Method for making a container for consumer goods and container for consumer goods

Abstract

The present invention relates to a method for making a container (1) for consumer goods, the method comprising the steps of: - folding the first cellulosic layer (30) to form a package (10), the package defining a housing for the consumer good; forming an outer wrapper, the outer wrapper including a second cellulosic layer (40) having an inner surface (44) defining an inner region and an outer surface (45) defining an outer region, a first polymeric layer (41) disposed on the inner surface, and a second polymeric layer (42) disposed on less than 30 percent of the outer surface; forming a first polymer layer and a second polymer layer, the first polymer layer and the second polymer layer being heat-sealable layers; - wrapping the package in an outer wrapper, the wrapping being performed such that the first polymeric layer is disposed on an inside of the second cellulosic layer; - heating the package and outer wrapper and sealing the outer wrapper onto the package to form a container.

Description

[Technical field]

[0001] The present invention relates to a method of making a container and to a container for consumer goods. The container is preferably used to contain elongated objects, such as aerosol-generating articles. [Background technology]

[0002] It is known to package cigarettes, and more generally aerosol-generating articles, in carton boxes wrapped in a biaxially oriented polypropylene film (BOPP film), in other words a plastic film. This solution has been the industry standard for decades. Summary of the Invention [Problem to be solved by the invention]

[0003] However, plastic packaging can have detrimental effects on the environment, not only in terms of the potential for littering, but also in terms of the use of non-renewable resources and potential impacts on global warming. It is therefore desirable to have packaging solutions that contain less plastic than those available.

[0004] At the same time, a packaging solution for an aerosol-generating article preferably provides protection of the product from moisture uptake or loss. Indeed, too much or not enough moisture in an aerosol-generating article can alter the smoking experience of the user. It is therefore desirable to have a packaging solution that protects the product from moisture.

[0005] Additionally, it is desirable for packaging for aerosol-generating articles to be "tamper evident," that is, it is preferable for it to be readily apparent whether the packaging has already been opened.

[0006] There is therefore a need for a method of making a container, and a container for consumer goods, adapted to contain, among other things, an aerosol-generating article that has a reduced plastic content relative to prior art containers. There is also a need for a method of making a container, and a container for consumer goods, adapted to contain, among other things, an aerosol-generating article, where it is clear whether the container has been opened. [Brief description of the drawings]

[0007] [Figure 1] 1 is a perspective schematic view of components of a container according to the present invention; [Diagram 2] FIG. 2 is a front view of the components of the container of FIG. 1. [Diagram 3] FIG. 3 is an enlarged side view of the element of FIG. 2. [Figure 4] FIG. 2 is a front view of another component element of a container according to the present invention. [Diagram 5] FIG. 5 is an enlarged side view of the element of FIG. 4. [Figure 6] 5 is a side view of a different embodiment of the element of FIG. 4. [Figure 7] FIG. 7 is a front view of one embodiment of the element of FIGS. 4-6. [Figure 8] FIG. 7 is a front view of another embodiment of the element of FIGS. 4-6. [Figure 9] FIG. 7 is a front view of another embodiment of the element of FIGS. 4-6. [Figure 10] 2A-2C are perspective views of method steps for the realization of the container of FIG. 1. [Figure 11] 2A-2C are perspective views of method steps for the realization of the container of FIG. 1. [Figure 12] 2A-2C are perspective views of method steps for the realization of the container of FIG. 1. [Figure 13] 2A-2C are perspective views of method steps for the realization of the container of FIG. 1. [Figure 14] 2A-2C are perspective views of method steps for the realization of the container of FIG. 1. [Figure 15] 2A-2C are perspective views of method steps for the realization of the container of FIG. 1. [Figure 16]2A-2C are perspective views of method steps for the realization of the container of FIG. 1. [Figure 17] 2A-2C are perspective views of method steps for the realization of the container of FIG. 1. [Figure 18] FIG. 11 is a schematic enlarged view of a detail of FIG. 10. [Figure 19] FIG. 12 is a schematic enlarged view of a detail of FIG. [Figure 20] 1 is a graph showing a comparison test between the container of the present invention and a prior art container. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] According to one aspect, the present invention relates to a method of making a container for a consumer product. The method may include folding a first cellulosic layer to form a package, the package defining a housing for the consumer product. The method may include forming an outer wrapper, the outer wrapper including a second cellulosic layer having an inner surface defining an inner region and an outer surface defining an outer region, a first polymer layer disposed on the inner surface, and a second polymer layer disposed on less than 30 percent of the outer surface. The first polymer layer and the second polymer layer may be heat-sealable layers. The method may include wrapping the package with an outer wrapper, the wrapping being performed such that the first polymer layer is disposed on the inside of the second cellulosic layer. The method may include heating the package and the outer wrapper to seal the outer wrapper onto the package to form the container.

[0009] To form a container according to the present invention, a package is formed. The package is formed by folding a first cellulosic layer. The first cellulosic layer is a layer that includes a cellulosic material. The first cellulosic layer is preferably a paper or cardboard layer, i.e. a layer made of paper or cardboard. The first cellulosic layer preferably forms a blank, which preferably has a shape standard in the industry, for example defining a rectangular sheet of material.

[0010] The first cellulosic layer, e.g., the blank, is then folded to produce the package. The manner in which the blank is folded depends on the desired geometric shape of the package. For example, typically the package has the form of a parallelepiped. The blank is preferably folded so that the package is closed, i.e. so as to define a completely closed internal volume, completely separated from the surroundings. The internal volume defined by the package is preferably completely separated from the outside. Preferably, consumer goods are stored within the internal volume.

[0011] The package preferably includes a front package wall, a left package wall, a right package wall, a rear package wall, a top package wall, and a bottom package wall. The package defines an interior surface and an exterior surface.

[0012] In addition to the first cellulosic layer, it is preferred that there are no other layers within the package. The first multilayer is formed and has the function of an outer wrapper. The outer wrapper includes a second cellulosic layer, a first polymer layer, and a second polymer layer. The definition of the second cellulosic layer is the same as that of the first cellulosic layer, so the second cellulosic layer is preferably a layer that contains cellulosic material. The second cellulosic layer is preferably a paper or cardboard layer, i.e. a layer made of paper or cardboard.

[0013] The first polymer layer and the second polymer layer are heat-sealable layers. A heat-sealable layer is a layer that can be fusion bonded by conventional indirect heating means that generates sufficient heat on at least one film contacting surface to conduct to an adjacent film contacting surface and form an adhesive interface between the surfaces without compromising the integrity of the film. The adhesive interface between successive layers preferably has sufficient physical strength to withstand the packaging process and subsequent handling. The heat-sealable layer can be designed to meet different conditions of intended use, and a variety of heat-sealable layer formulations are known in the art and can be employed in the present invention.

[0014] It is further preferred that the first polymer layer is a heat-sealable layer optimized for bonding with the first cellulosic layer. The properties of the first polymer layer, if it has heat-sealing properties, are such that the heat-sealable properties are optimized for bonding with the first cellulosic layer.

[0015] It is further preferred that the second polymer layer is a heat-sealable layer optimized for bonding with the second cellulosic layer. The properties of the second polymer layer, if it has heat-sealing properties, are such that the heat-sealable properties are optimized for bonding with the second cellulosic layer.

[0016] Preferably, the heat-sealable layer, the first polymer layer, or the second polymer layer, or both, have a melting point, measured according to Differential Scanning Calorimetry (DSC), of less than 120 degrees Celsius. More preferably, the heat-sealable layer has a melting point, measured according to DSC, of ​​less than 100 degrees Celsius. Even more preferably, the heat-sealable layer has a melting point, measured according to DSC, preferably less than 80 degrees Celsius.

[0017] The second cellulosic layer, the first polymeric layer, and the second polymeric layer are permanently attached to one another. They preferably form a substantially "blank". The blank preferably has a standard shape in the industry, for example forming a rectangular sheet of multi-layer material. The first polymeric layer and the second polymeric layer are attached to opposing surfaces of the second cellulosic layer.

[0018] The second cellulosic layer preferably defines an inner surface and an outer surface, and thus the first polymer layer is preferably applied onto the inner surface of the second cellulosic layer and the second polymer layer is preferably applied onto the outer surface of the second cellulosic layer.

[0019] The first polymer layer and the second cellulosic layer are attached to each other. The second cellulosic layer and the first polymer layer can be attached together, preferably permanently, using any technique. The first polymer layer may be glued onto the inner surface of the second cellulosic layer. The first polymer layer may be coated onto the inner surface of the second cellulosic layer. The first polymer layer and the second cellulosic layer preferably have the same geometric dimensions. The first polymer layer and the second cellulosic layer preferably are congruent. The first polymer layer preferably completely coats the inner surface of the second cellulosic layer.

[0020] The second polymer layer and the second cellulosic layer are attached to each other. Any technique can be used to attach the second cellulosic layer and the second polymer layer together, preferably permanently. The second polymer layer may be glued onto the outer surface of the second cellulosic layer. The second polymer layer may be coated onto the outer surface of the second cellulosic layer. The second polymer layer preferably covers only an area of ​​less than 30 percent of the area of ​​the outer surface of the second cellulosic layer. The second polymer layer covers one or more portions of the outer surface of the second cellulosic layer. The sum of the areas of the portions of the outer surface of the second cellulosic layer covered by the second polymer layer is less than 30 percent of the total area of ​​the outer surface of the second cellulosic layer.

[0021] The second cellulosic layer preferably defines a first end and a second end. The second polymer layer preferably covers a portion of the outer surface of the second cellulosic layer located at the first end or the second end. More preferably, the second polymer layer covers a portion of the outer surface of the second cellulosic layer located at the first end and the second end.

[0022] The second polymer layer may be applied according to a different pattern. The second polymer layer preferably has the function of sealing the flaps of the outer wrapper formed when the outer wrapper is wrapped around the package with an "envelope-type fold". The outer wrapper with such a pattern of the second polymer layer can then be wrapped and sealed on the outer surface of the package without applying a heat-sealable coating on the package, thanks to the first polymer layer facing the outside of the package. This greatly simplifies the manufacturing process of the container, while still ensuring moisture resistance.

[0023] The outer wrapper preferably includes a metallized layer. By providing an outer wrapper with a metallized layer or a metallized outer wrapper, the barrier characteristics of the outer wrapper may be improved, which may provide additional protection for consumer goods contained within the container, since the metallized outer wrapper has significantly less permeability to gases or vapors, such as oxygen or moisture.

[0024] The outer wrapper may include additional layers, for example additional barrier layers, to enhance the barrier performance of the resulting container. For example, a pre-coated second cellulosic layer may be used as a substrate for the manufacture of the outer wrapper of the present invention. The pre-coated second cellulosic layer may include, for example, one or more layers of polyvinyl alcohol (PVOH), polyethylene-co-vinyl alcohol (EVOH), polyvinylidene dichloride coating (PVDC), and styrene-butadiene or styrene-acrylate based latex. These pre-applied coatings (often applied on a paper mill) can help achieve a second cellulosic layer with excellent surface planarity, thus further enhancing the performance of the coating described in the present invention. Furthermore, pre-applied coatings such as PVOH, EVOH, and PVDC can add additional functionality to the resulting container of the present invention, such as a barrier against odors, fragrances, and oxygen. Such pre-applied coatings often contain mineral fillers, such as calcium carbonate, kaolin, talcum, mica, or other platelet-type minerals.

[0025] A first multilayer (outer wrapper) is wrapped around the outer surface of the package. The first multilayer preferably completely covers the outer surface of the package. Preferably, no part of the outer surface of the package is visible from the outside when the package is wrapped with the outer wrapper. The wrapping is performed such that the first polymer layer is on the inside with respect to the second polymer layer. Thus, when the package is wrapped with the outer wrapper, the first polymer layer is in contact with the first cellulosic layer. Additionally, the first multi-layer is folded such that the first polymer layer is positioned inwardly relative to the second polymer layer.

[0026] The first cellulosic layer preferably comprises an inner surface of the package. The inner surface of the first cellulosic layer is therefore the inner surface of the package, which in turn is the inner surface of the container. The second cellulosic layer preferably comprises an outer surface of the container. The outer surface of the container is preferably at least partially the free surface of the second cellulosic layer.

[0027] In this way, a wrapped package is formed. The wrapping is preferably performed by folding an outer wrapper blank around the package to cover the entire outer surface of the package with the outer wrapper. The resulting wrapped package geometry is substantially identical or very similar to the geometry of the package. The outer wrapper is folded around the package such that contact is made between the walls of the package and the outer wrapper. The outer wrapper preferably contacts all walls of the package. The outer wrapper preferably contacts the front package wall, the left package wall, the right package wall, the rear package wall, the top package wall, and the bottom package wall.

[0028] Heat is then applied to the package wrapped by the first multi-layer. Heat is preferably applied from the outside of the wrapped package. Both heat and pressure are preferably applied to the wrapped package. Heat or pressure, or both, seal the first polymer layer onto the outer surface of the package. The first polymer layer is adhered onto the first cellulosic layer. Further application of heat and pressure seals the second polymer layer onto itself or onto the second cellulosic layer, "closing" the outer wrapper onto itself. The heat applied to the outer wrapper is preferably such that the first polymer layer or the second polymer layer reaches a temperature of less than 100 degrees Celsius, more preferably less than 80 degrees Celsius. Pressure applied to the outer wrapper is preferably comprised between 1 kilopascal and 100 kilopascal.

[0029] The materials of the first polymeric layer partially melt to seal themselves onto the package, thus sealing the outer wrapper onto the package. The materials of the first polymeric layer adhere to the first cellulosic layer.

[0030] The second polymer layer material is located on the top and bottom walls of the container when the first multilayer is folded and wrapped around the package. In other words, the second polymer layer covers the portion of the outer surface of the second cellulosic layer that corresponds to the top or bottom wall or both of the container when the blank is folded. When the second polymer layer material melts, it seals the outer wrapper to itself and blocks the creases formed in the bottom and top walls of the package.

[0031] Manufacturing of the container is simplified by the fact that with the application of heat once, both the first polymeric layer and the second polymeric layer melt and seal the outer wrapper onto the package.

[0032] After application of heat and / or pressure, a container according to the present invention is formed. A container is a wrapped package after application of heat and / or pressure such that the outer wrapper is permanently attached to the package.

[0033] After application of heat or pressure, or both, the outer wrapper becomes permanently attached to the package and it is not possible to remove the outer wrapper without deforming or damaging the container.

[0034] The container preferably includes a container front wall, a container left side wall, a container right side wall, a container rear wall, a container top wall, and a container bottom wall, which correspond to the wrapped package front wall, the wrapped package left side wall, the wrapped package right side wall, the wrapped package rear wall, the wrapped package top wall, and the wrapped package bottom wall, respectively. The container has an interior surface and an exterior surface. The container interior surface is the interior surface of the package.

[0035] The first cellulosic layer preferably comprises an inner surface of the container. The second cellulosic layer preferably comprises an outer surface. The inner surface of the container is preferably a free surface of the first cellulosic layer. The outer surface of the container is preferably a free surface (at least partially) of the second cellulosic layer.

[0036] The first and second polymer layers may be formed of the same polymer material. For example, the first and second polymer layers may be formed of a polymer material that has both heat seal properties and moisture barrier properties. The first and second polymer layers preferably have approximately the same melting point. The first polymer layer and the second polymer layer may be formed by two different polymer materials.

[0037] The first cellulosic layer and the second cellulosic layer can be formed from the same cellulosic material. After packaging, the exterior surface of the container realized according to the present invention may be printed, embossed, debossed or otherwise decorated with a manufacturer's or brand's logo, trademark, slogan and other consumer information and indicia. Because the exterior surface of the container is made of cellulosic materials, printing thereon is easy and can be done according to techniques standard in the art.

[0038] Additionally, other elements may be part of the container formed by the method of the present invention. For example, the container may include an inner package that contains a consumer good, such as an aerosol-generating article. The inner package may be located inside the package. The inner package is preferably formed of metal foil or metallized paper. The inner package material may be formed as a laminate of metallized polyethylene film and a liner material.

[0039] The container according to the invention has a recyclability equal to or better than current packaging solutions: the same or lesser amount of plastic is used and the same or more amount of cellulosic material is used in the realization of the container according to the invention, compared to cellulosic containers wrapped in transparent plastic films.

[0040] At the same time, the consumer perceives the container as being more environmentally friendly, since the second cellulosic layer substantially forms the outer surface of the container. Furthermore, if any indicia, such as a trademark, is provided on the outer surface of the second cellulosic layer, these can still be easily formed according to standard processes.

[0041] The container according to the invention is simple to manufacture and does not require significant modification of existing packaging equipment, in particular, there is substantially no need to modify the folding process used to form the package using the first multi-ply blank, or the type of packaging machine that processes the blank.

[0042] Furthermore, because the outer wrapper is permanently attached to the package, no waste is generated when the user opens the container, as opposed to standard containers, where the outer plastic film is typically removed.

[0043] According to another aspect, the present invention relates to a container for consumer goods. The container comprises a package including a box portion and a lid portion, the package defining a housing for the consumer goods, the lid portion hinged to the box portion by a hinge line, the tear line separating the box portion and the lid portion outside the hinge line, the box portion and the lid portion being formed by folding a first multi-layer blank including a first cellulosic layer. The container may also preferably comprise an outer wrapper enclosing the package, sealed and at least partially covering the tear line. The outer wrapper may comprise a second cellulosic layer having an inner surface and an outer surface. The outer wrapper may comprise a first polymeric layer disposed on the inner surface of the second cellulosic layer. The outer wrapper may comprise a second polymeric layer disposed on less than 30 percent of the area of ​​the outer surface of the second cellulosic layer. The first polymeric layer and the second polymeric layer may be heat-sealable layers.

[0044] A container for consumer goods preferably has a lid portion for easy access to the consumer goods contained within the container. The lid portion is movable between a closed position and an open position. When the lid portion is in the closed position, the container defines a closed housing for the consumer goods. Furthermore, when the lid portion is in the open position, the housing containing the consumer goods is accessible.

[0045] In known solutions, containers with lids may not be tamper-proof, i.e. it is difficult to assess when the container is opened for the first time. According to the present invention, the container is formed as detailed according to the first aspect of the invention and has the advantages already outlined in the previous aspects. In addition, the container of the present invention is also tamper-proof, since the outer wrapper must be broken in order to open the lid.

[0046] The package is formed by folding the first cellulosic layer. The first cellulosic layer in the form of a blank may include an opening line and a hinge line configured such that when the blank is folded to form the package, the package is divided into a lid portion and a box portion by the opening line and by the hinge line. The hinge line and the opening line are preferably continuous. The opening line and the hinge line preferably form a closed loop on the outer package surface. The opening line preferably includes a first end and a second end. The hinge line preferably includes a first end and a second end. The first end of the hinge line preferably touches (contacts) the first end of the opening line. The second end of the hinge line preferably touches the second end of the opening line.

[0047] The opening line is a first line of weakness. The first line of weakness may be a tear notch. The tear notch may be formed by an edge of the lid portion closing over the box portion. The lid portion remains tightly closed against the box portion due to the presence of the outer wrapper that keeps the lid portion closed over the box portion.

[0048] The first line of weakness may be continuous or discontinuous (e.g., perforated). Further, the first line of weakness may be formed using any suitable technique or combination of techniques, such as laser cutting or mechanical cutting (e.g., die cutting, kiss cutting).

[0049] The first cellulosic layer preferably has a given thickness. The first line of weakness may have any suitable depth across the inner and outer surfaces of the first cellulosic layer. The first line of weakness preferably has a depth of at least about 90 percent of the total thickness of the first cellulosic layer. More preferably, the first line of weakness has a depth of about 100 percent of the total thickness of the first cellulosic layer, i.e., is a cut.

[0050] The lid portion preferably includes a lid front wall, a lid left side wall, a lid right side wall, a lid rear wall, and a lid top wall. The lid portion has an inner surface and an outer surface.

[0051] The box portion preferably includes a box front wall, a box left side wall, a box right side wall, a box rear wall, and a box top wall. The box portion has an inner surface and an outer surface.

[0052] A hinge line is preferably realised 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 part and the rear wall of the box part. The hinge line is preferably formed parallel to the bottom wall of the package.

[0053] The front wall of the package preferably includes a segment of a tear line which divides the front wall of the package into two parts: the front wall of the lid part and the front wall of the box part. The tear line segment is preferably realized parallel to the bottom wall of the package.

[0054] The left and right side walls of the package also preferably each include a segment of a tear line. Each segment of the tear line on a side wall preferably connects a hinge line on the rear wall of the package to a segment of the tear line on the front wall. The tear lines divide each of the side walls of the package into two portions: a left (right) side wall of the lid portion and a left (right) side wall of the box portion.

[0055] The tear line on the side walls may form an angle with the rear wall other than 90 degrees. Thus, the segments of the tear line on the right and left walls of the package are preferably not parallel to the bottom wall of the package. The height of the hinge line is preferably different from the height of the segments of the tear line on the front wall of the package.

[0056] When the package is enclosed with an outer wrapper, which is then heated and sealed onto the package, the outer wrapper becomes an integral part of the package and forms the container of the present invention. The outer wrapper cannot be separated from the package without damaging both the outer wrapper and the package.

[0057] The outer wrapper at least partially covers the tear line. Preferably, the outer wrapper completely covers the tear line. Preferably, the outer wrapper covers the tear line and the hinge line. Thus, in order to open the lid portion from the box portion and access the consumer goods stored within the housing defined by the package, it is necessary to break the outer wrapper, as it at least partially covers the tear line. It is necessary to break the outer wrapper to allow movement of the lid portion from a closed position to an open position. The tear line is an edge of the lid portion.

[0058] Both the first line of weakness and the outer wrapper preferably tear or rupture when the container is opened.

[0059] When a force is applied to separate the box portion from the lid portion, the most likely location for the outer wrapper to break is near the tear line. The package is opened at the tear line. Once the outer wrapper is broken, the lid portion rotates about the hinge line and moves to open the package. At the start of this movement, the lid portion breaks the outer wrapper at least partially covering the tear line.

[0060] Since the outer wrapper breaks, it is impossible to hide the fact that the container has been opened at least once after manufacture. Moreover, the outer wrapper cannot be replaced since it is permanently sealed on the package. In this way, a user who purchases a container according to the invention is sure that the container has never been opened when he finds no damage on the outer wrapper. As a result, the user can be sure that no one has tampered with the consumer goods present in the package after they have been inserted therein.

[0061] In the following, the lid portion wrapped with the outer wrapper is referred to as the lid of the container after the outer wrapper has been torn, i.e., after the "first opening", and the box portion wrapped with the outer wrapper is referred to as the box of the container after the outer wrapper has been torn, i.e., after the "first opening".

[0062] The step of heating the package and outer wrapper preferably includes heating the package and outer wrapper while applying pressure to seal the outer wrapper onto the package. To properly seal the outer wrapper onto the package, both heat and pressure are preferably applied such that the first polymeric layer adheres onto the first cellulosic layer, whereby the second polymeric layer closes the outer wrapper onto itself.

[0063] The method preferably includes folding the first cellulosic layer to form a package including a lid portion and a box portion, the box portion and the lid portion being divided by a tear line, the lid portion being hinged to the box portion. The method preferably includes wrapping the box portion and the lid portion with an outer wrapper, the outer wrapper covering at least a portion of the tear line. A package having a lid portion and a box portion is preferably realized. The lid portion and the box portion are divided by a tear line. The advantages of this configuration have already been outlined with reference to one aspect of the invention and will not be repeated here.

[0064] The opening line preferably includes a first line of weakness, which may be a complete severance.

[0065] The method preferably includes the step of completely covering the tear line with an outer wrapper. The outer wrapper covers the tear line in all its extension. For example, the tear line extends over the front wall, and the left and right side walls of the package. The outer wrapper thus encases the package over its front wall, left side wall and right side wall. The outer wrapper preferably covers the entire outer surface of the package. Good control of the structural integrity of the resulting container is obtained.

[0066] The step of folding the first cellulosic layer to form a package includes folding the first cellulosic layer to form a package defining a base wall and a top wall, and the method preferably includes providing a second polymeric layer on a portion of the outer surface of the second cellulosic layer that covers the top or base wall of the package when the outer wrapper is wrapped around the package. The second polymeric layer is primarily used to "close" the flaps of the outer wrapper when the top and base walls are folded around the package. The remaining portion of the outer surface of the second cellulosic layer is preferably not covered by the second polymeric layer so that the second cellulosic layer is visible.

[0067] Preferably, forming the outer wrapper includes forming an outer wrapper that includes a third polymer layer. More preferably, the third polymer layer is located between the second cellulosic layer and the first polymer layer. Even more preferably, the third polymer layer is a moisture barrier layer.

[0068] When a third polymer layer is present, said first polymer layer may be applied in a pattern to only partially cover the surface of said third polymer layer. When a third polymer layer is present, the first polymer layer may cover only less than 30% of the surface of the polymer layer.

[0069] For purposes of this invention, a moisture barrier layer is a layer having a water vapor or moisture transmission rate (VWTR) of 60 grams / meter squared per 24 hours or less at 38 degrees Celsius and 90 percent relative humidity as determined by ISO 2528:1995 or ASTM F3299. It is preferred that the moisture barrier layer of the container of the present invention have a WVTR of less than 20 grams / meter squared per 24 hours, and more preferably less than 10 grams / meter squared per 24 hours, at 38 degrees Celsius and 90 percent relative humidity.

[0070] When wrapped around a package defining an interior volume, the outer wrapper may control the relative humidity within the interior volume. To this end, the third polymer layer belonging to the outer wrapper is a moisture barrier layer. The third polymer layer may include a filler such as calcium carbonate, kaolin, talcum, mica, or other platelet-type minerals. Preferably, the third polymer layer is not sealable and may be crosslinked or may include a crosslinking agent.

[0071] The package is preferably capable of being opened and closed. The relative humidity within the internal volume is preferably within a given desired range. The desired range is the range of relative humidity that is optimal for the consumer goods stored within the internal volume. When the container is opened to access one or more consumer goods stored within the internal volume, the relative humidity of the internal volume begins to equilibrate with the external environment and the relative humidity of the internal volume may deviate from the desired range. When the container is closed, the moisture barrier layer may help to restore the desired relative humidity to within the desired range. This is particularly advantageous when one or more consumer goods remain within the container after opening and closing.

[0072] The second cellulosic layer preferably defines an inner surface and an outer surface. The step of forming the outer wrapper preferably includes coating the inner surface of the second cellulosic layer with a first polymer layer. More preferably, the method includes coating the entire inner surface of the second cellulosic layer with the first polymer layer. Among the possible techniques for forming a multilayer, in which the various layers of the multilayer form an integral part, coating is the preferred technique due to its reliability and the relative ease of implementation. Due to the tensile strength of the first polymer layer, the blank formed by the first multilayer may contain less cellulosic material than blanks for cigarette containers realized according to the prior art.

[0073] During the coating of the second cellulosic layer with the material forming the first polymeric layer, care is preferably taken to prevent the formation of pinholes and other defects that may adversely affect the moisture barrier performance or heat seal properties of the coated material. The formation of defects can be minimized by a careful selection of the polymer application technique, the drying conditions, and the rheology of the applied dispersion. In particular, techniques such as rod coating, slot-die coating, and curtain coating allow the preparation of polymer layers with reduced defects and therefore enhanced barrier properties. However, it is also possible to apply a satisfactory coating using printing techniques such as flexographic printing or gravure coating. In the case of these latter techniques, the coating is preferably applied by several layers until the desired thickness of the first polymeric layer is reached. In fact, each subsequent layer or step of printing makes it possible to fill the pinhole defects left during the previous coating step. The coating made of the first polymeric material may be cast from the molten state onto the second cellulosic layer, for example a paper or cardboard sheet, using techniques well known in the art, such as hot melt coating or extrusion coating. Details of 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).

[0074] Alternatively, when the outer wrapper includes a third polymer layer, the step of forming the outer wrapper includes coating the inner surface of the second cellulosic layer with a third polymer layer and coating the inner surface of the third polymer layer with a second polymer layer. The third polymer layer is preferably a moisture barrier layer. This layer is located between the second cellulosic layer and the first polymer layer. When the outer wrapper is wrapped around the package and heat and / or pressure is applied, the first polymer layer melts and adheres to the outer surface of the package. The third polymer layer is preferably unaffected and provides moisture barrier properties. Having two different layers improves the properties of the container because having more than one layer allows for the use of special compositions for each layer between the first and third polymer layers to improve moisture barrier or seal performance or both.

[0075] Forming the outer wrapper preferably includes coating the outer surface of the second cellulosic layer with a second polymer layer. In this way, two heat-sealable layers are formed on two opposite sides of the outer wrapper. In this way, sealing of the outer wrapper onto the package is optimized. The coating of the second cellulosic layer with the second polymer layer is preferably performed according to the preferred characteristics described with reference to the coating of the second cellulosic layer with the first polymer layer.

[0076] The method preferably includes folding the first cellulosic layer to form a package including a lid portion and a box portion, the box portion and the lid portion being divided by a tear line, the lid portion being hinged to the box portion. The method preferably includes wrapping the box portion and the lid portion with an outer wrapper, the outer wrapper covering at least a portion of the tear line. The method preferably includes forming a second line of weakness on a portion of the outer wrapper covering the tear line. More preferably, the method includes opening the lid portion by tearing or breaking the second line of weakness. It is preferable to have an easy opening that allows the user to perform the opening without applying too much force in order to rotate the lid portion about the hinge line to properly open the package and access the consumer goods stored in the container. Furthermore, due to the fact that the outer wrapper covers at least a portion of the tear line, it is preferable that the need to tear or break the outer wrapper is somewhat controlled. For this purpose, a second line of weakness is formed on the outer wrapper. The second line of weakness is preferably formed on the outer surface of the outer wrapper. The second line of weakness preferably follows the extension of the tear line. In the front view, the second line of weakness is preferably located at the same height as the tear line. In the left and right side views, the second line of weakness is preferably located at the same height as the tear line. In this way, when applying a force to the container to open the lid portion, for example by rotating the lid portion about the hinge line, the force required to break or tear the outer wrapper at the second line of weakness is less than the force required to break or tear the outer wrapper if the second line of weakness is not present. In addition, the outer wrapper is torn or broken in a controlled manner, improving the aesthetics of the opened container.

[0077] Preferably, the opening line comprises a first line of weakness. More preferably, the method comprises opening the lid portion by tearing or breaking the opening line and the second line of weakness. If the opening line is the first line of weakness, then using the same motion, the user breaks or tears both the first line of weakness and the second line of weakness.

[0078] The second line of weakness may preferably be produced by any suitable partial cutting process of the second cellulosic layer (i.e., the cutting process cuts through less than 100% of the thickness of the second cellulosic layer or the cutting process cuts through less than 100% of the width of the second cellulosic layer when in an unfolded state).

[0079] The method preferably includes forming a second line of weakness on the second cellulosic layer before providing the second cellulosic layer with the first or second polymer layer. After partial cutting of the second cellulosic layer, the first and second polymer layers are applied to the second cellulosic layer. This second line of weakness can preferably be made on the outer wrapper before wrapping the package with the outer wrapper. The second line of weakness is preferably formed on the second cellulosic layer before being covered by the second or first polymer layer. Alternatively, the second line of weakness is formed on the second cellulosic layer when the second cellulosic layer is already covered by the first polymer layer or by the second polymer layer (or the third polymer layer, if there is a third polymer layer), or by both.

[0080] The method preferably comprises printing indicia relating to the consumer good or to the manufacturer of the consumer good on the part of the outer surface of the second cellulosic layer that is not covered by the second polymeric layer. The container preferably defines an outer surface. The outer surface of the container is preferably formed - at least in part - by the outer surface of the second cellulosic layer. The outer surface of the container is preferably made of paper or cardboard. Any indicia can therefore be printed on this outer surface using standard printing techniques. The printing is not easily removable and remains substantially unchanged over a long period of time. This makes it possible, for example, to print health warnings on the container without the risk that they can be easily removed (the outer wrapper cannot be removed from the package after sealing).

[0081] The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising an ethylene polymer or copolymer. The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising a propylene polymer or copolymer. The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising a styrene acrylate copolymer. The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising a styrene butadiene copolymer. The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising a styrene isoprene copolymer. The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising a copolymer of hydrogenated styrene butadiene. The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising a copolymer of hydrogenated styrene isoprene. The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising a copolymer of an ester of acrylic acid or methacrylic acid. The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising a copolymer of vinyl acetate. The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising a copolymer of polybutene. The above-listed polymers or copolymers preferably comprise from 30 percent to 50 percent by weight based on the total weight of the composition.

[0082] More preferably, the composition comprises a polymer, copolymer, or omopolymer of ethylene and propylene. More preferably, the composition comprises a polymer, copolymer, or omopolymer of ethylene and 1-butene. More preferably, the composition comprises a polymer, copolymer, or omopolymer of ethylene and isobutylene. More preferably, the composition comprises a polymer, copolymer, or omopolymer of ethylene and 1-octene. More preferably, the composition comprises a polymer, copolymer, or omopolymer of ethylene and 1-ecene. More preferably, the composition comprises a polymer, copolymer, or omopolymer of ethylene and norbornene. More preferably, the composition comprises a polymer, copolymer, or omopolymer of ethylene and vinyl acetate. More preferably, the composition comprises a polymer, copolymer, or omopolymer of ethylene and an acrylic or methacrylic ester. More preferably, the composition comprises a polymer, copolymer, or omopolymer of ethylene and an acrylic or methacrylic acid. More preferably, the composition comprises a polymer, copolymer, or omopolymer of ethylene and dicyclopentadiene.

[0083] More preferably, the composition comprises a polymer, copolymer, or omopolymer of propylene and 1-butene. More preferably, the composition comprises a polymer, copolymer, or omopolymer of propylene and isobutylene. More preferably, the composition comprises a polymer, copolymer, or omopolymer of propylene and 1-octene. More preferably, the composition comprises a polymer, copolymer, or omopolymer of propylene and 1-exene. More preferably, the composition comprises a polymer, copolymer, or omopolymer of propylene and norbornene. More preferably, the composition comprises a polymer, copolymer, or omopolymer of propylene and vinyl acetate. More preferably, the composition comprises a polymer, copolymer, or omopolymer of propylene and an acrylic or methacrylic ester. More preferably, the composition comprises a polymer, copolymer, or omopolymer of propylene and an acrylic or methacrylic acid. More preferably, the composition comprises a polymer, copolymer, or omopolymer of propylene and dicyclopentadiene. More preferably, the composition comprises a polymer, copolymer, or omopolymer of propylene and polybutene.

[0084] More preferably, the composition further comprises a wax.Preferred waxes are paraffin wax, microcrystalline wax, polyethylene wax, or hydrocarbon-based wax.Adding a certain amount of wax to one or more of the above-listed polymers or copolymers reduces 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.

[0085] The wax content is preferably comprised between 10 percent and 70 percent by weight based on the total weight of the composition. More preferably, the wax content is comprised between 10 percent and 40 percent by weight based on the total weight of the composition. In this way, suitable moisture barrier properties are obtained and a good emulsion is achieved.

[0086] The composition preferably further comprises a hydrocarbon resin. The hydrocarbon resin is more preferably a hydrogenated hydrocarbon resin. The hydrocarbon resin is more preferably a polyterpene resin. The content of the hydrocarbon resin is preferably 30 weight percent to 50 weight percent based on the total weight of the composition.

[0087] Preferably, the hydrocarbon resin is a polymer or copolymer of C5 and C9 monomers, or a polyterpene resin (as described in the book Hydrocarbon Resins, Dr. R. Mildenberg, Dr. M. Zander, Dr. G. Collin, ISBN: 9783527286171, published by Wiley in 1997).

[0088] Preferably, the hydrocarbon resin is a hydrogenated polymer or copolymer of C5 and C9 monomers, or a modified polyterpene resin (as described in the book Hydrocarbon Resins, Dr. R. Mildenberg, Dr. M. Zander, Dr. G. Collin, ISBN: 9783527286171, published by Wiley in 1997).

[0089] The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising a copolymer of styrene butadiene, a hydrocarbon resin, and a wax. The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising a copolymer of styrene isoprene, a hydrocarbon resin, and a wax. The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising a copolymer of hydrogenated styrene butadiene, a hydrocarbon resin, and a wax. The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising a copolymer of hydrogenated styrene isoprene, a hydrocarbon resin, and a wax. The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising a copolymer of an ester of acrylic or methacrylic acid, a hydrocarbon resin, and a wax.The step of providing the first polymer layer, or the step of providing the second polymer layer, or the step of providing the third polymer layer preferably comprises forming a composition comprising a copolymer of vinyl acetate, a hydrocarbon resin, and a wax. Preferably the composition is a hot melt composition.

[0090] In the case of extrusion coating process or hot melt coating process, where the second cellulosic layer is coated by a polymer layer (either the first polymer layer, the second polymer layer, or the third polymer layer), the material forming the first polymer layer, the second polymer layer, or the third polymer layer is preferably a polymer such as an amorphous or low crystalline polymer and a copolymer of propylene, ethylene, vinyl acetate, acrylic or methacrylic acid esters, polyethylene gypsum, polypropylene gypsum, very low density polyethylene (VLDPE), low density polyethylene (LDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE). These compositions have the desired heat sealability at the temperature of interest and may be advantageously formulated with ingredients such as hydrocarbon resins and waxes that allow optimizing the rheological, barrier, and adhesive properties. These compositions are also preferred because they may have high fluidity when in the molten state. The fluidity of the material can be expressed by the MFI (Melt Flow Index) at 190C and 2.16 kg of pressure (ASTM D1238). The preferred heat sealable layer (as the first polymer layer and the second polymer layer) has an MFI of more than 100 grams / min, more preferably more than 500 grams / min. The MFI can give an indication of the rheology of the first polymer layer or the second polymer layer. The higher the MFI, the higher the flowability at low shear rate (where the shear rate is linked to the pressure applied during sealing). This is because a high MFI is preferred to achieve good sealing of the outer wrapper onto the package at a relatively low pressure. The lower the pressure applied, the higher the MFI is preferred.

[0091] The definitions of LDPE, MDPE and HDPE as used herein are in accordance with ASTM D0883-20B (Standard Terminology Relating to Plastics) and are as follows: LDPE has a density of 0.910 grams per cubic centimeter (g / cm 3 ) ~ 0.925 grams per cubic centimeter (g / cm 3), and the density of HDPE is 0.941 grams per cubic centimeter (g / cm 3 ) and the density of MDPE is 0.926 grams per cubic centimeter (g / cm 3 ) ~ 0.940 grams per cubic centimeter (g / cm 3 )

[0092] The outer wrapper preferably includes a second line of weakness formed on a portion of the outer wrapper overlying the tear line.The second line of weakness is preferably formed on an outer surface of the outer wrapper.

[0093] The second cellulosic layer preferably has a first thickness and the second line of weakness comprises an etched line having a depth of 80 percent or less of the first thickness. The second line of weakness is preferably realized only on the second cellulosic layer. The second line of weakness is preferably not deep enough to form an etch on the second polymeric layer or the third polymeric layer as well. The second polymeric layer may have heat sealable properties to ensure a substantially uniform seal when heat is applied due to the absence of the second line of weakness thereon. If a third polymeric layer is present, the etching may result in an area where moisture is free to exchange. The first thickness of the second cellulosic layer is preferably comprised between 30 micrometers and 60 micrometers. The depth of the second line of weakness is preferably at least 50 percent of the first thickness. The depth of the second line of weakness is preferably comprised between 50 percent and 80 percent of the thickness of the second cellulosic layer. In this way, easy opening of the container is possible and the properties of the second polymeric layer are not hindered.

[0094] The first and second polymer layers are preferably made of the same material. The first and second polymer layers preferably have the same physical and chemical properties. The first and second polymer layers preferably have the same melting point. In this way, a single application of heat melts both the first and second polymer layers, closing the outer wrapper on the package. The container formation process is simplified.

[0095] The first cellulosic layer preferably has a basis weight comprised between 170 grams per square meter (gsm) and 270 grams per square meter (gsm). The weight per square meter of the first cellulosic layer is preferably greater than the weight per square meter of the second cellulosic layer. The first cellulosic layer has a weight per square meter that is equal to or lower than the cellulosic layers used to form standard packages of cigarettes known in the art. The stiffness and mechanical properties of the container according to the invention are preferably similar to those of cigarette packages known in the art. The "loss" of stiffness due to the lower weight per square meter is compensated for by the presence of the first polymer layer. It is preferred that the first polymer layer have a thickness of less than 15 micrometers, more preferably less than 10 micrometers.

[0096] The second cellulosic layer preferably has a basis weight comprised between 40 grams per square meter and 70 grams per square meter. The second cellulosic layer included in the outer wrapper is preferably relatively lightweight since it is not required to provide structural stability to the container.

[0097] The first polymer layer preferably has a basis weight comprised between 4 grams per square meter and 15 grams per square meter. The third polymer layer preferably has a basis weight comprised between 5 grams per square meter and 10 grams per square meter. The second polymer layer preferably has a basis weight comprised between 3 grams per square meter and 15 grams per square meter. The polymer layer is selected to have sufficient weight to achieve the desired heat sealability or water barrier properties.

[0098] The first polymer layer or the second polymer layer preferably has a melting point measured according to Differential Scanning Calorimetry (DSC) of less than 120 degrees Celsius. The heat-sealable layer(s) preferably has a melting point measured according to Differential Scanning Calorimetry (DSC) of less than 100 degrees Celsius. More preferably, the heat-sealable layer has a melting point measured according to Differential Scanning Calorimetry (DSC) of less than 80 degrees Celsius. Temperatures in the claimed ranges make it possible to obtain an optimal seal with the material forming the container without damaging the container.

[0099] The third polymer layer preferably has a melting point, as measured according to differential scanning calorimetry (DSC), that is higher than the melting temperatures of the first and second polymer layers. The third polymer layer, which has the function of a moisture barrier layer, is preferably formulated to have a higher melting point than the first and second polymer layers, which have the function of a heat sealable layer. The third polymer layer preferably does not exhibit thermoplastic behavior in the range of temperatures and pressures used in the packaging process. The components for the preparation of the composition for forming the third polymer layer and the first polymer layer (second polymer layer) may belong to the same family, but the selection of specific components / grades may determine a lower or higher melting point relative to each other layer. More generally, the selection of specific raw materials or grades can make a material that is or is not flowable at a specific temperature. The concept of flowability at a specific pressure and temperature is particularly relevant for compositions based on amorphous copolymers or compositions that exhibit multiple melting points as measured by DSC.

[0100] As an example, a paraffin wax may be selected that has a melting point of 60 degrees Celsius, or one that has a melting point of over 100 degrees Celsius. The addition of one or the other of the two paraffin waxes to the composition changes the melting point of the entire composition.

[0101] Similarly, hydrogenated styrene ethylene butylene copolymers (SEBS - completely amorphous and therefore exhibit no fixed melting point) may be selected based on molecular weight (highest flowable to lowest) to engineer thermoplastic / flowable or thermoplastic / non-flowable formulations at specific temperatures and pressures.

[0102] The composition of the third polymer layer is such that the layer is not thermoplastic / flowable at the temperatures or pressures required for the packaging process, and thus maintains its integrity during the process itself. In this way, even if the first and second polymer layers are damaged during the sealing / packaging process, the more resistant third polymer layer is hardly affected, either by having a higher melting point or by exhibiting negligible flowability at the packaging / gluing process temperature(s).

[0103] The outer wrapper preferably includes a metallized layer. For example, the pre-coated cellulosic layer may be a metallized paper. For the purposes of the present invention, the cellulosic layer may be metallized before applying one or more polymeric layers. The metallized layer may be a barrier layer intended to enhance the barrier performance of the resulting container. By providing an outer wrapper with a metallized layer, or a metallized outer wrapper, the barrier characteristics of the outer wrapper may be improved. The metallized outer wrapper may further protect the consumer goods contained in the container, since it is significantly less permeable to gases or vapors, such as oxygen or moisture. The metallization may later also be used for decorative purposes. Preferably, the step of providing an outer wrapper includes applying a metallized layer to the second cellulosic layer.

[0104] The metallized layer may be on the inner surface of the second cellulosic layer. Alternatively, the metallized layer may be on the outer surface of the second cellulosic layer. When the metallized layer is on the outer surface of the second cellulosic layer, the metallized layer may impart a more attractive appearance to the outer wrapper. The metallization layer is preferably an aluminum layer, however, the metallization layer may be a layer comprising any suitable metal. The metallized layer is preferably between the second cellulosic layer and the first polymeric layer.

[0105] The first polymer layer may be on at least 50 percent of the inner surface of the metallized layer, preferably the first polymer layer is on at least 80 percent of the inner surface of the metallized layer, and more preferably the first polymer layer is on the entire inner surface of the metallized layer.

[0106] The metallization layer may have a thickness of at least 10 nanometers, and preferably the metallization layer has a thickness of at least 15 nanometers. The metallization layer may be deposited using physical vapor deposition (PVD) techniques under high vacuum.

[0107] A primer layer may be between the second cellulosic layer and the metallized layer. The primer layer may smooth the surface of the second cellulosic layer and provide a suitable anchoring layer for deposition of the metallized layer.

[0108] The metallized layer may be covered with a protective layer. The protective layer may protect the metallized layer from damage that may occur during handling and formation of the container. The protective layer may be prepared by applying a solution or dispersion of a suitable polyester resin, such as a polycondensate of terephthalic acid, isophthalic acid, adipic acid, azelaic acid, and one or more diols, such as ethylene glycol, 1,3-propanediol, 1,4 propanediol, diethylene glycol, neopentyl glycol, 2-methyl-1,3-propanediol, and the like. The protective layer may also be prepared from a mixture of at least two dibasic acid or its methyl ester monomers with at least one or more glycols that provide a polymer with good solubility and adhesion to the metal layer. Other suitable compositions suitable for preparing the top coating include solutions of polymers such as cellulose acetate or cellulose propionate, dispersions of copolymers of ethylene and various olefins such as acrylic acid or methacrylic acid, and solutions or dispersions of hydrogenated hydrocarbon resins.

[0109] The container realised by the invention has particular application as a container for elongated aerosol-generating articles (such as cigarettes, cigars, cigarillos or other aerosol generators) that rely on heating, e.g., by electrical or carbon heat sources, rather than on burning tobacco. Naturally, by appropriate selection of its dimensions, the container according to the invention may be designed for a different number of conventional, king size, super king size, slim or super slim aerosol-generating articles. Alternatively, other consumer goods may be accommodated within the container.

[0110] For example, by appropriate selection of dimensions, a container according to the invention may be designed to hold a total of 10 to 30 aerosol-generating articles. The aerosol-generating articles may be arranged in different arrangements depending on the total number of aerosol-generating articles.

[0111] A container formed according to the present invention may be rectangular in shape, with rectangular longitudinal edges and rectangular transverse edges. Alternatively, the container may include one or more longitudinal rounded edges, transverse rounded edges, longitudinal chamfered edges, or transverse chamfered edges, or combinations thereof. Alternatively, the container may have a non-rectangular transverse cross-section, for example, polygonal (such as triangular or hexagonal), semi-elliptical, or semi-circular.

[0112] Typically, the outer dimensions of the container are from about 0.5 mm to about 5 mm larger than the dimensions of the bundle or bundles of aerosol-generating articles contained within the container.

[0113] The height of the container according to the present invention is preferably about 60 mm to about 150 mm, more preferably about 70 mm to about 125 mm, the height being measured from the bottom wall to the top wall of the container. The width of the container according to the present invention is preferably about 12 mm to about 150 mm, more preferably about 70 mm to about 125 mm, the width being measured from one side wall of the container to the other side wall.

[0114] Preferably, containers according to the present invention have a depth of from about 6 mm to about 150 mm, and more preferably the depth is from about 12 mm to about 25 mm, the depth being measured from the front wall to the rear wall of the container (including the hinge between the box and the lid).

[0115] The ratio of the container height to the container depth is preferably about 0.3:1 to about 10:1, more preferably about 2:1 to about 8:1, and most preferably about 3:1 to 5:1. The ratio of the container's depth to its width is preferably about 0.3:1 to about 10:1, more preferably about 2:1 to about 8:1, and most preferably about 2:1 to 3:1.

[0116] Where the container contains an aerosol-generating article, the container may further comprise a compartment for waste (e.g., for ashes or cigarette butts), or other consumer items (e.g., matches, lighters, fire extinguishing means, breath freshener or electronic components, etc.) The other consumer items may be attached to the outside of the container, may be contained within the container along with the aerosol-generating article in a separate compartment of the container, or a combination thereof.

[0117] The term "inner surface" is used throughout this specification to refer to a surface of an assembled container component that faces toward the interior of the container (e.g., toward the consumer goods) when the container is in a closed position. The term "outer surface" is used throughout this specification to refer to a surface of a container component that faces toward the exterior of the container. For example, the front wall of a container has an inner surface that faces toward the inside of the container and consumer goods, and an outer surface that faces away from the consumer goods. It is noteworthy that the inner or outer surface does not necessarily correspond to a certain side of the blank used to assemble the container. Depending on how the blank is folded around the consumer goods, the area on the same side of the blank may face either the inside or the outside of the container.

[0118] 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 and the access opening of the container is 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 outer hinged lid container is the wall that contains the hinge line.

[0119] 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 cross direction.

[0120] The term "panel" is used throughout this specification to refer to a portion of a blank that is used to form a wall of an erected container. A panel may be dependent on one or more other panels along one or more fold lines.

[0121] The term "crease" refers to a fold between two adjacent panels. When forming a container, the adjacent panels are folded along their common crease, which may define an edge of the container or of a portion of the container.

[0122] In the assembled container, a "wall" may be formed of one or several overlapping panels. If there are several overlapping panels, these may be attached to one another, for example by adhesive. Furthermore, a wall may be formed of two or more abutting or overlapping panels.

[0123] The term "height" is used to describe one such element dimension measured in a direction perpendicular to the element's width. When describing elements of a blank, generally the elements are described in the blank's flat state.

[0124] The term "thickness" as used herein refers to the smallest distance measured between two opposing surfaces of a sheet-like blank or a layer of a sheet blank. In practice, the distance at a given location is measured along a direction locally perpendicular to the opposing faces. The "thickness" of a layer is generally substantially constant across the layer (flat cross-section).

[0125] However, local variations are possible where parts of the sheet blank are, for example, embossed, debossed, weakened, etc.

[0126] The term "hinge line" refers to a line about which a lid may pivot in order to open a hinge-lid housing. The hinge line may be, for example, a crease or score line in a panel forming the rear wall of the container.

[0127] The term "line of weakness" is used herein to describe a portion of the surface of a container or package (or blank forming the container or package) where the structural strength of the material from which the container or package (or blank) is formed is weakened by any suitable technique, for example by bending, folding, or tearing along the line of weakness. For example, the line of weakness may be formed as a score line, a score line, a cut line, or a perforation line. A line of weakness can be created by removing material, by displacing material, by compressing material, by locally reducing the forces holding the material together (for example by breaking fibers in a fibrous material), and by combinations of all of the above. A line of weakness may be straight, curved, piecemeal or continuous, or a combination thereof. In many instances, the line of weakness is used to aid in the positioning of the folds in the blank. A line of weakness may also be used to strengthen the material in a direction perpendicular to the line of weakness, for example by compression. Additionally, the line of weakness can be used for decorative purposes.

[0128] The term "scoreline" is used to describe a line formed by partially cutting into the material of a blank. A scoreline may be formed by removing material from the blank (in which case the scoreline forms a groove or valley in the blank). Alternatively, a scoreline may be formed without removing any material from the blank, which typically involves partial lateral displacement and compression of the material, caused by a knife of non-zero thickness penetrating the material. The depth of the scoreline will be less than the thickness of the blank.

[0129] The term "score line" is used to describe a line formed by displacing a portion of material perpendicular to the plane of the blank, forming a groove or valley in the blank. The displacement may involve compression, and typically involves the use of a compression tool such as a roller. Alternatively, or additionally, the material in the score line may be displaced to protrude at least partially from the opposite side of the blank. Generally, no material is removed when the score line is formed.

[0130] The term "ablation line" is used to describe a line formed by ablation (eg, by a laser beam or blade) removing material from the surface of a blank to a predetermined depth.

[0131] The term "perforation line" is used to describe a line or array of individual holes or slots in a blank. The holes may be formed by pushing an object through the blank. This may result in material being removed from the blank, for example by punching. Alternatively, the holes may be created without removing material, but instead simply using an object to push material outward from the center of the hole. As another alternative, the holes may be formed by a laser beam.

[0132] The term "crease" is used to describe any line in a blank about which the blank folds. A crease may be defined by a line of weakness to assist in the folding action. Alternatively, a fold may be formed without the presence of a line of weakness, depending, for example, on the pliability characteristics of the blank material and other materials.

[0133] In 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 may come from wood, rags, grasses, or other plant sources. The water is then drained, for example, through a fine mesh to distribute the fibers evenly on the surface, followed by pressing and drying. The sheet of paper may also contain fillers and additives in addition to the pulp. The pulp used can be bleached or unbleached and is obtained from various processes. Among others, suitable pulp types are hardwood kraft pulp, softwood kraft pulp, sulfite pulp or other chemical pulp, mechanical pulp, thermomechanical pulp, chemi-thermomechanical pulp, or other types of mechanical pulp, and recycled paper pulp can also be used. For the purposes of the present invention, thermomechanical pulp, chemi-thermomechanical pulp (CTMP), chemical pulp, or blends thereof are preferred.

[0134] As used herein, an aerosol-forming article is any article that generates an inhalable aerosol when the aerosol-forming substrate is heated. This term includes articles that comprise an aerosol-forming substrate that is heated by an external heat source, such as an electric heating element. The aerosol-forming article may be a non-flammable aerosol-forming article, which is an article that releases a volatile compound without the combustion of the aerosol-forming substrate. The aerosol-forming article may be a heated aerosol-forming article, which is an aerosol-forming article that comprises an aerosol-forming substrate that is intended to be heated, rather than burned, to release a volatile compound that can form an aerosol. This term includes articles that comprise an aerosol-forming substrate and an integral heat source (e.g., a combustible heat source).

[0135] The aerosol-forming article according to the present invention may be in the form of a combustible filtered cigarette or other smoking article in which tobacco material is combusted to form smoke.

[0136] The aerosol-forming article may preferably 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 aerosol-forming article may have an overall length of about 30 millimeters to about 100 millimeters. The aerosol-forming article may have an outer diameter of about 5 millimeters to about 12 millimeters.

[0137] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of any other example, embodiment, or aspect described herein.

[0138] Example 1: A method of making a container for a consumer product, comprising: - folding a first cellulosic layer to form a package, the package defining a housing for the consumer good; and forming an outer wrapper, the outer wrapper including a second cellulosic layer having an inner surface defining an interior region and an outer surface defining an outer region, a first polymeric layer disposed on the inner surface, and a second polymeric layer disposed on less than 30 percent of the outer surface; forming a first polymer layer and a second polymer layer, the first polymer layer and the second polymer layer being heat-sealable layers; - wrapping the package with an outer wrapper, the first polymeric layer being disposed on an inner side of the second cellulosic layer; - heating the package and the outer wrapper to seal the outer wrapper onto the package to form a container.

[0139] Example 2: Heating the package and outer wrapper The method of claim 1, comprising heating the package and the outer wrapper while applying pressure to seal the outer wrapper onto the package.

[0140] Example 3: - folding the first cellulosic layer to form a package including a lid portion and a box portion, the box portion and the lid portion being divided by a tear line and the lid portion being hinged to the box portion; The method of example 1 or example 2, comprising: wrapping the box portion and the lid portion with an outer wrapper, the outer wrapper at least partially covering the tear line.

[0141] Example 4: The method of example 3, wherein the opening line includes a first line of weakness.

[0142] Example 5: -Completely covering the tear line with an outer wrapper The method according to Example 3 or 4.

[0143] Example 6: A method according to claim 1, wherein the step of folding the first cellulosic layer to form a package includes folding the first cellulosic layer to form a package defining a base wall and a top wall, the method comprising: The method of any one or more of the preceding Examples 1-5, comprising providing a second polymeric layer on a portion of an outer surface of the second cellulosic layer that covers the top wall or base wall of the package when the outer wrapper is wrapped around the package.

[0144] Example 7: The step of forming an outer wrapper comprises: The method of any one or more of the preceding Examples 1-6, comprising coating an inner surface of the second cellulosic layer with a first polymer layer.

[0145] Example 8: The method of any one or more of Examples 1-6, wherein forming the outer wrapper includes providing a third polymer layer.

[0146] Example 9: The method of example 8, wherein a third polymer layer is located between the second cellulosic layer and the first polymer layer.

[0147] Example 10: The method of example 8 or example 9, wherein the third polymer layer is a moisture barrier layer.

[0148] Example 11: - coating an inner surface of the second cellulosic layer with a third polymer layer; - coating the inner surface of the third polymer layer with a second polymer layer.

[0149] Example 12: The step of forming an outer surface comprises: The method of any one or more of the preceding Examples 1-11, comprising coating an outer surface of the second cellulosic layer with a second polymer layer.

[0150] Example 13: - folding the first cellulosic layer to form a package including a lid portion and a box portion, the box portion and the lid portion being divided by a tear line and the lid portion being hinged to the box portion; - wrapping the box portion and the lid portion with an outer wrapper, the outer wrapper at least partially covering the tear line; The method of any one or more of the preceding Examples 1-12, comprising: forming a second line of weakness on a portion of the outer wrapper covering the tear line.

[0151] Example 14: - opening the lid portion by tearing or breaking the second line of weakness.

[0152] Example 15: The method of example 14 and example 4, comprising opening the lid portion by tearing or breaking the first line of weakness and the second line of weakness.

[0153] Example 16: Forming a second line of weakness The method of one or more of Examples 13 to 15, comprising forming a second line of weakness on the second cellulosic layer prior to providing the first polymer layer or the second polymer layer to the second cellulosic layer.

[0154] Example 17: A method according to one or more of the preceding claims, comprising printing indicia relating to the consumer good or to the manufacturer of the consumer good on parts of the outer surface of the second cellulosic layer that are not covered by the second cellulosic layer.

[0155] Example 18: Providing a first polymer layer, or providing a second polymer layer, or providing a third polymer layer, Polymers or copolymers of ethylene, Propylene polymers or copolymers, Styrene acrylate copolymers, Styrene butadiene copolymers, Styrene-isoprene copolymers, Hydrogenated styrene butadiene copolymers, Hydrogenated styrene-isoprene copolymers, Copolymers of acrylic or methacrylic acid esters, The method of any one or more of the preceding Examples 1-17 comprising forming a composition comprising one or more copolymers of vinyl acetate.

[0156] Example 19: A composition comprising a polymer, copolymer, or omopolymer of ethylene and ·propylene, 1-butene, Isobutylene, 1-octene, 1-Eccentric, Norbornene, Vinyl acetate, Acrylic or methacrylic esters, acrylic or methacrylic acid, and The method of claim 18, comprising one selected from the group consisting of dicyclopentadiene.

[0157] Example 20: A composition comprising a polymer, copolymer, or omopolymer of propylene, and ·ethylene, 1-butene, Isobutylene, 1-octene, 1-Eccentric, Norbornene, Vinyl acetate Acrylic or methacrylic esters, acrylic or methacrylic acid, and The method of claim 18, comprising one selected from the group consisting of dicyclopentadiene.

[0158] Example 21: The method of any one of examples 18 to 20, wherein the composition further comprises a wax.

[0159] Example 22: Wax is Paraffin wax, Polyethylene wax, Microcrystalline wax, The method of claim 21, comprising one or more of the following: polypropylene wax.

[0160] Example 23: Composition The method of any one or more of Examples 18 to 22, further comprising a hydrocarbon resin.

[0161] Example 24: Hydrocarbon resin Hydrogenated hydrocarbon resins, The method of embodiment 23 comprising one or more polyterpene resins.

[0162] Example 25: The method of any one or more of Examples 18 to 25, wherein the composition is a hot melt composition.

[0163] Example 26: A container for consumer goods, comprising: - a package including a box portion and a lid portion, the package defining a housing for a consumer good, the lid portion being hinged to the box portion by a hinge line, a tear line separating the box portion and the lid portion outboard of the hinge line, the box portion and the lid portion being formed by folding a first multilayer blank including a first cellulosic layer; - an outer wrapper that is wrapped and sealed onto the package and at least partially covers the tear line, a second cellulosic layer having an inner surface and an outer surface; a first polymer layer disposed on an inner surface of the second cellulosic layer; a second polymeric layer disposed on less than 30 percent of an outer surface of the second cellulosic layer; and A container, wherein the first polymer layer and the second polymer layer are heat-sealable layers.

[0164] Example 27: The container of Example 26, wherein the opening line comprises a first line of weakness.

[0165] Example 28: The container of Example 26 or Example 27, wherein the outer wrapper comprises a third polymer layer.

[0166] Example 29: The container of Example 28, wherein a third polymeric layer is located between the second cellulosic layer and the first polymeric layer.

[0167] Example 30: The container of example 28 or example 29, wherein the third polymer layer is a moisture barrier layer.

[0168] Example 31: The container of example 27, wherein the outer wrapper includes a second line of weakness formed on a portion of the outer wrapper covering the tear line.

[0169] Example 32: A container described in one or more of claims 26 to 31, wherein the package includes a base wall and a top wall, and a second polymer layer is provided over a portion of the outer surface of the second cellulosic layer that covers the base wall or the top wall.

[0170] Example 33: The container of Example 31, wherein the second cellulosic layer has a first thickness and the second line of weakness comprises an etched line having a depth less than or equal to 80 percent of the first thickness.

[0171] Example 34: First polymer layer, second polymer layer, or third polymer layer Polymers or copolymers of ethylene, Propylene polymers or copolymers, Styrene acrylate copolymers, Styrene butadiene copolymers, Styrene-isoprene copolymers, Hydrogenated styrene butadiene copolymers, Hydrogenated styrene-isoprene copolymers, Copolymers of acrylic or methacrylic acid esters, A container according to one or more of Examples 26 to 33, comprising a composition comprising one or more of:

[0172] Example 35: A composition comprising a polymer, copolymer, or omopolymer of ethylene and ·propylene, 1-butene, Isobutylene, 1-octene, 1-Eccentric, Norbornene, Vinyl acetate Acrylic or methacrylic esters, acrylic or methacrylic acid, and The container of example 34 comprising one selected from the group consisting of dicyclopentadiene.

[0173] Example 36: A composition comprising a propylene polymer, copolymer, or omopolymer, ·ethylene, 1-butene, Isobutylene, 1-octene, 1-Eccentric, Norbornene, Vinyl acetate Acrylic or methacrylic esters, acrylic or methacrylic acid, and The container of example 35, further comprising one selected from the group consisting of dicyclopentadiene.

[0174] Example 37: The container of any one of Examples 34 to 36, wherein the composition further comprises a wax.

[0175] Example 38: Wax is Paraffin wax, Polyethylene wax, Microcrystalline wax, The container of example 37 comprising one or more polypropylene waxes.

[0176] Example 39: The composition comprises The container of one or more of Examples 34-38, further comprising a hydrocarbon resin.

[0177] Example 40: Hydrocarbon resin Hydrogenated hydrocarbon resins, The container of example 39 comprising one or more polyterpene resins.

[0178] Example 41: The container of Example 37 or Example 38 or the method of Example 21-Example 22, wherein the wax content by weight is 10 percent to 70 percent by weight based on the total weight of the composition.

[0179] Example 42: The container of Example 37 or Example 38 or the method of Example 21 or Example 22, wherein the wax content by weight is from 10 percent to 40 percent by weight based on the total weight of the composition.

[0180] Example 43: The container of Example 39 or Example 40, or the method of Example 23 or Example 24, wherein the content of the hydrocarbon resin by weight is 30 percent to 50 percent by weight based on the total weight of the composition.

[0181] Example 44: The container of one or more of Examples 34 to 43, or the method of one or more of Examples 18 to 24 or Examples 41 to 43, wherein the content of the one or more polymers or copolymers by weight is 30 percent to 50 percent by weight based on the total weight of the composition.

[0182] Example 45: The method of one or more of Examples 1 to 25, or Examples 41 to 44, or the container of one or more of Examples 26 to 44, wherein the first cellulosic layer has a basis weight comprised between 170 grams per square meter and 270 grams per square meter.

[0183] Example 46: The method of one of Examples 1 to 25 or Examples 41 to 45 or the container of one or more of Examples 26 to 45, wherein the second cellulosic layer has a basis weight comprised between 40 grams per square meter and 70 grams per square meter.

[0184] Example 47: The method of one or more of Examples 1 to 25 or Examples 41 to 46, or the container of one or more of Examples 26 to 46, wherein the first polymer layer has a basis weight comprised between 4 grams per square meter and 15 grams per square meter.

[0185] Example 48: The method of one or more of Examples 1 to 25 or Examples 41 to 47, or the container of one or more of Examples 26 to 47, wherein the second polymer layer has a basis weight comprised between 3 grams per square meter and 15 grams per square meter.

[0186] Example 49: The method of one or more of Examples 1 to 25 or Examples 41 to 48, or the container of one or more of Examples 26 to 48, wherein the third polymer layer has a basis weight comprised between 5 grams per square meter and 10 grams per square meter.

[0187] Example 50: The method of one or more of Examples 1 to 25 or Examples 41 to 49, or the container of one or more of Examples 26 to 49, wherein the first cellulosic layer has a thickness of 170 micrometers to 400 micrometers.

[0188] Example 51: The method of one or more of Examples 1 to 25 or Examples 41 to 50, or the container of one or more of Examples 26 to 50, wherein the second cellulosic layer has a thickness comprised between 30 micrometers and 60 micrometers.

[0189] Example 52: The method of one or more of Examples 1 to 25 or Examples 41 to 51, or the container of one or more of Examples 26 to 51, wherein the first polymer layer or the second polymer layer has a melting point of less than 120 degrees Celsius as measured by Differential Scanning Calorimetry (DSC).

[0190] Example 53: The method of any one of Examples 1 to 25 or Examples 41 to 52, or the container of any one or more of Examples 26 to 52, wherein the third polymer layer does not exhibit thermoplastic behavior at the temperatures and pressures used to bond the first polymer layer and the second polymer layer.

[0191] Example 54: The method of one or more of Examples 1 to 25 or Examples 41 to 53, or the container of one or more of Examples 26 to 53, wherein the third polymer layer has a melting point, as measured by differential scanning calorimetry (DSC), higher than the melting temperatures of the first polymer layer and the second polymer layer.

[0192] The embodiments will now be further described with reference to the figures.

[0193] 1 shows a package 10 for use with a container embodied in accordance with the present invention. Package 10 has a rectangular parallelepiped shape and includes 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.

[0194] The package further comprises a first right corner 27 and a second right corner 28 of the package 10. The first right corner 27 is formed between the rear wall 21 and the right side wall 24, and the second right corner 28 is formed between the front wall 22 and the right side wall 24. The package 10 also comprises a first left corner 29 formed between the rear wall 21 and the left side wall 23, and a second left corner 51 formed between the front wall 22 and the left side wall 23 (corners 29 are visible in FIG. 14).

[0195] The lid portion 16 is hinged about a hinge line 17 that extends across the rear wall of the parallelepiped. The package 10 further defines a housing or interior volume for containing, for example, a group of aerosol-generating articles (not shown in the drawings). When the package 10 is closed, the lid portion 16 and the box portion 14 define an opening line 19 that 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.

[0196] The opening line 19 is a first line of weakness, such as a cut, that allows the package 10 to be immediately opened or perforated such that the package 10 cannot be opened unless the opening line 19 is broken 19.

[0197] The package 10 is formed from a sheet blank 100 as shown in Figures 2 and 3. As shown in the side view of Figure 3, the sheet blank 100 comprises a first cellulosic layer 30 comprising cellulosic material. More preferably, the sheet blank comprises a first sheet 30 of cellulosic material. More particularly, the first cellulosic layer 30 is formed from a sheet of paper-based material. The first cellulosic layer 30 preferably has a basis weight comprised between 170 gsm and 270 gsm. The thickness of the first cellulosic layer is preferably comprised between 170 micrometers and 400 micrometers.

[0198] Sheet blank 100 is folded as is well known in the art to form package 10. Packages of any geometric shape are possible.

[0199] The package 10 formed by appropriately folding the sheet blank 100 is then wrapped using an outer wrapper to form a container 1 (shown in FIG. 17) for containing a consumer good (not shown), for example to contain an aerosol-generating article.

[0200] The outer wrapper is formed from a sheet blank 101, shown in Figures 4-9. In a first embodiment, shown in Figure 5, the sheet blank 101 includes a second cellulosic layer 40, which includes a second cellulosic material, and a first polymer layer 41 and a second polymer layer 42, both of which have heat seal and moisture barrier properties. The second cellulosic layer 40 has an inner surface 44 and an outer surface 45. The first polymer layer 41 completely covers the inner surface 44 of the second cellulosic layer 40, as shown in Figure 4. The second polymer layer 42 covers one or more portions of the outer surface 45 of the second cellulosic layer. The area covered by the portions onto which the second polymer layer is deposited is less than 30 percent of the total area of ​​the outer surface 45.

[0201] More specifically, the second cellulosic layer 40 is formed from a sheet of paper-based material. The second cellulosic layer 40 preferably has a basis weight comprised between 40 gsm and 70 gsm. The second polymeric layer 42 preferably has a weight comprised between 3 gsm and 15 gsm. The first polymeric layer preferably has a weight comprised between 4 gsm and 15 gsm. The thickness of the second cellulosic layer 40 is preferably comprised between 30 micrometers and 60 micrometers.

[0202] In a different embodiment shown in Figure 6, the sheet blank 101' forming the outer wrapper comprises a third polymer layer 43. The third polymer layer 43 is a moisture barrier layer. The third polymer layer is preferably located between the inner surface 44 of the second cellulosic layer 40 and the first polymer layer 41. The third polymer layer 43 preferably has a basis weight comprised between 5 grams per square meter and 10 grams per square meter.

[0203] In both the embodiments of Figures 5 and 6, the second polymeric layer 42 covers one or more portions of the outer surface 45 of the second cellulosic layer 40 according to a preferred pattern. Possible embodiments of these patterns are shown in Figures 7-9. The second polymeric layer preferably covers portions of the outer surface that correspond to portions of the top wall 26 or bottom wall 25 of the package when the outer wrapper is wrapped around the package 10. In Figures 7-9, the areas covered by the second polymeric layer are the grey areas. As can be seen, these areas are located in the portions of the blank 101, 101' that will cover the top or bottom wall of the package 10 when folded.

[0204] To form the container 1, an outer wrapper formed by a blank sheet 101 is wrapped around the package 10, as shown in Figures 10-17.

[0205] First, the second line of weakness 48 is formed on the blank sheet 101 or 101'. As can be seen in Figures 15 to 17, the second line of weakness 48 is formed on the blank sheets 101, 101' such that the second line of weakness 48 coincides with the tear line 19 when the blank sheets 101, 101' are wrapped around the package 10.

[0206] The second line of weakness 48 may be produced using a laser scoring process or partial mechanical cutting of the second cellulosic layer 40 through its thickness without damaging the sealable and moisture barrier layers.

[0207] A second line of weakness 48 is formed on the second cellulosic layer 40. The scoring is performed on the outer surface 45 of the second cellulosic layer 40 which will become the exterior surface of the container 1. The depth of the scoring is controlled so as not to affect the moisture barrier properties of the third polymeric layer 43 or the heat sealability of the first polymeric layer 41. The second line of weakness 48 is not realized in the area of ​​the outer surface 45 covered by the second polymeric layer 42.

[0208] Considering the scoring tolerances of both the laser and mechanical processes, and having good functionality (ease of opening), the scoring depth is preferably 50 percent to 80 percent of the thickness of the second cellulosic layer 40. For laser scoring, a 1000 watt CO2 laser may be used. Beam control of the laser may be via a scanner. The process may be reel-to-reel with a speed of 200 meters / min.

[0209] In the case of mechanical scoring, a rotary cutting unit may be used. The operation is carried out by inserting the second cellulosic layer between the knife of the cutting unit and a blind counter roller. The distance between the knife and the counter roller is between 15 micrometers and 30 micrometers depending on the substrate.

[0210] Although only blank 101 is shown in Figures 10-19, the same process applies to blank 101'.

[0211] The sheet blank 101, 101' of the outer wrapper is abutted against the right side wall 24 of the package 10 (see FIG. 10). The sheet blank 101, 101' is positioned such that the first polymeric layer 41 contacts the first polymeric layer 40 at the right side wall 24. Thus, the first polymeric layer 41 is the inner layer of the outer wrapper and the second cellulosic layer 40 is the outer layer of the outer wrapper.

[0212] The close-up view of Figure 18 (corresponding to the circled feature shown in Figure 10) shows how the blank 101 is applied to the package 10 and brought into contact with the package. Two creases 102, 103 are formed in the sheet blank 101 corresponding to the locations of the first and second right corners 27, 28 of the package 10. This is shown in Figure 11. The sheet blank 101 is then compressed against the side wall 24 as indicated by the arrow at the inlet in Figure 19 (corresponding to the circled feature shown in Figure 11).

[0213] The blank sheet 101 is then folded at two creases 102, 103 so that the front wall 22 and rear wall 21 of the package 10 also contact the outer wrapper. This is shown in FIG.

[0214] Package 10 is then preferably rearranged for ease of wrapping, for example, so that left side wall 23 faces upwardly as shown in FIG.

[0215] Two additional creases, creases 104, 105, are then formed in the sheet blank 101 corresponding to the locations of the first left corner 29 and the second left corner 51. The sheet blank 101 is then folded at the two creases 104, 105 so that the two opposing flaps of the sheet blank overlap on the left side wall 23, as shown in Figure 14. In this manner, panels of the sheet blank 101 are formed on the left side wall 23, the right side wall 24, the front wall 22 and the rear wall 21 of the package 10. In this manner, the entire tear line 19 and the hinge line 17 are covered by the outer wrapper.

[0216] The package 10 and outer wrapper are then preferably reoriented so that the front wall 22 faces upwardly, as shown in FIG.

[0217] The sheet blank 101 is then folded in a known manner (called an "envelope fold") to cover the top and bottom walls 26, 25 of the package 10. This is shown in Figures 16 and 17. In Figure 17, 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 48 is located in register with the tear line 19 located below it.

[0218] Heat and pressure are applied to securely bond the outer wrapper to the package 10. For example, a temperature of 110 degrees Celsius and a pressure of 1 Newton per square centimeter (N / cm 2 ) pressure is applied for 100 milliseconds. These conditions provide a satisfactory seal and high adhesion.

[0219] Example 1 Outer Wrapper A first embodiment of a sheet blank 101 will now be described. The second cellulosic layer 40 is a 50 grams per square meter paper. The entire inner surface of the paper is coated with a first polymer layer (15 grams per square meter) using a slot die or curtain coating process. This technique allows convenient application of a uniform, thin, and defect-free layer onto a fibrous substrate. The composition of the first polymer layer is as follows: The composition forming the first polymer layer is a 40 weight percent ethylene vinyl acetate copolymer having a vinyl acetate comonomer content of 18 weight percent and a MFI (Melt Flow Index) of greater than 500 grams / minute at 190°C, weighing 2.16 kg (EVATANE 18-550 from SK Polymers); 35.6 weight percent C9 hydrogenated hydrocarbon resin (Novares Pure 1120, Rain Carbon); 20 weight percent paraffin wax (Parvan 1470 from Exxon Mobil); 4 weight percent microcrystalline PE wax (Multiwax 180-MH from Sonneborn); and 0.4 weight percent pentaerythritol tetrakis(3,5-di-tert-butyl-4-hydroxyhydrocinnamate), such as Irganox 1010 (manufactured by BASF, CAS number 6683-19-8). This material prevents undesirable decomposition / oxidation of the hot melt composition during processing. The composition was prepared in a sigma blade mixer at a temperature of 170°C. The resulting coated cardboard (sheet blank 101) has a hardness of 11 grams / m at 38° C. and 90% RH (as determined by ISO 2528:1995). 2 It has a moisture permeability of 100 / day.

[0220] Example 2 Outer Wrapper A second embodiment of the sheet blank 101 will now be described. The second cellulosic layer 40 is a 50 grams per square meter paper. The entire inner surface of the paper is coated with a first polymer layer (15 grams per square meter) using a slot die or curtain coating process. This technique allows convenient application of a uniform, thin, and defect-free layer onto a fibrous substrate. The composition of the first polymer layer is as follows: The composition forming the first polymer layer is 40 weight percent of a low molecular weight polyethylene resin (Epolene C-15 from Westlake), the polymer having an MFI (Melt Flow Index) of greater than 4000 grams per minute; 25.8 weight percent C9 hydrogenated hydrocarbon resin (Novares Pure 1120, Rain Carbon); 17 weight percent styrene-modified polyterpene resin (Sylvares 6100 from Kraton); 15 weight percent paraffin wax (Parvan 1470 from Exxon Mobil); 2 weight percent microcrystalline PE wax (Multiwax 180-MH from Sonneborn); and 0.2 weight percent of Irganox 1010 (BASF). The resulting coated cardboard (sheet blank 101) has a thermal conductivity of 8 grams / m at 38° C. and 90% RH (as determined by ISO 2528:1995). 2 It has a moisture permeability of 100 / day.

[0221] Example 3 Outer Wrapper A third embodiment of the sheet blank 101 will now be described. The second cellulosic layer 40 is a 50 grams per square meter paper. The entire inner surface of the paper is coated with a first polymer layer (15 grams per square meter) using a slot die or curtain coating process. This technique allows convenient application of a uniform, thin, and defect-free layer onto a fibrous substrate. The composition of the first polymer layer is as follows: 39.9 weight percent of a polyolefin elastomer (Affinity GA1900 from Dow Inc.); 30 weight percent C9 hydrogenated hydrocarbon resin (Novares Pure 1120 from Rain Carbon); 20 weight percent paraffin wax (Parvan 1470 from Exxon Mobil); 10 percent by weight of Fischer-Tropsch wax (Shell GTL Sarawax SX 105); 0.1 weight percent Irganox 1010 (BASF). The resulting coated cardboard (sheet blank 101) has a thermal conductivity of 4 grams / m at 38° C. and 90% RH (as determined by ISO 2528:1995). 2 It has a moisture permeability of 100 / day.

[0222] Example 4 Outer Wrapper A fourth embodiment of the sheet blank 101 will now be described. The second cellulosic layer 40 is a 50 grams per square meter paper. The entire inner surface of the paper is coated with a first polymer layer (15 grams per square meter) using a slot die or curtain coating process. This technique allows convenient application of a uniform, thin, and defect-free layer onto a fibrous substrate. The composition of the first polymer layer is as follows: The composition forming the first polymer layer is 40 weight percent ethylene propylene copolymer with low crystallinity (Vistamaxx 8880 from Exxon); 25.8 weight percent C9 hydrogenated hydrocarbon resin (Novares Pure 1120, Rain Carbon); 17 weight percent styrene-modified polyterpene resin (Sylvares 6100 from Kraton); 15 weight percent paraffin wax (Parvan 1470 from Exxon Mobil); 2 weight percent microcrystalline PE wax (Multiwax 180-MH from Sonneborn); and 0.2 weight percent of Irganox 1010 (BASF). The resulting coated cardboard (sheet blank 101) has a hardness of 6.5 grams / m2 at 38°C and 90% RH (as determined by ISO 2528:1995). 2 It has a moisture permeability of 100 / day. This composition is similar to that of Example 2, except that the low molecular weight polyethylene is replaced with an ethylene propylene copolymer having low crystallinity (Vistamaxx 8880 from Exxon). This composition has improved adhesion and flexibility at low temperatures.

[0223] Example 5 Outer Wrapper A fifth embodiment of the sheet blank 101 will now be described. The second cellulosic layer 40 is a 50 grams per square meter paper. The entire inner surface of the paper is coated with a first polymer layer (15 grams per square meter) using a slot die or curtain coating process. This technique allows convenient application of a uniform, thin, and defect-free layer onto a fibrous substrate. The composition of the first polymer layer is as follows: The composition forming the first polymer layer is 40 weight percent of a low crystalline resin (Affinity GA1900 from Dow Chemical Company) derived from the metallocene-catalyzed polymerization of ethylene and octene; 25.8 weight percent C9 hydrogenated hydrocarbon resin (Novares Pure 1120, Rain Carbon); 17 weight percent styrene-modified polyterpene resin (Sylvares 6100 from Kraton); 15 weight percent paraffin wax (Parvan 1470 from Exxon Mobil); 2 weight percent microcrystalline PE wax (Multiwax 180-MH from Sonneborn); and 0.2 weight percent of Irganox 1010 (BASF). The resulting coated cardboard (sheet blank 101) has a hardness of 12 grams / m at 38°C and 90% RH (as determined by ISO 2528:1995). 2 It has a moisture permeability of 100 / day. This composition is similar to that of Example 2 in which the low molecular weight polyethylene is replaced with a low crystallinity resin derived from the metallocene catalyzed polymerization of ethylene and octene (Affinity GA1900 from Dow Chemical Company). This composition has improved flexibility.

[0224] Example 6 Outer Wrapper A sixth embodiment of the sheet blank 101 will now be described. The second cellulosic layer 40 is a 50 grams per square meter paper. The entire inner surface of the paper is coated with a first polymer layer (15 grams per square meter) using a slot die or curtain coating process. This technique allows convenient application of a uniform, thin, and defect-free layer onto a fibrous substrate. The composition of the first polymer layer is as follows: The composition forming the first polymer layer is 40 weight percent of an amorphous polypropylene-based polymer (Eastoflex E1060, Eastman); 25.8 weight percent C9 hydrogenated hydrocarbon resin (Novares Pure 1120, Rain Carbon); 17 weight percent styrene-modified polyterpene resin (Sylvares 6100 from Kraton); 15 weight percent paraffin wax (Parvan 1470 from Exxon Mobil); 2 weight percent microcrystalline PE wax (Multiwax 180-MH from Sonneborn); and 0.2 weight percent of Irganox 1010 (BASF). The resulting coated cardboard (sheet blank 101) has a hardness of 16 grams / m at 38° C. and 90% RH (as determined by ISO 2528:1995). 2 It has a moisture permeability of 100 / day. This composition is similar to that of Example 2, except that the low molecular weight polyethylene is replaced with an amorphous polypropylene-based polymer (Eastoflex E1060, manufactured by Eastman). This composition has improved adhesion at low temperatures.

[0225] Example 7 Outer Wrapper A seventh embodiment of the sheet blank 101 will now be described. The second cellulosic layer 40 is a 50 grams per square meter paper. The entire inner surface of the paper is coated with a first polymer layer (15 grams per square meter) using a slot die or curtain coating process. This technique allows convenient application of a uniform, thin, and defect-free layer onto a fibrous substrate. The composition of the first polymer layer is as follows: The composition forming the first polymer layer is 20 weight percent styrene-isoprene copolymer (Kraton D1111 K, Kraton); 40 weight percent hydrogenated hydrocarbon resin (Eastotac™ H-130, manufactured by Eastman); 20 weight percent polyterpene resin (Piccolyte S125, manufactured by DRT); 19.5 weight percent paraffin wax (Parvan 1470 from Exxon Mobil); and 0.5 weight percent Irganox 1010. The composition has improved adhesion. The resulting coated cardboard (sheet blank 101) has a thermal conductivity of 20 grams / m at 38° C. and 90% RH (as determined by ISO 2528:1995). 2 It has a moisture permeability of 100 / day.

[0226] Example 8 Outer Wrapper An eighth embodiment of the sheet blank 101 will now be described. The second cellulosic layer 40 is a 50 grams per square meter paper. The entire inner surface of the paper is coated with a first polymer layer (15 grams per square meter) using a slot die or curtain coating process. This technique allows convenient application of a uniform, thin, and defect-free layer onto a fibrous substrate. The composition of the first polymer layer is as follows: 20 weight percent styrene-isoprene copolymer (Kraton D1111 K, Kraton); 20 weight percent of an amorphous polypropylene-based polymer (Eastoflex E1060, manufactured by Eastman); 20 weight percent low viscosity tackifying hydrocarbon resin (Escorez 5690 from Exxon Mobil Chemical); 20 weight percent hydrogenated hydrocarbon resin (Eastotac® H-130, manufactured by Eastman); 16.5 weight percent paraffin wax (Parvan 1470 from Exxon Mobil); 3 weight percent microcrystalline PE wax (Multiwax 180-MH from Sonneborn); 0.5 weight percent Irganox 1010. The composition exhibits high adhesion. The resulting coated cardboard (sheet blank 101) has a hardness of 13 grams / m at 38° C. and 90% RH (as determined by ISO 2528:1995).2 It has a moisture permeability of 100 / day.

[0227] Example 9 Outer Wrapper A ninth embodiment of the sheet blank 101 will now be described. The second cellulosic layer 40 is a 50 grams per square meter paper. The entire inner surface of the paper is coated with a first polymer layer (15 grams per square meter) using a slot die or curtain coating process. This technique allows convenient application of a uniform, thin, and defect-free layer onto a fibrous substrate. The composition of the first polymer layer is as follows: 20 weight percent hydrogenated ethylene norbornene polymer (TOPAS 8007F-600, manufactured by Topas); 40 weight percent hydrogenated hydrocarbon resin (Eastotac® H-130, manufactured by Eastman); 20 weight percent of an amorphous polypropylene-based polymer (Eastoflex E1060, Eastman); 19.9 weight percent paraffin wax (Parvan 1470 from Exxon Mobil); It is 0.1 percent Irganox 1010. The composition exhibits low tack and high viscosity. The resulting coated cardboard (sheet blank 101) has a thermal conductivity of 5 grams / m at 38° C. and 90% RH (as determined by ISO 2528:1995). 2 It has a moisture permeability of 100 / day.

[0228] Example 10 Outer Wrapper A tenth embodiment of the sheet blank 101 will now be described. The second cellulosic layer 40 is a 50 grams per square meter paper. The entire inner surface of the paper is coated with a first polymer layer (15 grams per square meter) using a slot die or curtain coating process. This technique allows convenient application of a uniform, thin, and defect-free layer onto a fibrous substrate. The composition of the first polymer layer is as follows: 10 weight percent styrene ethylene butylene copolymer (Kraton G1657, Kraton); 10 weight percent of a low crystalline resin (Affinity EG8200G from Dow Chemical Company) derived from the metallocene-catalyzed polymerization of ethylene and octene; 39.9 weight percent of a hydrogenated hydrocarbon resin (Regalite R1125 manufactured by Eastman); 20 weight percent paraffin wax (Parvan 1270 from Exxon Mobil) having a melting point comprised between 51° C. and 54° C.; 20 weight percent paraffin wax (Parvan 1470 from Exxon Mobil) having a melting point comprised between 62°C and 65°C; 0.1 weight percent Irganox 1010. The composition exhibits high adhesion to paper and high viscosity. The resulting coated cardboard (sheet blank 101) has a thermal conductivity of 8 grams / m at 38° C. and 90% RH (as determined by ISO 2528:1995). 2 It has a moisture permeability of 100 / day. The coated multi-layer materials according to Examples 1 to 10 are coated on the outer surface with a second polymer layer (heat sealable layer). The second polymer layer comprises an ethylene vinyl acetate based hot melt sealant. The second polymer layer is deposited according to the pattern of FIG. 7. The composition of the second polymer layer is the same as the composition of the first polymer layer described in Example 1.

[0229] Example 11 Outer Wrapper A first embodiment of a sheet blank 101' will now be described. The second cellulosic layer 40 is a 50 grams per square meter paper. The entire inner surface of the paper is coated with a third polymer layer (10 grams per square meter) using a coating process. The composition of the third polymer layer (moisture barrier layer) is as follows: 40 weight percent high density polyethylene wax (Mitsui Excerex 40800); 30 weight percent hydrogenated hydrocarbon resin (Eastotac™ H-130, manufactured by Eastman); 20 weight percent of a low crystalline ethylene propylene copolymer (Vistamaxx 8880 from Exxon); 9.9 weight percent paraffin wax (Parvan 1470 from Exxon Mobil); and 0.1 weight percent Irganox 1010 from BASF. This "intermediate" material has a density of 8 grams / m 2 / day penetration and did not exhibit any tack or thermoplastic behavior below 100°C. The above material was coated with a 6 gsm first polymer layer having the same composition as described in Example 1. The first polymer layer was applied by curtain coating. The material was further provided with a second polymer layer according to the pattern of Figure 7. The composition of the second polymer layer was that detailed for the first polymer layer in Example 1. The final moisture permeability of the multilayer blank 101' is 6 grams / m 2 / day.

[0230] Comparative Example Below, comparative examples were prepared comparing the performance of the following containers: Comparative container (BOPP film): A hinged-lid package of 20 cigarettes made from lacquered 180-270 gsm cardboard and wrapped in 16 micrometer BOPP film. This container A is represented by the solid lines in Figure 20. Container of the invention (paper barrier): 20 cigarette packages with hinged lid packaging were prepared, made of a sheet blank 100. The blank 100 is made of 240 gsm (298 micron thickness) bleached cellulose pulp (SBS) cardboard (brand Invercote L PM, manufactured by IGGESUND PAPERBOARD AB). The hinged lid is then wrapped with a sheet blank 101 realized according to Example 3. The container is represented by a dashed line in Figure 20. The container BOPP and the container of the present invention were placed in a climatic chamber to simulate extreme environmental conditions and the moisture gain or loss was monitored by the oven evaporation method. The graph in FIG. 20 shows that containers according to the invention have similar moisture uptake or loss as comparative containers packaged in BOPP film. Oven volatilization (OV in the figures) was measured according to the 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). The results are shown in Figures 14 and 15. In Figure 20, the condition "Jungle" is applied. The container BOPP and the container of the present invention are maintained at a temperature of 32 degrees Celsius and a relative humidity of 85 percent. The container BOPP and the container of the present invention have very similar behavior, as shown by the solid and dashed lines, i.e., oven volatilization increases slowly within 90 days. ---

[0231] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like, should be understood in all instances as modified by the term "about." Also, all ranges include the maximum and minimum points disclosed, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number A is understood as A±10 percent. Within this context, the number A may be considered to include a numerical value that is within the general standard error for the measurement of the property represented by the number A. The number A may deviate by the percentages recited above, in some cases as used in the appended claims, provided that the amount by which A deviates does not materially affect the basic and novel property(ies) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. A method for manufacturing a container for a consumer product, comprising: - folding a first cellulosic layer to form a package that defines a housing for the consumer product; - forming an outer wrapper, the outer wrapper including a second cellulosic layer having an inner surface defining an inner region and an outer surface defining an outer region, a first polymer layer provided on the inner surface, and a second polymer layer provided on less than 30 percent of the outer surface; - forming the first polymer layer and the second polymer layer as heat-sealable layers; - wrapping the package with the outer wrapper, the wrapping being performed such that the first polymer layer is provided on the inside of the second cellulosic layer; - heating the package and the outer wrapper to seal the outer wrapper onto the package to form the container.

2. - folding the first cellulosic layer to form a package including a lid portion and a box portion, the box portion and the lid portion being separated by an opening line, and the lid portion being hinged to the box portion; - wrapping the box portion and the lid portion with the outer wrapper, the outer wrapper at least partially covering the opening line. The method according to claim 1.

3. The method according to claim 2, wherein the opening line includes a first weakened line.

4. The step of folding the first cellulosic layer to form a package includes folding the first cellulosic layer to form a package defining a base wall and an upper wall, and the method includes: - providing the second polymer layer on a portion of the outer surface of the second cellulosic layer that covers the upper wall or the base wall of the package when the package is wrapped around with the outer wrapper. The method according to any one of claims 1 to 3.

5. The method according to any one of claims 1 to 3, wherein the step of forming the outer wrapper includes forming an outer wrapper including a third polymer layer.

6. The method according to claim 5, wherein the third polymer layer is located between the second cellulose-based layer and the first polymer layer.

7. The method according to claim 5, wherein the third polymer layer is a moisture barrier layer.

8. - Folding the first cellulose-based layer to form a package including a lid portion and a box portion, wherein the box portion and the lid portion are separated by an opening line, and the lid portion is hinged to the box portion, the folding; - Wrapping the box portion and the lid portion with the outer wrapper, wherein the outer wrapper at least partially covers the opening line, the wrapping; - Forming a second weakened line on the portion of the outer wrapper covering the opening line, the method according to any one of claims 1 to 3.

9. Providing a first polymer layer, or providing a second polymer layer, or providing a third polymer layer is ・ A polymer or copolymer of ethylene, ・ A polymer or copolymer of propylene, ・ A copolymer of styrene acrylate, ・ A copolymer of styrene butadiene, ・ A copolymer of styrene isoprene, ・ A copolymer of hydrogenated styrene butadiene, ・ A copolymer of hydrogenated styrene isoprene, ・ A copolymer of an ester of acrylic acid or methacrylic acid, ・ A copolymer of vinyl acetate, ・ Forming a composition containing one or more of a copolymer of polybutene, the method according to any one of claims 1 to 3.

10. The method according to claim 9, wherein the composition further comprises a wax.

11. The composition is ・ The method according to claim 9, comprising a hydrocarbon resin.

12. A container for consumer goods, - A package including a box portion and a lid portion, the package defining a housing for the consumer goods, the lid portion being hinged to the box portion by a hinge line, an opening line separating the box portion and the lid portion outside the hinge line, the box portion and the lid portion being formed by folding a first multilayer blank including a first cellulose-based layer, the package; - An outer wrapper wrapped and sealed on the package and at least partially covering the opening line, - A second cellulosic layer having an inner surface and an outer surface; - A first polymer layer provided on the inner surface of the second cellulosic layer; - A second polymer layer provided on less than 30 percent of the outer surface of the second cellulosic layer, comprising an outer wrapper; - The first polymer layer and the second polymer layer are heat-sealable layers, a container.

13. The container according to claim 12, wherein the opening line includes a first weakened line.

14. The container according to claim 12 or 13, wherein the outer wrapper includes a second weakened line formed on the portion of the outer wrapper covering the opening line.

15. The container according to claim 12 or 13, wherein the package comprises a base wall and an upper wall, and a second polymer layer provided on a portion of the outer surface of the second cellulosic layer covering the base wall or the upper wall.

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