acrylate, a copolymer of styrene and butadiene, a copolymer of ethylene and vinyl acetate, a copolymer of ethylene and acrylic acid or methacrylic acid, or a polymer or copolymer of ethylene and propylene, 1-butene, isobutylene, 1-octene, 1-hexene, or norbornene.

[0092] Preferred waxes are paraffin waxes, microcrystalline waxes or hydrocarbon waxes.

[0093] Preferably, the wax comprises paraffin wax, microcrystalline wax or hydrocarbon wax. The wax may comprise a combination of one or more of paraffin wax, microcrystalline wax or hydrocarbon wax.

[0094] Preferably, the heat-sealable layer comprises a copolymer of ethylene. Preferably, the heat-sealable layer comprises a copolymer of methacrylic acid. Preferably, the heat-sealable layer comprises a copolymer of an ester of acrylic acid or methacrylic acid. Preferably, the heat-sealable layer comprises two or more of the following: a copolymer of ethylene, a copolymer of methacrylic acid, or a copolymer of an ester of acrylic acid or methacrylic acid. Preferred examples of polymers for making the heat-sealable layer include ethylene-based copolymers, such as, but not limited to, copolymers of ethylene with acrylic acid or methacrylic acid, or esters thereof, such as methyl, ethyl, butyl, or ethylhexyl acrylic acid or methacrylic acid.

[0095] In one embodiment of the present invention, the heat sealable layer is made of a dispersion of ethylene acrylic acid copolymer (EAA) modified with paraffin wax. A suitable EAA copolymer is Primacor 5980I mechanically dispersed in water and partially neutralized with ammonia. The dispersion may contain up to 10% paraffin wax by weight relative to the EAA. The preferred paraffin wax has a melting point of 60 degrees Celsius.

[0096] Such aqueous dispersions can be prepared by mechanical high shear mixing in hot water with solids contents as high as 35%-40% (ratio between solid components and total weight of the dispersion).

[0097] Preferably, the first polymer layer and the third polymer layer are made of the same material. Preferably, the first polymer layer and the third polymer layer have the same physical and chemical properties. Preferably, the first polymer layer and the third polymer layer are heat-sealable layers.

[0098] Preferably, the first cellulose-based layer has a basis weight between 180 grams per square meter (gsm) and 270 grams per square meter (gsm). Preferably, the weight per square meter of the first cellulose-based layer is higher than the weight per square meter of the second cellulose-based layer. The first cellulose-based layer has a weight per square meter that is comparable to or lower than the weight per square meter of a cellulose layer for forming a standard packing of cigarettes known in the art. The hardness and mechanical properties of the container according to the present invention are preferably similar to those of cigarette packings known in the art. The "loss" of hardness due to the lower weight per square meter is compensated for by the presence of the first polymer layer.

[0099] Preferably, the second layer of paper material has a basis weight of between 40 and 60 g / m2.The second cellulose-based sheet material comprised in the overwrap is preferably relatively lightweight as it does not have to impart structural stability to the container.

[0100] Preferably, the first polymer layer has a basis weight between 4 and 10 g / m 2 , more preferably between 4 and 6 g / m 2 .

[0101] Preferably, the third polymer layer has a basis weight between 4 g / m2 and 10 g / m2, between 4 g / m2 and 10 g / m2.

[0102] Preferably, the second polymeric layer has a basis weight between 5 g / m2 and 12 g / m2.

[0103] The polymer layer is selected to have a weight sufficient to achieve the desired heat sealability or moisture barrier properties.

[0104] Preferably, the heat sealable layer has a melting point of less than 100 degrees Celsius as measured by differential scanning calorimetry (DSC). More preferably, the heat sealable layer has a melting point of less than 80 degrees Celsius as measured by differential scanning calorimetry (DSC). The claimed temperature range allows obtaining an optimal seal with the material forming the container without damaging the container.

[0105] Preferably, the heat-sealable layer has a melt flow index of 100 g / min or more at 190 degrees Celsius and an applied force of 2.16 kg.

[0106] Containers implemented according to the present invention are particularly suitable as containers for elongated aerosol-generating articles such as cigarettes, cigars, cigarillos, or other aerosol generators that rely on heating (e.g., via an electric or carbon heat source) rather than burning tobacco. It will be appreciated that, by appropriately selecting its dimensions, containers according to the present invention can be designed for varying numbers of standard, extra-large, super-large, elongated, or extra-elongated aerosol-generating articles. Alternatively, other consumer products may be housed within the container.

[0107] For example, through appropriate size selection, containers according to the present invention may be designed to accommodate a total of between ten and thirty aerosol-generating articles.Depending on the total number of aerosol-generating articles, the aerosol-generating articles may be arranged in different orderings.

[0108] Containers formed according to the present invention may be in the shape of a rectangular parallelepiped having right-angled longitudinal edges and right-angled transverse edges. Alternatively, the container may include one or more rounded longitudinal edges, rounded transverse edges, angled longitudinal edges, or angled transverse edges, or a combination thereof. Alternatively, the container may have a non-rectangular transverse cross-section, such as a polygonal cross-section, such as a triangle or hexagon, a semi-elliptical cross-section, or a semi-circular cross-section.

[0109] Typically, the outer dimensions of the container are between about 0.5 mm and about 5 mm larger than the dimensions of the bundle or bundles of aerosol-generating articles contained within the container.

[0110] Preferably, the container according to the present invention has a height of between about 60 mm and about 150 mm, more preferably between about 70 mm and about 125 mm, wherein the height is measured from the bottom wall to the top wall of the container. Preferably, the container according to the present invention has a width of between about 12 mm and about 150 mm, more preferably between about 70 mm and about 125 mm, wherein the width is measured from one side wall of the container to the other side wall.

[0111] Preferably, containers according to the present invention have a depth of between about 6 mm and about 150 mm, more preferably between about 12 mm and about 25 mm, wherein the depth is measured from the front wall to the back wall of the container (including the hinge between the box and the lid).

[0112] Preferably, the ratio of the height of the container to the depth of the container is between about 0.3 to 1 and about 10 to 1, more preferably between about 2 to 1 and about 8 to 1, and most preferably between about 3 to 1 and 5 to 1.

[0113] Preferably, the ratio of the width of the container to the depth of the container is between about 0.3 to 1 and about 10 to 1, more preferably between about 2 to 1 and about 8 to 1, and most preferably between about 2 to 1 and 3 to 1.

[0114] Where the container includes an aerosol-generating article, the container may further include a waste compartment (e.g., for cigarette ashes or butts) or other consumer products, such as matches, lighters, extinguishing devices, breath fresheners, or electronic devices. Other consumer products may be attached to the outside of the container, contained within the container along with the aerosol-generating article, in a separate compartment of the container, or a combination thereof.

[0115] Throughout this specification, the term "inner surface" is used to refer to the surface of a component of a container that faces the interior of the container (e.g., facing the consumer goods) when the assembled container is in a closed position. Throughout this specification, the term "outer surface" is used to refer to the surface of a component of a container that faces the exterior of the container. For example, the front wall of a container has an inner surface that faces the interior of the container and the consumer goods, and an outer surface that faces away from the consumer goods. It should be noted that the inside surface or the outside surface is not necessarily equivalent to a certain side of the blank used when assembling the container. Depending on how the blank is folded around the consumer goods, the area on the same side of the blank may face the inside of the container or the outside of the container.

[0116] As used herein, the terms "front," "rear," "upper," "lower," "top," "bottom," and "side" refer to the relative positions of portions of a container according to the present invention and its components when the container is in an upright position with the access opening at the top of the container. When describing a container according to the present invention, these terms are used regardless of the orientation of the container being described. The rear wall of an outside hinged-lid container is the wall that includes the hinge line.

[0117] The term "width" is used to describe the dimension of an element, such as a panel of a blank or a wall of a container, measured in the transverse direction.

[0118] Throughout this specification, the term "panel" is used to refer to a portion of a blank used to form a wall in an assembled container.A panel may depend from one or more other panels along one or more fold lines.

[0119] The term "fold line" refers to a fold between two adjacent panels. When forming a container, the adjacent panels are folded along their common fold line, which may define an edge of the container or a portion of the container.

[0120] In an assembled container, a "wall" may be formed from one or several overlapping panels. If there are several overlapping panels, these panels may be attached to each other, for example, by adhesive. Alternatively, a wall may be formed from two or more adjacent or overlapping panels.

[0121] The term "height" is used to describe the dimension of an element measured in a direction perpendicular to the width of such an element.When describing elements of a blank, reference is generally made to the elements of the blank in a flat state.

[0122] The term "thickness" is used herein to refer to the minimum distance measured between two opposing surfaces of a sheet blank or a sheet blank layer. In practice, the distance at a given position is measured along a direction locally perpendicular to the opposing surfaces.

[0123] The "thickness" of a layer will typically be substantially constant across the layer (flat configuration).

[0124] However, local variations are possible if parts of the sheet blank are, for example, embossed, indented, weakened or the like.

[0125] The term "hinge line" refers to the line about which the lid can be pivoted in order to open the hinge-lid housing. The hinge line may be, for example, a fold line or a score line in a panel forming the rear wall of the container.

[0126] Term " line of weakness " is used to describe the part of the surface of container or packaging (or the blank that forms container or packaging from it) in this article, wherein the structural strength of the material that forms container or packaging (or blank) from it is weakened by any suitable technology, for example, bends, folds or tears along the line of weakness.For example, line of weakness can be formed as score line, crease line, ablation line or perforation line.Line of weakness can be produced in the following manner: the displacement of material, material, the compression of material, for example, by making the fiber breakage in the fibrous material locally reduce the power that material is held together, and the combination of all the above methods.Line of weakness can be straight, curved, segmented or continuous or their combination.In many cases, line of weakness is used to assist in locating fold line in blank.Line of weakness can also be used for example, by compression, reinforcing material on the direction perpendicular to line of weakness.In addition, line of weakness can be used for decorative purposes.

[0127] The term "score line" is used to describe a line formed by partially cutting into the blank material. The score line can be formed by removing material from the blank (in which case the score line forms a groove or valley in the blank). Alternatively, the score line can be formed without removing any material from the blank, typically involving partial lateral displacement and compression of the material caused by a knife having a non-zero thickness penetrating the material. The depth of the score line will be less than the blank thickness.

[0128] The term "crease line" is used to describe a line formed by displacing a portion of material perpendicular to the plane of the blank, thereby forming a groove or valley in the blank. This displacement may involve compression, and typically involves the use of a compression tool, such as a roller. Alternatively or additionally, the material in the crease line may be displaced to at least partially protrude from the opposite side of the blank. Generally, no material is removed when forming the crease line.

[0129] The term "ablation line" is used to describe a line formed by removing material from the surface of the blank to a predetermined depth by means of ablation, for example by means of a laser beam or a blade.

[0130] The term "perforation line" is used to describe a line or sequence of discrete holes or slots in a blank. The holes can be formed by pushing an object through the blank. This can result in material being removed from the blank, for example, by punching. Alternatively, the holes can be created without removing material, simply using an object to push material outward from the center of the hole. As another alternative, the holes can be formed using a laser beam.

[0131] The term "fold line" is used to describe any line in a blank about which the blank folds. A fold line may be defined by a line of weakness to assist in the folding action. Alternatively, a fold may be formed without a line of weakness, depending on, for example, the flexibility and other material properties of the blank.

[0132] Within the framework of the present invention, paper is a sheet of material produced by mechanically and / or chemically processing cellulose fibers in water. The cellulose fibers can originate from wood, rags, grass or other plant sources. The water is then drained, for example through a fine mesh, so that the fibers are evenly distributed on the surface, followed by pressing and drying. In addition to pulp, the paper sheet may also contain fillers and additives. The pulp used can be bleached or unbleached and can be obtained from various processes. Suitable pulp types include hardwood kraft pulp, softwood kraft pulp, sulfite pulp or other chemical pulps, mechanical pulp, thermomechanical pulp, chemothermomechanical pulp or other types of mechanical pulp, and recycled pulp can also be used. For the purposes of the present invention, thermomechanical pulp, chemothermomechanical pulp (CTMP), chemical pulp or blends thereof are preferred.

[0133] As used herein, an aerosol-forming article is any article that generates an inhalable aerosol when an aerosol-forming substrate is heated. The term includes articles that include an aerosol-forming substrate that is heated by an external heat source, such as an electric heating element. An aerosol-forming article may be a non-flammable aerosol-forming article, which is an article that releases volatile compounds without burning the aerosol-forming substrate. An aerosol-forming article may be a heated aerosol-forming article, which is an aerosol-forming article that includes an aerosol-forming substrate that is intended to be heated rather than burned in order to release volatile compounds that can form an aerosol. The term includes articles that include an aerosol-forming substrate and an integrated heat source, such as a combustible heat source.

[0134] Aerosol-forming articles according to the present invention may be in the form of a combustible filter cigarette or other smoking article in which tobacco material is combusted to form smoke.

[0135] Preferably, the aerosol-forming article may be substantially cylindrical in shape. The aerosol-forming article may be substantially elongated. The aerosol-forming article may have a length and a circumference substantially perpendicular to the length. The total length of the aerosol-forming article may be between about 30 mm and about 100 mm. The outer diameter of the aerosol-forming article may be between about 5 mm and about 12 mm.

[0136] The present 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.

[0137] Example Ex1: A method of manufacturing a container for consumer products, the method comprising:

[0138] - forming a first multilayer comprising a first cellulose-based layer and a first polymer layer;

[0139] - folding the first multilayer to form a package, said package defining an enclosure for the consumer product, wherein the first multilayer is folded such that the first polymer layer is provided on an outer side of the first cellulose-based layer;

[0140] - forming an outer wrapper comprising a second cellulose-based layer and a second polymer layer;

[0141] - wherein one of the first polymer layer and the second polymer layer is a moisture barrier layer and the other of the first polymer layer and the second polymer layer is a heat sealable layer;

[0142] - wrapping the package with an outer wrapper, wherein the wrapping is performed such that the second polymer layer is provided on the inner side of the second cellulose-based layer;

[0143] - heating the package and the overwrap to seal the overwrap to the package, thereby forming a container.

[0144] Example Ex2: The method according to Ex1, wherein the heat pack and the outer wrapper comprise:

[0145] - heating the package and overwrap while applying pressure to seal the overwrap to the package.

[0146] Example Ex3: The method according to Ex1 or Ex2, comprising:

[0147] - folding the first plurality of layers to form a package comprising a lid portion and a box portion, the box portion and the lid portion being separated by an opening line, the lid portion being hinged to the box portion;

[0148] - wrapping the box portion and the lid portion with an outer wrapper, the outer wrapper at least partially covering the opening line;

[0149] - Heating the package and the wrapped overwrap to seal the overwrap to the package.

[0150] Example Ex4: The method of Ex3, wherein the line of opening comprises a first line of weakness.

[0151] Example Ex5: The method according to Ex3 or Ex4, comprising the steps of:

[0152] - Completely cover the opening line with the outer wrap.

[0153] Example Ex6: The method of one or more of Ex1-Ex5, wherein the first cellulose-based layer defines an inner surface and an outer surface and wherein forming the first multilayer comprises:

[0154] - coating the outer surface of the first cellulose-based layer with a first polymer layer.

[0155] Example Ex7: The method according to one or more of Ex1-Ex6, wherein the step of forming an overwrap comprises the step of forming an overwrap comprising a third polymer layer.

[0156] Example Ex8: The method of Ex7, wherein the second polymer layer defines an inner surface and an outer surface, the second cellulose-based layer defines an inner surface and an outer surface, and wherein the first polymer layer is a heat-sealable layer, forming the overwrap comprises:

[0157] - coating the inner surface of the second cellulose-based layer with a second polymer layer; and

[0158] - coating the inner surface of the second polymer layer with a third polymer layer.

[0159] Example Ex9: The method according to one or more of Ex1 to Ex8, comprising:

[0160] - folding the first plurality of layers to form a package comprising a lid portion and a box portion, the box portion and the lid portion being separated by an opening line, the lid portion being hinged to the box portion;

[0161] - wrapping the box portion and the lid portion with an outer wrapper, the outer wrapper at least partially covering the opening line;

[0162] - forming a second line of weakness on the portion of the overwrap covering the line of opening.

[0163] Example Ex10: The method according to Ex9, comprising:

[0164] - Opening the lid by tearing or breaking the second line of weakness.

[0165] Example Ex11: The method according to Ex10 and Ex4, comprising:

[0166] - Opening the lid by tearing or breaking the first and second lines of weakness.

[0167] Example Ex12: The method according to one or more of Ex1 to Ex11, comprising:

[0168] - Printing a logo relating to the consumer product or the manufacturer of the consumer product on the second cellulose-based layer.

[0169] Example Ex13: The method according to one or more of Ex1-Ex12, wherein forming the first multilayer or forming the outer wrap comprises one or more of:

[0170] o copolymers of styrene and acrylates;

[0171] o copolymers of styrene and butadiene;

[0172] o copolymers of ethylene and vinyl acetate;

[0173] o copolymers of ethylene and acrylic acid or methacrylic acid;

[0174] o polymers or copolymers of ethylene with propylene, 1-butene, isobutylene, 1-octene, 1-hexene or norbornene;

[0175] Emulsions or dispersions with waxes form a moisture barrier.

[0176] Example Ex14: The method according to one or more of Ex1-Ex13, wherein forming the first multilayer or forming the outer wrapper comprises forming a heat-sealable layer from an emulsion or dispersion of one or more of:

[0177] - copolymers of ethylene;

[0178] - copolymers of methacrylic acid;

[0179] - copolymers of esters of acrylic acid or methacrylic acid.

[0180] Example Ex15: A container for consumer products, comprising:

[0181] A package comprising a box portion and a lid portion, the package defining an enclosure for a consumer product, the lid portion being hingedly connected to the box portion by a hinge line, an opening line separating the box portion and the lid portion beyond the hinge line, the box portion and the lid portion being formed by folding a first multi-layer blank, the first multi-layer blank comprising:

[0182] o a first cellulose-based layer;

[0183] o providing a first polymer layer on the outer side of the first cellulose-based layer;

[0184] - an outer wrapper wrapped around and sealed to the package and at least partially covering the opening line, the outer wrapper comprising:

[0185] o a second cellulose-based layer;

[0186] o providing a second polymer layer on the inner side of the second cellulose-based layer;

[0187] - wherein one of the first polymer layer and the second polymer layer is a moisture barrier layer and the other of the first polymer layer and the second polymer layer is a heat sealable layer.

[0188] Example Ex16: The container according to Ex15, wherein the opening line comprises a first weakening line.

[0189] Example Ex17: A container according to Ex15 or Ex16, wherein the outer wrapper comprises a third polymer layer.

[0190] Example Ex18: A container according to Ex17, wherein the third polymer layer is located on the inner side of the second polymer layer.

[0191] Example Ex19: A container according to Ex17 or Ex18, wherein the third polymer layer is a heat-sealable layer.

[0192] Example Ex20: A container according to one or more of Ex15-Ex19, wherein the overwrap comprises a second line of weakness formed on a portion of the overwrap covering the opening line.

[0193] Example Ex21: A container according to Ex20 or a method according to Ex6, wherein the second cellulose-based layer has a first thickness and the second line of weakness comprises an etched line having a depth no greater than 80% of the first thickness.

[0194] Example Ex22: A container according to one or more of Ex15-Ex21, wherein the moisture barrier layer comprises one or more of the following:

[0195] - copolymers of styrene and acrylates,

[0196] - copolymers of styrene and butadiene,

[0197] - copolymers of ethylene and vinyl acetate,

[0198] - copolymers of ethylene and acrylic acid or methacrylic acid;

[0199] - polymers or copolymers of ethylene with propylene, 1-butene, isobutylene, 1-octene, 1-hexene or norbornene;

[0200] and wax.

[0201] Example Ex23: A container according to Ex22, wherein the wax comprises paraffin wax, microcrystalline wax or hydrocarbon wax.

[0202] Example Ex24: A container according to Ex22 or Ex23 or a method according to Ex13, wherein the wax content is between 5% and 15% by weight relative to the weight of the polymer or copolymer.

[0203] Example Ex25: A container according to one or more of Ex15-Ex24, wherein the heat-sealable layer comprises one or more of the following copolymers:

[0204] -ethylene;

[0205] - acrylic acid or methacrylic acid;

[0206] - Esters of acrylic acid or methacrylic acid.

[0207] Example Ex26: A container according to one or more of the methods of Ex1-Ex14 or according to one or more of Ex15-Ex25, wherein the first cellulose-based layer has a basis weight of between 180 g / m2 and 270 g / m2.

[0208] Example Ex27: A method according to one or more of Ex1 to Ex14 or a container according to one or more of claims Ex15 to Ex28, wherein the second layer of paper material has a basis weight of between 40 g / m2 and 60 g / m2.

[0209] Example Ex28: A method according to one or more of Ex1-Ex14 or a container according to one or more of Ex15-Ex27, wherein the first polymer layer has a basis weight of between 4 g / m2 and 10 g / m2.

[0210] Example Ex29: A method according to one or more of Ex1-Ex14 or a container according to one or more of Ex15-Ex28, wherein the third polymer layer has a basis weight of between 4 g / m2 and 10 g / m2.

[0211] Example Ex30: A container according to one or more of the methods of Ex1-Ex14 or according to one or more of Ex15-Ex29, wherein the second polymer layer has a basis weight of between 5 g / m2 and 12 g / m2.

[0212] Example Ex31: A container according to the method of one or more of Ex1-Ex14 or according to one or more of Ex15-Ex30, wherein the heat-sealable layer has a melting point below 100 degrees Celsius as measured by differential scanning calorimetry (DSC).

[0213] Example Ex32: A container according to one or more of the methods of Ex1-Ex14 or one or more of Ex15-Ex31, wherein the heat-sealable layer has a melt flow index of 100 g / min or more at 190 degrees Celsius and 2.16 kg applied force.

[0214] Embodiments will now be further described with reference to the accompanying drawings, in which:

[0215] - Figure 1 is a perspective schematic diagram of components of a container according to the present invention;

[0216] - Figure 2 for Figure 1 a front view of an element of a component of a container;

[0217] - Figure 3 for Figure 2 an enlarged side view of an element of a component;

[0218] - Figure 4 is a front view of an element of another component of a container according to the present invention;

[0219] - Figure 5 for Figure 2 an enlarged side view of an element;

[0220] - Figure 6-13 To achieve Figure 1 A perspective view of the steps of the method of the container;

[0221] - Figure 14 is a graph showing a comparative test between a container of the present invention and a prior art container under a first condition;

[0222] - Figure 15 is a graph showing a comparative test between a container of the present invention and a prior art container under a first condition;

[0223] - Figure 16 for Figure 6 a schematic enlarged view of a detail of; and

[0224] - Figure 17 for Figure 7 Schematic enlargement of the details.

[0225] Figure 1 The package 10 according to the invention is shown. The package 10 has a rectangular parallelepiped shape and comprises a box portion 14 and a lid portion 16. The parallelepiped defines a rear wall 21, a front wall 22, a left side wall 23, a right side wall 24, a bottom wall 25 and a top wall 26.

[0226] The lid 16 is hinged about a hinge line 17 extending across the rear wall of the parallelepiped and can be in an open position ( Figure 1 The package 10 pivots between an open position (shown in the figures) and a closed position. Furthermore, the package 10 defines an outer shell or interior volume 18 that houses, for example, a group of aerosol-generating articles (not shown in the figures). When the package 10 is closed, the lid portion 16 and the box portion 14 define an opening line 19, which is a separation line between the lid portion and the box portion. The opening line 19 is a geometric continuation of the hinge line 17. The opening line 19 is formed on the left side wall 23, the right side wall 24, and the front wall 22.

[0227] In a different embodiment (not shown), the opening line is not a cut, it is for example a perforation, and therefore the package cannot be opened (ie the lid 16 cannot be rotated about the hinge line unless the opening line is broken).

[0228] Packaging 10 Figure 2 and 3 The sheet blank 100 shown in FIG. Figure 3 As shown in a side view of FIG, sheet blank 100 includes a first cellulose-based layer 30 comprising a cellulose material and a first polymer layer 31 having heat-sealable or moisture-barrier properties, or both. The first polymer layer 31 is provided on the outer side of the first cellulose-based layer 30. More specifically, the first cellulose-based layer 30 is formed from a sheet of paper-based material. Preferably, the first polymer layer is a heat-sealable layer. Preferably, the first cellulose-based layer 30 has a weight between 180 gsm and 270 gsm. Preferably, the first polymer layer 31 has a weight between 4 gsm and 10 gsm.

[0229] The sheet blank 100 is folded in such a way that the first cellulose-based layer 30 is the inner layer of the package 10 and the first polymer layer 31 is the outer layer of the package.

[0230] The package 10 formed by appropriately folding the sheet blank 100 to form the container 1 ( Figure 13 ) to accommodate a consumer product (not shown) for containing an aerosol-generating article.

[0231] The outer wrapping is made of Figure 4 and 5 The sheet blank 101 shown in FIG is formed. Figure 5As shown in FIG, sheet blank 101 includes a second cellulose-based layer 40 comprising a second cellulose material, a second polymer layer 41 having heat-sealable properties, moisture barrier properties, or both, and a third polymer layer 42 having heat-sealable properties, moisture barrier properties, or both. Second polymer layer 41 is provided on the inner side of second cellulose-based layer 40. Third polymer layer 42 is provided on the inner side of second polymer layer 41. More specifically, second cellulose-based layer 40 is formed from a sheet of paper-based material. Preferably, the third polymer layer is a heat-sealable layer and the second polymer layer is a moisture barrier layer. Preferably, second cellulose-based layer 40 has a weight between 40 gsm and 60 gsm. Preferably, the third polymer layer has a weight between 4 gsm and 10 gsm. Preferably, the second polymer layer has a weight between 6 gsm and 12 gsm. Preferably, the thickness of the second cellulose-based layer is between 30 microns and 50 microns.

[0232] To form the container 1, an overwrap formed from the blank sheet 101 is wrapped around the package 10, such as Figure 6-13 As shown in .

[0233] First, a second line of weakness 45 is formed on the blank sheet 101. The second line of weakness 45 is formed on the blank sheet 101 so that when the blank sheet 101 is wrapped around the package 10, the second line of weakness 45 coincides with the opening line 19, as shown in FIG. Figure 11-13 As can be seen in .

[0234] The second line of weakness 45 can be produced with a laser scoring process or partial mechanical cutting through the thickness of the paper without damaging the sealable layer and the moisture barrier layer.

[0235] A second weakening line 45 is formed on the second cellulose-based layer 40. Scoring is performed on one side of the second cellulose-based layer 40 that becomes the outer surface of the container 1. The depth of the scoring is controlled so as not to affect the moisture barrier properties of the second polymer layer 41.

[0236] Considering scoring resistance to laser and mechanical processes and ensuring good functionality (ease of opening), the score depth is preferably between 50% and 80% of the thickness of the second cellulose-based layer. For laser scoring, a 1000-watt CO2 laser can be used. Laser beam control can be performed using a scanner. The process can be roll-to-roll at speeds of 200 meters per minute.

[0237] In the case of mechanical scoring, a rotary cutting unit can be used. The second cellulose-based layer is inserted between the knife of the cutting unit and a blind counter roller. Depending on the substrate, the distance between the knife and the counter roller is between 15 and 30 microns.

[0238] The outer wrap sheet blank 101 is brought into abutment with the right side wall 24 of the package 10 (see Figure 6 ). The sheet blank 101 is positioned in such a way that the third polymer layer 42 contacts the first polymer layer at the right side wall 24. The third polymer layer 42 is thus the inner layer of the overwrap and the second cellulose-based layer 40 is the outer layer of the overwrap.

[0239] Figure 16 The enlarged view in FIG shows how the blank 101 is applied to the package 10 so that the blank is in contact with the package. Two fold lines 102, 103 are formed in the sheet blank 101, which correspond to the positions of the two corners 27, 28 formed between the rear wall 21 and the right side wall 24 and between the front wall 22 and the right side wall 24, respectively. Figure 7 Then the sheet blank 101 is as shown in FIG. Figure 17 The inlet is pressed against the side wall 24 as shown by the arrow.

[0240] The blank sheet 101 is then folded at two fold lines 102, 103 so that the front wall 22 and the back wall 21 of the package 10 are also in contact with the outer wrapper. Figure 8 Shown in the middle.

[0241] The package 10 is then preferably reoriented to facilitate wrapping, for example, the left side wall 23 may now face upward, as in Figure 9 As shown in .

[0242] Then two more fold lines are formed in the sheet blank 101: fold lines 104, 105, which correspond to the positions of the two corners 29, 51 formed between the rear wall 21 and the left side wall 23 and between the front wall 22 and the left side wall 23, respectively. The sheet blank 101 is then folded at the two fold lines 104, 105 and the two opposite flaps of the sheet blank overlap on the left side wall 23. This is Figure 10 The panels of the sheet blank 101 are thus formed on the left side wall 23, right side wall 24, front wall 22 and rear wall 21 of the package 10. In this way, the entire opening line 19 and hinge line 17 are covered by the overwrap.

[0243] The package 10 and overwrap are then preferably reoriented so that the front wall 22 is now facing upward, as in Figure 11 middle.

[0244] The sheet blank 101 is then folded in a known manner to cover the top wall 26 and bottom wall 25 of the package 10. Figure 12 and 13 In Figure 13 In the embodiment shown, the entire package 10 is covered by an outer wrapper which forms a panel on each wall of the package 10. The second line of weakness 45 coincides with the opening line 19 located below.

[0245] Heat and pressure are applied to secure and bond the outer wrap to the package 10. For example, a temperature of 110 degrees Celsius and a pressure of 1 Newton per square centimeter (N / cm 2 ) for a period of 100 milliseconds. These conditions provide a satisfactory seal and high adhesion.

[0246] Example 1 Outer Wrap

[0247] A first embodiment of a sheet blank 101 is given.

[0248] The second cellulose-based layer 40 is a 45 gsm paper layer.

[0249] A 45 gsm paper was coated with 10 gsm of the wax-modified styrene acrylic dispersion using a bar coater, thereby forming a second polymer layer 41 .

[0250] The dispersion used was supplied by Trueb Chemie under the trade name TB 16. The dispersion was diluted with water to give a solids content of 40%.

[0251] The coating is dried in a convection oven at a temperature not exceeding 90 degrees Celsius and formed into a sheet blank 101 .

[0252] Instead of TB16, a dispersion consisting of a paraffin wax with a melting point of 60 degrees Celsius (° C.) and a styrene acrylate latex obtained by emulsion polymerization of styrene, butyl acrylate, ethylhexyl methacrylate, and acrylic acid can be used as the second polymer layer. Preferred copolymers contain 60-80 mol% styrene and up to 20% acrylate.

[0253] Paraffin wax can be added during the emulsion polymerization process or added to the pre-emulsion, with a typical wax content of 10%. Preferably, the wax content is less than 15% relative to the polymer content, as higher wax contents may result in unstable dispersions.

[0254] The moisture permeability of the resulting coated paperboard was measured at 38 degrees Celsius and 90 RH according to ASTM F3299 and was between 20 and 30 g / m2 / atm / day.

[0255] Example 2 Outer Wrap

[0256] The sheet blank 101 of Example 1 was prepared.

[0257] An additional 4-5 gsm coating layer is applied over the second polymer layer to enhance seal and barrier properties. This coating is the third polymer layer and is formed from a dispersion of a low molecular weight ethylene acrylic acid copolymer (Primacor 5980I). This coating is applied from an aqueous dispersion consisting of Primacor 5980I and 10% by weight of wax (relative to Primacor 5980I). The dispersion used has a solids content of 35%.

[0258] Drying of the resulting multilayer comprising the second cellulose-based layer, the second polymer layer and the third polymer layer was carried out in a convection oven at a temperature of 80 degrees Celsius.

[0259] Example 3 Outer Wrap

[0260] A 45 gsm calendered paper as the second cellulose-based layer was coated with 10 gsm of the second polymeric layer material as described below.

[0261] A wax-modified styrene acrylic dispersion was formed as described in Example 1.

[0262] To this dispersion is added an inorganic pigment such as kaolin, vermiculite, calcium carbonate (CaCO3) to achieve a 50 / 50 pigment / polymer dispersion weight ratio. The inorganic pigment can improve the moisture barrier properties of the polymer layer thus formed.

[0263] Water was added to maintain the total solids content of the resulting dispersion below 55 wt%.

[0264] The resulting coated paper formed from the second cellulose-based layer and the second polymer layer had a moisture permeability of between 20 and 35 g / m2 / atm / day measured at 38 degrees Celsius and 90 RH according to ASTM F3299.

[0265] An additional 4-5 gsm sealable coating layer is applied to enhance sealability and barrier. This coating is described in Example 2 as the third polymer layer.

[0266] The blank sheet 101 according to Examples 2-3 may be printed with branding information, health warnings, and designs on the uncoated surface of the second cellulose-based layer.

[0267] The second cellulose-based layer is laser scored to allow for easy opening and tamper resistance. Care must be taken that the laser scoring (etching) does not cut more than 80% of the thickness of the second cellulose-based layer to avoid damaging the moisture barrier layer and the sealable layer.

[0268] Example 4 - First Multilayer

[0269] 180-270 gsm paperboard was used as the first cellulose-based layer.

[0270] A 180-270 gsm paperboard was coated on the surface intended for the outside of the packaging with 10 gsm of a wax-modified styrene acrylic dispersion to form a first polymer layer. The dispersion was formed as described in Example 1.

[0271] The sheet blank 100 can be painted according to standard techniques in the field of cigarette packaging. A polymer layer without heat sealable or moisture barrier properties is applied to the coating by standard painting. The basis weight of the standard painting layer is less than 4 gsm.

[0272] The moisture permeability of the resulting multilayer was measured according to ASTM F3299 at 38 degrees Celsius and 90 RH and was between 10-20 g / m2 / day.

[0273] Example 5 - First Multilayer

[0274] 180-220 gsm paperboard was used as the first cellulose-based layer.

[0275] A 180-220 gsm paperboard was coated with 10 gsm of the wax-modified styrene acrylic dispersion prepared according to Example 1 to form a first polymer layer.

[0276] The resulting multilayer had a moisture permeability of between 10 and 20 g / m2 / atm / day as measured at 38°C and 90 RH according to ASTM F3299.

[0277] An additional 4-5 gsm coating layer is applied to enhance sealability and barrier properties and comprises a dispersion of a low molecular weight ethylene acrylic acid copolymer (Primacor 5980I from SK Chemicals). This coating is applied from an aqueous dispersion of this copolymer and 10% by weight of wax (relative to Primacor 5980I). The dispersion used has a solids content of 35%. This layer, the fourth polymer layer, is applied over the first polymer layer.

[0278] Preferred polymers from which the aqueous dispersion is prepared to form the first polymer layer or the third polymer layer or both having heat sealable properties are:

[0279]

[0280] Preferred polymers from which the aqueous dispersion is prepared to form the second polymer layer having moisture barrier properties are:

[0281]

[0282]

[0283] These polymers will be combined with wax.

[0284] Comparative Example

[0285] Comparative Examples The performance of container 1 according to the present invention was compared with:

[0286] Comparative Container A (BOPP Film): A 20 cigarette hinged lid pack formed from varnished 180-270 gsm paperboard and wrapped with 16 micron BOPP film. Figure 14 and 15 Indicated by dotted line.

[0287] Comparative Container B (No Film): A 20 cigarette hinged lid pack formed from varnished 180-270 gsm paperboard, not wrapped in film (no barrier). This container B was Figure 14 and 15 Indicated as dotted line.

[0288] Containers according to the invention (paper barrier): Packs of 20 cigarettes were prepared using hinged lid packaging made from sheet blank 100 of Example 4 and wrapped with sheet blank 101 realized according to Example 2. This container C was Figure 14 and 15 Indicated by solid line.

[0289] Containers A and B and container C of the present invention were placed in a climate chamber to simulate extreme environmental conditions (referred to as jungle and desert in the figures and below) and moisture absorption or loss was monitored via the oven volatiles method.

[0290] Figure 14 and 15 The graphs show that the containers according to the invention have similar moisture absorption or loss as the comparative container A (cigarettes wrapped in BOPP film).

[0291] Oven volatiles (OV in the figures) were measured according to the following method: DETERMINATION OF MOISTURE CONTENT (OVEN VOLATILES) OF TOBACCO AND TOBACCO PRODUCTS, CORESTA Recommended Method No. 76 (published July 2017, https: / / www.coresta.org / sites / default / files / technical_documents / main / CRM_76-July2017).

[0292] The results are shown in Figure 14 and 15 middle.

[0293] exist Figure 14In this study, "jungle" conditions were applied. Containers A, B, and the inventive container C were maintained at 32°C and 85% relative humidity. In container B, the moisture content immediately increased. As shown by the solid and dashed lines, container A and the inventive container C exhibited very similar behavior, with oven volatiles increasing slowly over 90 days.

[0294] exist Figure 15 In this experiment, "desert" conditions were applied. Containers A, B, and the container of the present invention were maintained at a temperature of 43°C and a relative humidity of 15%. In container B, the moisture in the container disappeared immediately. As shown by the solid and dashed lines, container A and the container of the present invention exhibit very similar behavior, with oven volatiles slowly decreasing over 90 days.

[0295] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers indicating amounts, quantities, percentages, etc. should be understood to be modified by the term "about" in all cases. In addition, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein. Therefore, in this context, the number A is understood to be A±10%A. In this context, the number A can be regarded as including the numerical value within the general standard error for the measurement of the attribute represented by the number A. In some examples as used in the appended claims, the number A may deviate from the percentages listed above, as long as the amount of A deviation does not significantly affect the basic and novel features of the claimed invention. In addition, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein.

Claims

1. A method of manufacturing a container for a consumer product, the method comprising: - forming a first multilayer comprising a first cellulose-based layer and a first polymer layer; - folding the first multilayer to form a package comprising a lid portion and a box portion, said box portion and said lid portion being separated by an opening line, said lid portion being hinged to said box portion, said package defining an enclosure for said consumer product, wherein said first multilayer is folded such that said first polymer layer is provided on an outer side of said first cellulose-based layer; - forming an outer wrapper comprising a second cellulose-based layer and a second polymer layer; - wherein one of the first polymer layer and the second polymer layer is a moisture barrier layer and the other of the first polymer layer and the second polymer layer is a heat sealable layer; - wrapping the package with the outer wrapper, the outer wrapper at least partially covering the opening line, wherein the wrapping is performed such that the second polymer layer is provided on the inner side of the second cellulose-based layer; - heating the package and the overwrap to seal the overwrap to the package, thereby forming the container.

2. The method of claim 1 , wherein the first cellulose-based layer defines an inner surface and an outer surface and wherein forming the first multilayer comprises: - coating the outer surface of said first cellulose-based layer with said first polymer layer. 3 . The method of claim 1 , wherein forming the overwrap comprises forming the overwrap comprising a third polymer layer.

4. The method of claim 3, wherein the second cellulose-based layer defines an inner surface and an outer surface, wherein the first polymer layer is a heat-sealable layer, and forming the overwrap comprises: - coating the inner surface of the second cellulose-based layer with the second polymer layer; - coating the inner surface of the second polymer layer with the third polymer layer.

5. The method according to claim 1, comprising: - forming a second line of weakness on a portion of the overwrap covering the line of opening.

6. The method of claim 1 , wherein forming the first multilayer or forming the overwrap comprises one or more of: oCopolymers of styrene and acrylates; o Copolymers of styrene and butadiene; o Copolymers of ethylene and vinyl acetate; o Copolymers of ethylene and acrylic acid or methacrylic acid; o Polymers or copolymers of ethylene with propylene, 1-butene, isobutylene, 1-octene, 1-hexene, or norbornene; The moisture barrier layer is formed by an emulsion or dispersion with a wax.

7. The method of claim 1 , wherein forming the first multilayer or forming the overwrap comprises forming the heat-sealable layer from an emulsion or dispersion of one or more of: - copolymers of ethylene; - copolymers of methacrylic acid; - copolymers of esters of acrylic acid or methacrylic acid.

8. The method of claim 1, wherein the first cellulose-based layer has a basis weight between 180 and 270 grams per square meter.

9. The method of claim 1, wherein the second cellulose-based layer has a basis weight between 40 and 60 grams per square meter.

10. The method of any one of claims 1 to 9, wherein the first polymer layer has a basis weight between 4 and 6 g / m2, or wherein the second polymer layer has a basis weight between 5 and 12 g / m2.

11. The method of claim 3 or 4, wherein the third polymer layer has a basis weight between 4 and 6 grams per square meter.

12. A container for consumer products, the container comprising: a package comprising a box portion and a lid portion, the package defining a housing for the consumer product, the lid portion being hinged to the box portion by a hinge line, an opening line separating the box portion and the lid portion beyond the hinge line, the box portion and the lid portion being formed by folding a first multi-layer blank, the first multi-layer blank comprising: o a first cellulose-based layer; o providing a first polymer layer on the outer side of the first cellulose-based layer; - an outer wrapper wrapped and sealed on the package and at least partially covering the opening line, the outer wrapper comprising: o a second cellulose-based layer; o providing a second polymer layer on the inner side of the second cellulose-based layer; - wherein one of the first polymer layer and the second polymer layer is a moisture barrier layer and the other of the first polymer layer and the second polymer layer is a heat sealable layer.

13. The container of claim 12, wherein the overwrap comprises a third polymer layer.

14. The container of claim 13, wherein the third polymer layer is a heat sealable layer.

15. The container of claim 12, wherein the overwrap includes a second line of weakness formed on a portion of the overwrap covering the opening line.

16. The container of any one of claims 12-15, wherein the first cellulose-based layer has a basis weight of between 180 g / m2 and 270 g / m2.

17. The container of any one of claims 12-15, wherein the second cellulose-based layer has a basis weight of between 40 g / m2 and 60 g / m2.

18. The container of any one of claims 12-15, wherein the first polymer layer has a basis weight between 4 and 6 g / m2, or wherein the second polymer layer has a basis weight between 5 and 12 g / m2.

19. The container of claim 13 or 14, wherein the third polymer layer has a basis weight of between 4 and 6 grams per square meter.

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