Method for manufacturing multilayer materials

Abstract

A method of manufacturing a web of multi-layer material (174, 374, 474) is provided, the method including providing a web of cellulosic material (112). The method also includes perforating the web of cellulosic material (112) to form a perforated web of cellulosic material. The method also includes applying a polymeric material to a surface of the perforated web of cellulosic material to form a web of multi-layer material (174, 374, 474), the web of multi-layer material (174, 374, 474) having a perforated first layer (200) comprising cellulosic material and a second layer (206, 406) comprising polymeric material. The layer of polymeric material covers, fills, or covers and fills the perforations on the surface of the web of cellulosic material to which the polymeric material is applied.

Description

[Technical Field]

[0001] The present invention relates to a method and apparatus for producing a web of multi-layer material. [Background technology]

[0002] It is known to encase containers of consumer goods in outer wrappers to protect the containers until they are purchased by a consumer. For example, a single pack of cigarettes and other aerosol-generating articles may be surrounded by an outer wrapper that is removed by the consumer when initially accessing the articles in the pack. Similarly, a bundle of such packs may be held together by an outer wrapper that is removed by the consumer when removing the pack from the bundle.

[0003] Typically, such wrappers are formed from plastic materials, such as biaxially oriented polypropylene (BOPP) film, to provide moisture barrier protection for the enclosed consumer goods. However, to provide more sustainable and environmentally friendly packaging, it would be desirable to provide alternative materials for forming such outer wrappers that reduce the plastic content of the wrapper without reducing its moisture barrier properties. Summary of the Invention

[0004] According to the present disclosure, there is provided a method of manufacturing a web of multi-layer material. The method may include providing a web of cellulosic material. The method may include perforating the web of cellulosic material to form a perforated web of cellulosic material. The method may include applying a polymeric material to a surface of the perforated web of cellulosic material to form a web of multi-layer material, the web of multi-layer material having a perforated first layer comprising cellulosic material and a second layer comprising a polymeric material.

[0005] According to a first aspect of the present disclosure, there is provided a method of manufacturing a web of multi-layer material, the method including providing a web of cellulosic material. The method may also include perforating the web of cellulosic material to form a perforated web of cellulosic material. The method also includes applying a polymeric material to a surface of the perforated web of cellulosic material to form a web of multi-layer material, the web of multi-layer material having a perforated first layer comprising cellulosic material and a second layer comprising a polymeric material.

[0006] Advantageously, the web of cellulosic material may form the base layer of the web of multi-layer material. Advantageously, the cellulosic material may facilitate significantly reduced plastic content of the web of multi-layer material compared to known materials for forming wrappers, such as biaxially oriented polypropylene (BOPP) film.

[0007] Advantageously, applying a layer of polymeric material to the surface of the cellulosic material may impart desirable moisture barrier properties to the web of multilayer material. Specifically, the layer of polymeric material may impart moisture barrier properties to the web of multilayer material that are comparable to the moisture barrier properties of known materials for forming wrappers, such as biaxially oriented polypropylene (BOPP) film.

[0008] Advantageously, perforating the web of cellulosic material may facilitate removal of a wrapper formed from the web of multi-layer material. For example, perforating the web of cellulosic material may form tear lines or tear strips in a wrapper formed from the web of multi-layer material.

[0009] Advantageously, perforating the web of cellulosic material prior to the step of applying the polymeric material to the surface of the web of cellulosic material reduces or prevents the risk that the perforations will compromise the moisture barrier formed by the layer of polymeric material. Specifically, the layer of polymeric material may cover, infill, or both cover and fill the perforations on the surface of the web of cellulosic material to which the polymeric material is applied.

[0010] Preferably, the web of cellulosic material has a first side and a second side opposite the first side, and the step of perforating the web of cellulosic material may include perforating the web of cellulosic material from the first side, and the step of applying the polymeric material may include applying the polymeric material to the second side of the web of cellulosic material.

[0011] Advantageously, forming the perforations on the side of the web of cellulosic material opposite the side on which the polymeric material is applied can facilitate improving the appearance of the wrapper formed from the web of multilayer material. For example, when a web of multilayer material is used to form a wrapper, it may be desirable to position a moisture barrier formed by a layer of polymeric material on the inner surface of the wrapper. In this case, the side of the web of cellulosic material on which the perforations are formed defines the outer surface of the wrapper. Advantageously, by positioning the side of the web of cellulosic material on which the perforations are formed as the outer surface of the wrapper, the appearance of the perforations can be optimized.

[0012] The web of cellulosic material may include at least one of text, graphics, logos, and indicia on at least one of the first and second sides. Preferably, the web of cellulosic material includes at least one of text, graphics, logos, and indicia on at least the first side. As noted above, when a web of multi-layer material is used to form a wrapper, it may be desirable to place a moisture barrier formed by a layer of polymeric material on the inner surface of the wrapper. In this case, the second side forms the inner surface of the wrapper, and the first side forms the outer surface of the wrapper. Advantageously, placing the at least one of text, graphics, logos, and indicia on at least the first side allows the at least one of text, graphics, logos, and indicia to be visible from the outside of the wrapper.

[0013] The step of providing a web of cellulosic material may include providing a web of cellulosic material that already includes at least one of text, graphics, logos, and indicia on a surface of the web of cellulosic material.

[0014] The method may further include printing at least one of text, graphics, logos, and indicia on at least one of the first and second sides of the web of cellulosic material.

[0015] Advantageously, including a printing step in the method of manufacturing a web of multi-layer material may simplify the manufacturing process by combining multiple steps into a single process.

[0016] The printing step may be performed before the perforating step. Advantageously, performing the printing step before the perforating step may facilitate alignment of the perforations with text, graphics, logos, and / or indicia printed on the web of cellulosic material.

[0017] The printing process may include at least one of lithographic printing, flexographic printing, digital printing, and gravure printing.

[0018] The step of perforating the web of cellulosic material may include perforating the web of cellulosic material using a rotary die cutter.

[0019] The step of applying the polymeric material may include applying the polymeric material to the cellulosic material using a slot die coater. Preferably, the slot die coater is a rotary bar slot die coater.

[0020] Advantageously, the inventors have recognized that a rotary bar slot die coater may facilitate depositing a uniform second layer of polymeric material having a relatively thin thickness at high process speeds. For example, the use of a rotary bar slot die coater may facilitate depositing a uniform second layer of polymeric material having a thickness of less than 20 micrometers at web speeds of at least 100 meters / minute.

[0021] Preferably, the rotary bar slot die coater includes at least one chill roller. Advantageously, in embodiments where the polymeric material is a hot melt polymeric material deposited in a molten state onto the web of cellulosic material by the rotary bar slot die coater, the at least one chill roller may facilitate rapid cooling and solidification of the polymeric material.

[0022] Preferably, at least one cooling roller comprises a water cooling circuit disposed inside the cooling roller. The water cooling circuit may have a spiral shape.

[0023] Preferably, the second layer comprising a polymeric material is a moisture barrier layer that may advantageously impart moisture barrier properties to the web of multilayer material that are comparable to the moisture barrier properties of known materials for forming wrappers, such as biaxially oriented polypropylene (BOPP) film.

[0024] As used herein, the term "moisture barrier" refers to a layer having a water vapor or moisture transmission rate (WVTR) of 20 grams per square meter per 24 hours or less at 38 degrees Celsius and 90 percent relative humidity when measured in accordance with ISO 2528:1995 or ASTM F3299. Preferably, the moisture barrier of the multilayer material of the present invention has a WVTR of less than 10 grams per square meter per 24 hours at 38 degrees Celsius and 90 percent relative humidity.

[0025] The polymeric material includes at least one of homopolymers of ethylene, propylene, 1-butene, isobutene, 1-octene, and 1-hexene; copolymers of at least two of the monomers ethylene, propylene, 1-butene, isobutene, 1-octene, 1-hexene, and styrene; copolymers of ethylene and vinyl acetate; copolymers of ethylene and an ester of acrylic acid or methacrylic acid; copolymers of ethylene and acrylic acid or methacrylic acid; copolymers of styrene, ethylene, and propylene; hydrogenated copolymers of styrene and butadiene; hydrogenated copolymers of styrene and isoprene; copolymers of styrene and isobutene; and waxes.

[0026] The polymeric material may include a polymer component in an amount of 50 to 90 percent by weight of the polymeric material. The polymer component may include at least one of an ethylene polymer, a propylene polymer, an ethylene copolymer, a propylene copolymer, a polyethylene plastomer, a polypropylene plastomer, and an amorphous polypropylene. The polymeric material may include a wax in an amount of 2 to 20 percent by weight of the polymeric material. The wax may include at least one of a paraffin wax and a polyethylene wax. The polymeric material may include a tackifier in an amount of 48 percent by weight or less of the polymeric material. The tackifier may include a hydrogenated hydrocarbon resin. The polymeric material may include an antioxidant in an amount of 1 percent by weight or less of the polymeric material.

[0027] The antioxidant may include at least one of a phenolic antioxidant, a phosphite antioxidant, vitamin E, a hindered amine stabilizer, and a hydroxylamine stabilizer.

[0028] An exemplary polymeric material may include a propylene homopolymer in an amount of 70 weight percent of the polymeric material, a propylene-ethylene copolymer in an amount of 14 weight percent of the polymeric material, a hydrogenated aromatic hydrocarbon resin in an amount of 10 weight percent of the polymeric material, and paraffin wax in an amount of 6 weight percent of the polymeric material. Preferably, the paraffin wax has a melting point of about 60 degrees Celsius, e.g., 55 degrees Celsius to 65 degrees Celsius.

[0029] The polymeric material may comprise a polymer component in an amount of 20 to 60 weight percent of the polymeric material. The polymer component may comprise at least one of: a polymer of ethylene, a polymer of propylene, an ethylene copolymer, a propylene copolymer, a polyethylene plastomer, a polypropylene plastomer, an amorphous polypropylene, a polyethylene-co-vinyl acetate copolymer, an ethylene-acrylic copolymer, an ethylene-methacrylic acid copolymer, a polyisobutylene, a copolymer of styrene and one or more monomers selected from butadiene, isobutylene, and isoprene, and a hydrogenated copolymer of styrene and one or more monomers selected from butadiene, isobutylene, and isoprene. The polymeric material may comprise a wax in an amount of 20 to 50 weight percent of the polymeric material. The wax may comprise at least one of paraffin wax, microcrystalline wax, and polyethylene wax. The polymeric material may comprise a tackifier in an amount of up to 60 weight percent of the polymeric material. The tackifier may include hydrocarbon resins, hydrogenated hydrocarbon resins, polyterpene resins, hydrogenated polyterpene resins, rosin esters, and hydrogenated rosin esters. The polymeric material may include an antioxidant in an amount of 1 weight percent or less of the polymeric material. The antioxidant may include at least one of a phenolic antioxidant, a phosphite antioxidant, vitamin E, a hindered amine stabilizer, and a hydroxylamine stabilizer.

[0030] A further exemplary polymeric material includes a propylene-ethylene-copolymer plastomer in an amount of 45 weight percent of the polymeric material, a hydrogenated aromatic hydrocarbon resin in an amount of 15 weight percent of the polymeric material, and paraffin wax in an amount of 40 weight percent of the polymeric material. Preferably, the paraffin wax has a melting point of about 60 degrees Celsius, e.g., 55 to 65 degrees Celsius.

[0031] A still further exemplary polymeric material includes low molecular weight polyethylene in an amount of 45 weight percent of the polymeric material, hydrogenated aromatic hydrocarbon resin in an amount of 10 weight percent of the polymeric material, Fischer-Trofsch polyethylene wax in an amount of 10 weight percent of the polymeric material, and paraffin wax in an amount of 35 weight percent of the polymeric material. Preferably, the paraffin wax has a melting point of about 60 degrees Celsius, e.g., 55 degrees Celsius to 65 degrees Celsius.

[0032] The polymeric material may be a first polymeric material. The method may further include applying a second polymeric material to the apertured web of cellulosic material.

[0033] Advantageously, applying a second polymeric material may impart one or more desirable properties to the multi-layer material. For example, the second layer comprising the first polymeric material may be a moisture barrier, as described above. The second polymeric material may also be a heat-sealable material.

[0034] The step of applying the second polymeric material may be performed before the step of applying the first polymeric material, but preferably the step of applying the second polymeric material is performed after the step of applying the first polymeric material.

[0035] The step of applying a second polymeric material may include applying the second polymeric material to form a third layer comprising the second polymeric material. The third layer comprising the second polymeric material may be a heat seal layer.

[0036] As used herein, the term "heat-sealable layer" refers to a layer that can be fusion-bonded by conventional indirect heating means, which generates sufficient heat at the contacting surface of at least one multi-layer material to be conducted to the contacting surface of an adjacent multi-layer material to form a bonded interface between the surfaces without compromising the integrity of the multi-layer material. The bonded interface between successive surfaces 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 various heat-sealable layer formulations are known in the art and can be employed in the present invention.

[0037] Preferably, the heat seal layer has a melting point measured according to differential scanning calorimetry (DSC) of less than 100 degrees Celsius. More preferably, the heat seal layer has a melting point measured according to DSC of less than 80 degrees Celsius.

[0038] Preferably, a second layer comprising the first polymeric material is applied to the second surface of the web of cellulosic material, as described above. Preferably, the second layer covers substantially the entire second surface of the web of cellulosic material. Covering the entire second surface of the web of cellulosic material can be particularly advantageous in embodiments in which the second layer is a moisture barrier.

[0039] A third layer comprising a second polymeric material may be applied to the second surface of the web of cellulosic material, and the third layer comprising the second polymeric material may at least partially overlap the second layer comprising the first polymeric material.

[0040] A third layer comprising a second polymeric material may be applied to the first surface of the web of cellulosic material.

[0041] The third layer may cover substantially the entire first or second side of the web of cellulosic material, or the third layer may be applied to the first or second side of the web of cellulosic material in a repeating pattern.

[0042] Instead of applying the second polymeric material separately from the first polymeric material, the step of applying the polymeric material to the surface of the apertured web of cellulosic material to form the web of multi-layer material may include simultaneously applying the first polymeric material and the second polymeric material to the surface of the apertured web of cellulosic material to form the web of multi-layer material. In such embodiments, the web of multi-layer material has an apertured first layer comprising cellulosic material and a second layer comprising both the first polymeric material and the second polymeric material.

[0043] Advantageously, applying the first and second polymeric materials simultaneously may simplify the process of forming the multi-layer material, particularly in embodiments in which the first and second polymeric materials are applied to the same side of the web of cellulosic material.

[0044] The step of simultaneously applying a first polymeric material and a second polymeric material to a surface of the apertured web of cellulosic material to form a web of multi-layer material may include applying a polymer mixture to a surface of the apertured web of cellulosic material to form a web of multi-layer material, the polymer mixture comprising the first polymeric material and the second polymeric material.

[0045] The second polymeric material comprises at least one of a homopolymer of ethylene, propylene, 1-butene, isobutene, 1-octene, or 1-hexene; a copolymer of at least two of the monomers ethylene, propylene, 1-butene, isobutene, 1-octene, 1-hexene, or styrene; a copolymer of ethylene and vinyl acetate; a copolymer of ethylene and an ester of acrylic acid or methacrylic acid; a copolymer of ethylene and acrylic acid or methacrylic acid; a copolymer of styrene, ethylene, and propylene; a hydrogenated copolymer of styrene and butadiene; a hydrogenated copolymer of styrene and isoprene; or a copolymer of styrene and isobutene.

[0046] It is important to note that although the components of the first and second polymeric materials may be very similar, selecting the most suitable grade may result in differences in their respective thermal or rheological properties. Indeed, different grades of polyethylene can be selected to provide melting points as high as 130°C or as low as 70°C.

[0047] The method may further include slitting the web of multi-layer material to form multiple webs of multi-layer material. Advantageously, this may facilitate forming multiple webs of multi-layer material using a single process line. Slitting the web of multi-layer material to form multiple webs of multi-layer material may include slitting the web of multi-layer material to form two, three, four, five, or six webs of multi-layer material.

[0048] Preferably, the web of cellulosic material comprises a paper web or a paperboard web.

[0049] The web of cellulosic material may have a basis weight of at least 30 grams per square meter, at least 40 grams per square meter, at least 50 grams per square meter, at least 60 grams per square meter, at least 70 grams per square meter, at least 80 grams per square meter, at least 90 grams per square meter, at least 100 grams per square meter, at least 110 grams per square meter, at least 120 grams per square meter, at least 130 grams per square meter, at least 140 grams per square meter, or at least 150 grams per square meter.

[0050] The web of cellulosic material may have a basis weight of 270 grams per square meter or less, 250 grams per square meter or less, 240 grams per square meter or less, 230 grams per square meter or less, 220 grams per square meter or less, 210 grams per square meter or less, 200 grams per square meter or less, 190 grams per square meter or less, 180 grams per square meter or less, 170 grams per square meter or less, 160 grams per square meter or less, 150 grams per square meter or less, 140 grams per square meter or less, 130 grams per square meter or less, or 120 grams per square meter or less.

[0051] The web of cellulosic material may have a basis weight of 40 grams per square meter to 120 grams per square meter.The web of cellulosic material may have a basis weight of 150 grams per square meter to 250 grams per square meter.

[0052] The step of providing a web of cellulosic material may include providing a web of cellulosic material already having a coating on at least a portion of the web of cellulosic material. Generally speaking, the coating may include a polymeric material and may be applied by dispersion coating during the papermaking process. Suitable coating materials may include at least one of polyvinyl alcohol, an emulsion or dispersion of polystyrene-co-butadiene, or other copolymers of styrene and acrylic or methacrylate monomers, and a filler, such as kaolin, calcium carbonate, talc, etc.

[0053] The step of providing a web of cellulosic material may include providing a web of laminate material including at least one layer of cellulosic material. Preferably, the laminate material includes at least one layer of non-cellulosic material. The non-cellulosic material may include a non-cellulosic polymer. The at least one layer of non-cellulosic material may include a non-cellulosic polymer film. The non-cellulosic polymer film may include at least one of an oriented polypropylene film and an oriented polyethylene terephthalate film. Preferably, these films have a thickness of 6 micrometers to 15 micrometers.

[0054] The second layer comprising a polymeric material or polymer blend may have a basis weight of at least 8 grams per square meter, at least 9 grams per square meter, at least 10 grams per square meter, at least 11 grams per square meter, at least 12 grams per square meter, at least 13 grams per square meter, or at least 14 grams per square meter.

[0055] The second layer comprising a polymeric material or polymer blend may have a basis weight of 15 grams per square meter or less, 14 grams per square meter or less, 13 grams per square meter or less, 12 grams per square meter or less, 11 grams per square meter or less, 8 grams per square meter or less, or 6 grams per square meter or less.

[0056] The second layer comprising a polymeric material or polymer mixture may have a basis weight of 8 grams per square meter to 15 grams per square meter.

[0057] The second layer comprising a polymeric material or polymer blend may have a thickness of 20 micrometers or less, 19 micrometers or less, 18 micrometers or less, 17 micrometers or less, 16 micrometers or less, 15 micrometers or less, 14 micrometers or less, 13 micrometers or less, 12 micrometers or less, 11 micrometers or less, or 10 micrometers or less.

[0058] The second layer comprising a polymeric material or polymer mixture may have a thickness of at least 6 micrometers, at least 9 micrometers, at least 10 micrometers, at least 11 micrometers, at least 12 micrometers, at least 13 micrometers, at least 14 micrometers, or at least 15 micrometers.

[0059] The step of applying the polymeric material or polymer mixture may include applying the polymeric material or polymer mixture at a temperature of 200 degrees Celsius or less, 190 degrees Celsius or less, 180 degrees Celsius or less, 170 degrees Celsius or less, 160 degrees Celsius or less, 150 degrees Celsius or less, 140 degrees Celsius or less, 130 degrees Celsius or less, 120 degrees Celsius or less, or 110 degrees Celsius or less.

[0060] The step of applying the polymeric material or polymer mixture can include applying the polymeric material or polymer mixture at a temperature of at least 100 degrees Celsius, at least 110 degrees Celsius, at least 120 degrees Celsius, at least 130 degrees Celsius, at least 140 degrees Celsius, at least 150 degrees Celsius, at least 160 degrees Celsius, at least 170 degrees Celsius, at least 180 degrees Celsius, or at least 190 degrees Celsius.

[0061] The step of applying the polymeric material or the step of applying the polymeric mixture may comprise applying the polymeric material or polymeric mixture at a dynamic viscosity of less than 40,000 millipascal-seconds, preferably less than 20,000 millipascal-seconds, preferably less than 10,000 millipascal-seconds, preferably less than 5,000 millipascal-seconds.

[0062] In the step of applying the polymeric material or applying the polymer mixture, the method may include conveying the web of apertured cellulosic material at a speed of at least 100 meters / minute, at least 110 meters / minute, at least 120 meters / minute, at least 130 meters / minute, at least 140 meters / minute, at least 150 meters / minute, at least 160 meters / minute, at least 170 meters / minute, at least 180 meters / minute, at least 190 meters / minute, at least 200 meters / minute, at least 210 meters / minute, at least 220 meters / minute, at least 230 meters / minute, or at least 240 meters / minute.

[0063] In the step of applying the polymeric material or the step of applying the polymer mixture, the method may include conveying the web of apertured cellulosic material at a speed of 300 meters / minute or less, 240 meters / minute or less, 230 meters / minute or less, 220 meters / minute or less, 210 meters / minute or less, or 200 meters / minute or less.

[0064] According to a second aspect of the present invention, there is provided a web of multi-layer material produced using the method of the first aspect of the present invention, in accordance with any of the examples or embodiments described herein.

[0065] According to the present disclosure, there is provided a method of manufacturing a package of consumer goods. The method may comprise forming a web of multi-layer material using a method according to the first aspect of the present invention. The method may comprise providing a web of multi-layer material using a method according to the first aspect of the present invention. The method may comprise cutting a layered blank from the web of multi-layer material. The method may comprise folding the layered blank to form the package of consumer goods.

[0066] According to a third aspect of the present invention, there is provided a method of manufacturing a package of consumer goods. The method may comprise forming a web of multi-layer material using the method of the first aspect of the present invention, according to any of the examples or embodiments described herein. Alternatively, the method may comprise providing a web of multi-layer material using the method of the first aspect of the present invention, according to any of the examples or embodiments described herein. The method also comprises cutting a layered blank from the web of multi-layer material and folding the layered blank to form a package of consumer goods.

[0067] Preferably, the second layer comprising a polymeric material forms an inner surface of the folded laminar blank. Advantageously, disposing the polymeric material on the inner surface of the folded laminar blank may reduce the risk of damage to the second layer comprising a polymeric material during handling of the consumer goods package. This may be particularly advantageous in embodiments where the polymeric material is a moisture barrier and the second layer comprising a polymeric material forms a moisture barrier.

[0068] Preferably, the layered blank comprises a second polymeric material or polymer blend described herein, the second polymeric material or polymer blend comprising a heat seal material. Advantageously, the heat seal material may hold the layered blank in a folded state. Advantageously, the heat seal material is capable of sealing one or more consumer goods within the folded layered blank.

[0069] Preferably, the method includes the step of applying heat to the folded laminar blank to form at least one bond interface between adjacent surfaces of the folded laminar blank.

[0070] Depending on the particular packaging application and how the layered blank is folded to form the consumer goods package, the second polymeric material may be disposed on the same side of the web of cellulosic material as the first polymeric material, or on the opposite side of the web of cellulosic material. In embodiments in which the second polymeric material is disposed on the same side of the web of cellulosic material as the first polymeric material, the first and second polymeric materials may be applied separately or simultaneously as a polymer mixture, as described herein.

[0071] Preferably, the method includes the step of providing one or more consumer goods, and the step of folding the layered blank includes folding the layered blank around the one or more consumer goods.

[0072] The one or more consumer products include a plurality of aerosol-generating articles. The web of multi-layer material forming the layered blank may include a first polymeric material and a second polymeric material disposed on the same side of the web of cellulosic material and forming an inner surface of the folded layered blank. The first polymeric material and the second polymeric material may be disposed separately on the web of cellulosic material or may be disposed together as a polymer blend.

[0073] The one or more consumer goods may include a stack of packages of aerosol-generating articles. At least one of the packages of aerosol-generating articles may be manufactured using the method according to the present invention. The web of multi-layer material forming the layered blank may comprise a second polymeric material disposed on a first side of the web of cellulosic material and a first polymeric material disposed on a second side of the web of cellulosic material, the second side of the web of cellulosic material forming the inner surface of the folded layered blank. Preferably, the second polymeric material is disposed on only a portion of the first side of the web of cellulosic material. Preferably, the second polymeric material is disposed only on one or more portions of the layered blank that overlap one or more other portions of the layered blank when the layered blank is folded.

[0074] According to a fourth aspect of the present invention, there is provided a package of consumer goods produced using the method of the third aspect of the present invention, in accordance with any of the examples or embodiments described herein.

[0075] According to the present disclosure, a multi-layer material is provided. The multi-layer material may include a first layer including a cellulosic material. The multi-layer material may include a second layer including a polymeric material. The multi-layer material may include a plurality of perforations. Each perforation may extend only through the first layer.

[0076] According to a fifth aspect of the present invention, there is provided a multi-layer material. The multi-layer material includes a first layer including a cellulosic material. The multi-layer material also includes a second layer including a polymeric material. The multi-layer material also includes a plurality of perforations, each perforation penetrating only the first layer.

[0077] Preferably, the first layer comprising the cellulosic material has a first surface and a second surface opposite the first surface, the perforations are formed from the first surface of the first layer, and the second layer comprising the polymeric material is on the second surface of the first layer.

[0078] Advantageously, forming perforations on the side of the first layer containing cellulosic material opposite the side on which the polymeric material is applied can facilitate improving the appearance of the wrapper formed from the multilayer material. For example, when a multilayer material is used to form a wrapper, it may be desirable to position a moisture barrier formed by a layer of polymeric material on the inner surface of the wrapper. In this case, the side of the first layer containing cellulosic material on which the perforations are formed defines the outer surface of the wrapper. Advantageously, by positioning the side of the first layer containing cellulosic material on which the perforations are formed as the outer surface of the wrapper, the appearance of the perforations can be optimized.

[0079] The first layer including cellulosic material includes at least one of text, graphics, logos, and indicia on the first surface.

[0080] The multilayer material of the fifth aspect of the invention may comprise any of the optional or preferred features described above in relation to the web of material produced according to the method of the first aspect of the invention. The multilayer material of the fifth aspect of the invention may be produced using the method according to the first aspect of the invention in accordance with any of the examples or embodiments described herein.

[0081] According to a sixth aspect of the present invention, there is provided a package of consumer goods, the package comprising a folded laminar blank formed from the multi-layer material of the fifth aspect of the present invention, in accordance with any of the examples or embodiments described herein, the package also including one or more consumer goods contained within the folded laminar blank.

[0082] The package may comprise any of the optional or preferred features according to the third or fourth aspects of the invention. The package may be manufactured using the method of the third aspect of the invention, according to any of the examples or embodiments described herein.

[0083] According to the present disclosure, there is provided an apparatus for manufacturing a web of multi-layer material. The apparatus may include a supply for supplying a web of cellulosic material. The apparatus may include a perforation station for perforating the web of cellulosic material to form a perforated web of cellulosic material. The apparatus may also include a polymer application station for applying a polymer material to a surface of the perforated web of cellulosic material to form a web of multi-layer material, the web of multi-layer material having a perforated first layer comprising cellulosic material and a second layer comprising polymer material.

[0084] According to a seventh aspect of the present invention, there is provided an apparatus for manufacturing a web of multi-layer material. The apparatus includes a feeding station for feeding a web of cellulosic material. The apparatus also includes a perforation station for perforating the web of cellulosic material to form a perforated web of cellulosic material. The apparatus may also include a polymer application station for applying a polymer material to a surface of the perforated web of cellulosic material to form the web of multi-layer material, the web of multi-layer material having a perforated first layer comprising cellulosic material and a second layer comprising polymer material.

[0085] The apparatus may comprise any of the optional or preferred features described above in relation to the first aspect of the invention. The apparatus may be configured to carry out the method of the first aspect of the invention in accordance with any of the examples or embodiments described herein.

[0086] Preferably, the perforation station is arranged to perforate a first side of the web of cellulosic material and the polymer application station is arranged to apply a polymer material to a second side of the web of cellulosic material, the second side being opposite the first side. Preferably, the apparatus includes a turn bar located between the perforation station and the polymer application station. Advantageously, the turn bar reverses the orientation of the web of cellulosic material, which may facilitate perforation and polymer application on different sides of the web of cellulosic material.

[0087] The apparatus may include a printing station disposed to print at least one of text, graphics, logos, and indicia on the first side of the web of cellulosic material. The printing station may be located between the feeding station and the perforating station. The printing station may include at least one of a lithographic printer, a flexographic printer, a digital printer, and a gravure printer.

[0088] The perforation station may comprise a rotary die cutter.

[0089] The polymer application station may include a slot die coater. Preferably, the slot die coater is a rotary bar slot die coater. Preferably, the rotary bar slot die coater includes at least one cooling roller. Preferably, the at least one cooling roller includes a water cooling circuit disposed inside the cooling roller. Preferably, the cooling circuit has a spiral shape.

[0090] The polymer application station may be a first polymer application station for applying a first polymer material. The apparatus may further include a second polymer application station for applying a second polymer material to form a third layer including the second polymer material.

[0091] Preferably, the second polymer application station is positioned after the first polymer application station. The apparatus may include a turn bar positioned between the first polymer application station and the second polymer application station. The turn bar may be used to reverse the orientation of the web of cellulosic material when it is desired to apply the first and second polymer materials to opposite sides of the web of cellulosic material. The turn bar may be omitted in processes where it is desired to apply the first and second polymer materials to the same side of the web of cellulosic material. The apparatus may also include a removable turn bar positioned between the first and second polymer application stations, which may be removed or inserted depending on the particular process in which the apparatus is used and whether it is desired to apply the second polymer material to the first or second side of the web of cellulosic material.

[0092] The second polymer application station may comprise a pattern coater. Advantageously, the pattern coater can be used to apply the second polymer material to only one or more portions of the web of cellulosic material. This can be particularly advantageous in embodiments where the second polymer material is a heat seal material or other adhesive.

[0093] The apparatus may include a slitter arranged to slit the web of multi-layer material into a plurality of webs of multi-layer material.

[0094] According to an eighth aspect of the present invention, there is provided an apparatus for manufacturing packages of consumer goods. The apparatus comprises a web-forming apparatus comprising the apparatus of the seventh aspect of the present invention in accordance with any of the examples and embodiments described herein. The apparatus also comprises a cutting station for receiving a web of multi-layer material from the web-forming apparatus and for cutting layered blanks from the web of multi-layer material. The apparatus also comprises a folding station for folding the layered blanks to form packages of consumer goods.

[0095] The apparatus may comprise any of the optional or preferred features described above in relation to the third aspect of the invention. The apparatus may be configured to carry out the method of the third aspect of the invention in accordance with any of the examples or embodiments described herein.

[0096] Preferably, the folding station is arranged to fold the laminar blank so that the second layer comprising polymeric material forms an inner surface of the folded laminar blank.

[0097] Preferably, the apparatus includes a sealing station arranged to apply heat to the folded layered blank to form at least one bond interface between adjacent surfaces of the folded layered blank.

[0098] Preferably, the folding station is arranged to receive one or more consumer goods and to fold the layered blank around the one or more consumer goods.

[0099] According to the present disclosure, there is provided a method for manufacturing a web of multi-layer material. The method may include providing a web of cellulosic material. The method may include applying a moisture barrier material to a surface of the web of cellulosic material using a rotary bar slot die coater to form a web of multi-layer material. The web of multi-layer material may have a first layer and a second layer comprising cellulosic material, the second layer being a moisture barrier layer comprising the moisture barrier material.

[0100] According to a ninth aspect of the present invention, there is provided a method for manufacturing a web of multi-layer material. The method includes providing a web of cellulosic material. The method may also include applying a moisture barrier material to a surface of the web of cellulosic material using a rotary bar slot die coater to form a web of multi-layer material. The web of multi-layer material has a first layer and a second layer comprising cellulosic material, and the second layer is a moisture barrier layer comprising the moisture barrier material.

[0101] Advantageously, the inventors have recognized that a rotary bar slot die coater may facilitate depositing a uniform layer of moisture barrier material having a relatively thin thickness at high process speeds. For example, the use of a rotary bar slot die coater may facilitate depositing a uniform layer of moisture barrier material having a thickness of less than 20 micrometers at web speeds of at least 100 meters / minute.

[0102] Preferably, the rotary bar slot die coater includes at least one chill roller. Advantageously, in embodiments where the polymeric material is a hot melt polymeric material deposited in a molten state onto the web of cellulosic material by the rotary bar slot die coater, the at least one chill roller may facilitate rapid cooling and solidification of the polymeric material.

[0103] Preferably, at least one cooling roller comprises a water cooling circuit disposed inside the cooling roller. The water cooling circuit may have a spiral shape.

[0104] The moisture barrier material includes at least one of homopolymers of ethylene, propylene, 1-butene, isobutene, 1-octene, and 1-hexene; copolymers of at least two monomers selected from ethylene, propylene, 1-butene, isobutene, 1-octene, 1-hexene, and styrene; copolymers of ethylene and vinyl acetate; copolymers of ethylene and an ester of acrylic acid or methacrylic acid; copolymers of ethylene and acrylic acid or methacrylic acid; copolymers of styrene, ethylene, and propylene; hydrogenated copolymers of styrene and butadiene; hydrogenated copolymers of styrene and isoprene; copolymers of styrene and isobutene; and waxes.

[0105] The moisture barrier may include a polymer component in an amount of 50 to 90 weight percent of the moisture barrier. The polymer component may include at least one of an ethylene polymer, a propylene polymer, an ethylene copolymer, a propylene copolymer, a polyethylene plastomer, a polypropylene plastomer, and an amorphous polypropylene. The moisture barrier may include a wax in an amount of 2 to 20 weight percent of the moisture barrier. The wax may include at least one of a paraffin wax and a polyethylene wax. The moisture barrier may include a tackifier in an amount of 48 weight percent or less of the moisture barrier. The tackifier may include a hydrogenated hydrocarbon resin. The moisture barrier may include an antioxidant in an amount of 1 weight percent or less of the moisture barrier. The antioxidant may include at least one of a phenolic antioxidant and a phosphite antioxidant.

[0106] An exemplary vapor barrier may include a propylene homopolymer in an amount of 70 weight percent of the vapor barrier, a propylene-ethylene copolymer in an amount of 14 weight percent of the vapor barrier, a hydrogenated aromatic hydrocarbon resin in an amount of 10 weight percent of the vapor barrier, and paraffin wax in an amount of 6 weight percent of the vapor barrier. Preferably, the paraffin wax has a melting point of about 60 degrees Celsius, e.g., 55 to 65 degrees Celsius.

[0107] The moisture barrier may include a polymer component in an amount of 20 to 60 weight percent of the moisture barrier. The polymer component may include at least one of ethylene polymers, propylene polymers, ethylene copolymers, propylene copolymers, polyethylene plastomers, polypropylene plastomers, amorphous polypropylene, polyethylene-co-vinyl acetate copolymers, ethylene and acrylic copolymers, ethylene and methacrylic acid copolymers, polyisobutylene, copolymers of styrene and one or more monomers selected from butadiene, isobutylene, and isoprene, and hydrogenated copolymers of styrene and one or more monomers selected from butadiene, isobutylene, and isoprene. The moisture barrier may include a wax in an amount of 20 to 50 weight percent of the moisture barrier. The wax may include at least one of paraffin wax, microcrystalline wax, and polyethylene wax. The moisture barrier may include a tackifier in an amount of up to 60 weight percent of the moisture barrier. The tackifier may include a hydrocarbon resin, a hydrogenated hydrocarbon resin, a polyterpene resin, a hydrogenated polyterpene resin, a rosin ester, and a hydrogenated rosin ester. The moisture barrier may include an antioxidant in an amount of 1 weight percent or less of the moisture barrier. The antioxidant may include at least one of a phenolic antioxidant, a phosphite antioxidant, and vitamin E.

[0108] A further exemplary moisture barrier includes a propylene-ethylene copolymer plastomer in an amount of 45 weight percent of the moisture barrier, a hydrogenated aromatic hydrocarbon resin in an amount of 15 weight percent of the moisture barrier, and paraffin wax in an amount of 40 weight percent of the moisture barrier. Preferably, the paraffin wax has a melting point of about 60 degrees Celsius, e.g., 55 to 65 degrees Celsius.

[0109] A still further exemplary vapor barrier comprises low molecular weight polyethylene in an amount of 45 weight percent of the vapor barrier, hydrogenated aromatic hydrocarbon resin in an amount of 10 weight percent of the vapor barrier, Fischer-Tropsch polyethylene wax in an amount of 10 weight percent of the vapor barrier, and paraffin wax in an amount of 35 weight percent of the vapor barrier. Preferably, the paraffin wax has a melting point of about 60 degrees Celsius, e.g., 55 degrees Celsius to 65 degrees Celsius.

[0110] Preferably, the web of cellulosic material comprises a paper web or a paperboard web.

[0111] The web of cellulosic material may have a basis weight of at least 30 grams per square meter, at least 40 grams per square meter, at least 50 grams per square meter, at least 60 grams per square meter, at least 70 grams per square meter, at least 80 grams per square meter, at least 90 grams per square meter, at least 100 grams per square meter, at least 110 grams per square meter, at least 120 grams per square meter, at least 130 grams per square meter, at least 140 grams per square meter, or at least 150 grams per square meter.

[0112] The web of cellulosic material may have a basis weight of 270 grams per square meter or less, 250 grams per square meter or less, 240 grams per square meter or less, 230 grams per square meter or less, 220 grams per square meter or less, 210 grams per square meter or less, 200 grams per square meter or less, 190 grams per square meter or less, 180 grams per square meter or less, 170 grams per square meter or less, 160 grams per square meter or less, 150 grams per square meter or less, 140 grams per square meter or less, 130 grams per square meter or less, or 120 grams per square meter or less.

[0113] The web of cellulosic material may have a basis weight of 40 grams per square meter to 120 grams per square meter.The web of cellulosic material may have a basis weight of 150 grams per square meter to 250 grams per square meter.

[0114] The step of providing a web of cellulosic material may include providing a web of cellulosic material already having a coating on at least a portion of the web of cellulosic material. Typically, these coatings may include polymeric materials and may be applied by dispersion coating during the papermaking process. Suitable coating materials may include at least one of polyvinyl alcohol, emulsions or dispersions of polystyrene-co-butadiene, or other copolymers of styrene and acrylic or methacrylate monomers, and fillers such as kaolin, calcium carbonate, talc, etc.

[0115] The step of providing a web of cellulosic material may include providing a web of laminate material including at least one layer of cellulosic material. Preferably, the laminate material includes at least one layer of non-cellulosic material. The non-cellulosic material may include a non-cellulosic polymer. The at least one layer of non-cellulosic material may include a non-cellulosic polymer film. The non-cellulosic polymer film may include at least one of an oriented polypropylene film and an oriented polyethylene terephthalate film. Preferably, these films have a thickness of 6 micrometers to 15 micrometers.

[0116] The second layer including the vapor barrier may have a basis weight of at least 8 grams per square meter, at least 9 grams per square meter, at least 10 grams per square meter, at least 11 grams per square meter, at least 12 grams per square meter, at least 13 grams per square meter, or at least 14 grams per square meter.

[0117] The second layer including the vapor barrier may have a basis weight of 15 grams per square meter or less, 14 grams per square meter or less, 13 grams per square meter or less, 12 grams per square meter or less, 11 grams per square meter or less, 10 grams per square meter or less, or 9 grams per square meter or less.

[0118] The second layer, which includes a vapor barrier material, may have a basis weight of 8 grams per square meter to 15 grams per square meter.

[0119] The second layer including the vapor barrier may have a thickness of 20 micrometers or less, 19 micrometers or less, 18 micrometers or less, 17 micrometers or less, 16 micrometers or less, 15 micrometers or less, 14 micrometers or less, 13 micrometers or less, 12 micrometers or less, 11 micrometers or less, or 10 micrometers or less.

[0120] The second layer including the vapor barrier may have a thickness of at least 8 micrometers, at least 9 micrometers, at least 10 micrometers, at least 11 micrometers, at least 12 micrometers, at least 13 micrometers, at least 14 micrometers, or at least 15 micrometers.

[0121] The step of applying the vapor barrier may include applying the vapor barrier at a temperature of 200 degrees Celsius or less, 190 degrees Celsius or less, 180 degrees Celsius or less, 170 degrees Celsius or less, 160 degrees Celsius or less, 150 degrees Celsius or less, 140 degrees Celsius or less, 130 degrees Celsius or less, 120 degrees Celsius or less, or 110 degrees Celsius or less.

[0122] The step of applying the vapor barrier may include applying the vapor barrier at a temperature of at least 100 degrees Celsius, at least 110 degrees Celsius, at least 120 degrees Celsius, at least 130 degrees Celsius, at least 140 degrees Celsius, at least 150 degrees Celsius, at least 160 degrees Celsius, at least 170 degrees Celsius, at least 180 degrees Celsius, or at least 190 degrees Celsius.

[0123] The step of applying the vapor barrier may be followed by a calendering step. Advantageously, a calender roller may be used to further smooth the layer of vapor barrier by applying pressure. If the vapor barrier remains in a molten state, the calendering step can be carried out at a temperature lower than the temperature at which the vapor barrier is applied. If the vapor barrier has solidified, the calendering step may be carried out at a temperature higher than the temperature at which the vapor barrier is applied.

[0124] The calendering step may use calender rollers maintained at a low temperature, thus potentially facilitating the cooling and solidification of the molten moisture barrier. Alternatively, the calendering process can be applied when the coating is already solidified. Preferably, the calendering step uses calender rollers maintained at a temperature below the melting point of the moisture barrier.

[0125] The calender rollers may have surfaces made of polished metal. The calender rollers may also include composite surfaces, such as nickel-carbon or nickel-Teflon. Advantageously, in embodiments where the moisture barrier might otherwise adhere to the bare metal rollers, the composite surface can reduce or prevent adhesion of the moisture barrier to the calender rollers.

[0126] The step of applying the vapor barrier may include applying the vapor barrier at a dynamic viscosity of less than 40,000 millipascal seconds, preferably less than 20,000 millipascal seconds, preferably less than 10,000 millipascal seconds, preferably less than 5,000 millipascal seconds.

[0127] In the step of applying the vapor barrier, the method may include conveying the web of cellulosic material at a speed of at least 100 meters / minute, at least 110 meters / minute, at least 120 meters / minute, at least 130 meters / minute, at least 140 meters / minute, at least 150 meters / minute, at least 160 meters / minute, at least 170 meters / minute, at least 180 meters / minute, at least 190 meters / minute, at least 200 meters / minute, at least 210 meters / minute, at least 220 meters / minute, at least 230 meters / minute, or at least 240 meters / minute.

[0128] In the step of applying the vapor barrier, the method may include conveying the web of cellulosic material at a speed of 250 meters / minute or less, 240 meters / minute or less, 230 meters / minute or less, 220 meters / minute or less, 210 meters / minute or less, or 200 meters / minute or less.

[0129] The method may comprise any of the additional features described in relation to the first aspect of the invention, according to any of the examples or embodiments described herein.

[0130] According to a tenth aspect of the present invention, there is provided a web of multi-layer material produced using the method of the ninth aspect of the present invention, in accordance with any of the examples or embodiments described herein.

[0131] According to the present disclosure, there is provided a method of manufacturing a package of consumer goods. The method may comprise forming a web of multi-layer material using a method according to the ninth aspect of the present invention. The method may comprise providing a web of multi-layer material using a method according to the ninth aspect of the present invention. The method may comprise cutting a layered blank from the web of multi-layer material. The method may comprise folding the layered blank to form the package of consumer goods.

[0132] According to an eleventh aspect of the present invention, there is provided a method of manufacturing a package of consumer goods. The method may comprise forming a web of multi-layer material using the method of the ninth aspect of the present invention, according to any of the examples or embodiments described herein. Alternatively, the method may comprise providing a web of multi-layer material using the method of the ninth aspect of the present invention, according to any of the examples or embodiments described herein. The method also comprises cutting a layered blank from the web of multi-layer material and folding the layered blank to form a package of consumer goods.

[0133] The method may comprise any of the optional or preferred features described in relation to the third aspect of the invention, according to any of the examples or embodiments described herein.

[0134] According to a twelfth aspect of the present invention, there is provided a package of consumer goods produced using the method of the eleventh aspect of the present invention, in accordance with any of the examples or embodiments described herein. [Example]

[0135] The following provides 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 another example, embodiment, or aspect described herein.

[0136] Example 1: 1. A method of manufacturing a web of multi-layer material, the method comprising: Providing a web of cellulosic material; perforating a web of cellulosic material to form an apertured web of cellulosic material; applying a polymeric material to a surface of the perforated web of cellulosic material to form a web of multi-layer material, the web of multi-layer material having a perforated first layer comprising cellulosic material and a second layer comprising polymeric material. Example 2: 2. The method of example 1, wherein the web of cellulosic material has a first side and a second side opposite the first side, the step of perforating the web of cellulosic material comprises perforating the web of cellulosic material from the first side, and the step of applying the polymeric material comprises applying the polymeric material to the second side of the web of cellulosic material. Example 3: The method of example 2, wherein the web of cellulosic material comprises at least one of text, graphics, logos, and indicia on the first surface. Example 4: The method of example 3, further comprising printing at least one of text, graphics, logos, and indicia on the first side of the web of cellulosic material. Example 5: 5. The method of example 4, wherein the printing step is performed before the perforating step. Example 6: 6. The method of claim 4 or 5, wherein the printing process comprises at least one of lithographic printing, flexographic printing, digital printing, and gravure printing. Example 7: 7. The method of any of Examples 1-6, wherein the step of perforating the web of cellulosic material comprises perforating the web of cellulosic material using a rotary die cutter. Example 8: The method of any of Examples 1-7, wherein the step of applying the polymeric material comprises applying the polymeric material to the cellulosic material using a slot die coater. Example 9: The method of example 8 or 9, wherein the slot die coater is a rotary bar slot die coater. Example 10: 10. The method of any of examples 1-9, further comprising the step of calendering the second layer comprising a polymeric material to increase the smoothness of the second layer, wherein the calendering step is carried out at a temperature below the melting point of the polymeric material. Example 11: The method of any one of Examples 1 to 10, wherein the second layer comprising a polymeric material is a moisture barrier layer. Example 12: 12. The method of any one of Examples 1-11, wherein the polymeric material comprises at least one of: a homopolymer of ethylene, propylene, 1-butene, isobutene, 1-octene, 1-hexene; a copolymer of at least two of the monomers ethylene, propylene, 1-butene, isobutene, 1-octene, 1-hexene, and styrene; a copolymer of ethylene and vinyl acetate; a copolymer of ethylene and an ester of acrylic acid or methacrylic acid; a copolymer of ethylene and acrylic acid or methacrylic acid; a copolymer of styrene, ethylene, and propylene; a hydrogenated copolymer of styrene and butadiene; a hydrogenated copolymer of styrene and isoprene; a copolymer of styrene and isobutene; and a wax. Example 13: The method of any of Examples 1-12, wherein the polymeric material is a first polymeric material, and the method further comprises applying a second polymeric material to form a third layer comprising the second polymeric material. Example 14: 14. The method of example 13, wherein the step of applying the second polymeric material is performed after the step of applying the first polymeric material. Example 15: The method of any one of Examples 13 to 14, wherein the third layer comprising the second polymeric material is a heat seal layer. Example 16: 16. The method of claim 13, 14 or 15, wherein the second polymeric material comprises at least one of a copolymer of ethylene, a copolymer of methacrylic acid, a copolymer of an ester of acrylic acid, or a copolymer of an ester of methacrylic acid. Example 17: 16. The method of example 13, 14, or 15, wherein the second polymeric material comprises at least one of a polymer or copolymer of ethylene, propylene, or 1-butene. Example 18: The method of any of Examples 1-17, further comprising slitting the web of multi-layer material to form a plurality of webs of multi-layer material. Example 19: The method of any of Examples 1-18, wherein the web of cellulosic material comprises a paper web or a paperboard web. Example 20: A web of multi-layer material produced using the method of any of Examples 1-19. Example 21: 1. A method of manufacturing a package of consumer goods, said method comprising: forming a web of multi-layer material using the method of any one of Examples 1-19; cutting layered blanks from a web of multi-layer material; and folding the layered blank to form a package of consumer goods. Example 22: 1. A method of manufacturing a package of consumer goods, the method comprising: Providing a web of multi-layer material produced using the method of any one of Examples 1 to 19; cutting layered blanks from a web of multi-layer material; and folding the layered blank to form a package of consumer goods. Example 23: 23. The method of example 21 or 22, wherein the second layer comprising the polymeric material forms an interior surface of a package for the consumer product. Example 24: 24. The method of example 21, 22 or 23, further comprising providing one or more consumer goods, and wherein folding the layered blank comprises folding the layered blank around the one or more consumer goods. Example 25: 25. The method of example 24, wherein the one or more consumer products comprise a plurality of aerosol-generating articles. Example 26: 25. The method of example 24, wherein the one or more consumer goods comprise a bundle of packages of aerosol-generating articles. Example 27: The method of Example 26, wherein each package of aerosol-generating articles is manufactured using the method of Example 25. Example 28: A consumer goods package manufactured using the method of any of Examples 21-27. Example 29: A multi-layer material, comprising: a first layer comprising a cellulosic material; a second layer comprising a polymeric material; and a plurality of perforations, each perforation extending through only the first layer. Example 30: 29. The multilayer material of Example 29, wherein a first layer comprising a cellulosic material has a first surface and a second surface opposite the first surface, the perforations being formed from the first surface of the first layer, and a second layer comprising a polymeric material overlies the second surface of the first layer. Example 31: 31. The multi-layer material of example 30, wherein the first layer comprising cellulosic material comprises at least one of text, graphics, logos, and indicia on the first surface. Example 32: 32. The multilayer material of example 29, 30 or 31, wherein the second layer comprising a polymeric material is a moisture barrier layer. Example 33: 33. The multilayer material of any of Examples 29-32, wherein the polymeric material comprises at least one of: a copolymer of styrene and an acrylic ester; a copolymer of styrene and butadiene; a copolymer of ethylene and vinyl acetate; a copolymer of ethylene and acrylic acid or methacrylic acid; a polymer or copolymer of ethylene and propylene, 1-butene, isobutene, 1-octene, 1-hexene, or norbornene; and a wax. Example 34: The multilayer material of any of Examples 29-33, wherein the polymeric material is a first polymeric material, and the multilayer material further comprises a third layer comprising a second polymeric material. Example 35: The multi-layer material of example 34, wherein the third layer comprising the second polymeric material is a heat seal layer. Example 36: 36. The multilayer material of any one of Examples 34 and 35, wherein the second polymeric material comprises at least one of a copolymer of ethylene, a copolymer of methacrylic acid, a copolymer of an ester of acrylic acid, or a copolymer of an ester of methacrylic acid. Example 37: 37. The multi-layer material of any one of Examples 29-36, wherein the first layer comprising cellulosic material is a paper layer or a paperboard layer. Example 38: A package for a consumer product, the package comprising: A folded layered blank formed from the multilayer material of any one of Examples 29 to 37; and one or more consumer goods contained within the folded layered blank. Example 39: 39. The consumer goods package of Example 38, wherein the second layer comprising a polymeric material forms an inner surface of the folded layered blank. Example 40: A package of consumer goods described in Example 38 or 39, wherein the one or more consumer goods are a plurality of aerosol-generating articles and the folded layered blank forms an outer housing that contains the plurality of aerosol-generating articles. Example 41: A package of consumer goods described in Example 38 or 39, wherein the one or more consumer goods are a bundle of packages of aerosol-generating articles and the folded layered blank forms an outer wrapper wrapped around the bundle of packages of aerosol-generating articles. Example 42: A package of consumer goods as described in Example 41, wherein each package of aerosol-generating articles is a package of aerosol-generating articles as described in Example 40. Example 43: An apparatus configured to carry out the method according to any one of Examples 1 to 19 or any one of Examples 21 to 27. Example 44: 1. An apparatus for producing a web of multi-layer material, the apparatus comprising: a feeding station for feeding a web of cellulosic material; a perforation station for perforating the web of cellulosic material to form a perforated web of cellulosic material; an apparatus comprising: a polymer application station for applying a polymer material to a surface of a perforated web of cellulosic material to form a web of multi-layer material, the web of multi-layer material having a perforated first layer comprising cellulosic material and a second layer comprising polymer material; and a polymer application station for applying a polymer material to a surface of the perforated web of cellulosic material to form a web of multi-layer material, the web of multi-layer material having a perforated first layer comprising cellulosic material and a second layer comprising polymer material. Example 45: 45. The apparatus of Example 44, wherein the perforation station is arranged to perforate a first side of the web of cellulosic material and the polymer application station is arranged to apply a polymer material to a second side of the web of cellulosic material, the second side being opposite the first side. Example 46: 46. ​​The apparatus of example 45, further comprising a turn bar disposed between the punching station and the polymer application station. Example 47: 46. ​​The apparatus of example 44 or 45, further comprising a printing station disposed to print at least one of text, graphics, logos, and indicia onto the first side of the web of cellulosic material. Example 48: 48. The apparatus of example 47, wherein the printing station is disposed between the supply station and the perforation station. Example 49: 49. The apparatus of example 47 or 48, wherein the printing station comprises at least one of a lithographic printer, a flexographic printer, a digital printer, and a gravure printer. Example 50: 50. The apparatus of any one of Examples 44-49, wherein the perforation station comprises a rotary die cutter. Example 51: 51. The apparatus of any of Examples 44-50, wherein the polymer application station comprises a slot die coater. Example 52: The apparatus of example 51, wherein the slot die coater is a rotary bar slot die coater. Example 53: 53. The apparatus of any of Examples 44-52, further comprising a calender roller forming part of or positioned after the polymer application station, the calender roller arranged to increase the smoothness of the second layer comprising the polymer material, optionally arranged to operate the calender roll at room temperature, and optionally arranged to cool the calender roll to a temperature below room temperature. Example 54: 54. The apparatus of any of Examples 44-53, wherein the polymer application station is a first polymer application station for applying a first polymer material, and the apparatus further comprises a second polymer application station for applying a second polymer material to form a third layer comprising the second polymer material. Example 55: 55. The apparatus of example 54, wherein the second polymer application station is positioned after the first polymer application station. Example 56: 56. The apparatus of example 55, further comprising a turn bar disposed between the first polymer application station and the second polymer application station. Example 57: 57. The apparatus of example 54, 55 or 56, wherein the second polymer application station comprises a pattern coater. Example 58: 58. The apparatus of any of Examples 54-57, further comprising a calender roller forming part of or positioned after the second polymer application station, the calender roller arranged to increase the smoothness of the third layer comprising the second polymer material, optionally arranged to operate the calender roll at room temperature, and optionally arranged to cool the calender roll to a temperature below room temperature. Example 59: 59. The apparatus of any of Examples 44-58, further comprising a slitter arranged to slit the web of multi-layer material into a plurality of webs of multi-layer material. Example 60: 1. An apparatus for producing packages of consumer goods, the apparatus comprising: A web forming apparatus comprising the apparatus according to any one of Examples 44 to 59; a cutting station for receiving the web of multi-layer material from the web forming device and for cutting layer blanks from the web of multi-layer material; a folding station for folding the layered blank to form a package of consumer goods. Example 61: 61. The apparatus of example 60, wherein the folding station is configured to fold the layered blank such that the second layer comprising the polymeric material forms an inner surface of the package of the consumer good. Example 62: 62. The apparatus of claim 60 or 61, wherein the folding station is configured to receive one or more consumer goods and fold the layered blank around the one or more consumer goods. Example 63: 1. A method of manufacturing a web of multi-layer material, the method comprising: Providing a web of cellulosic material; applying a moisture barrier material to a surface of a web of cellulosic material using a rotary bar slot die coater to form a web of multi-layer material, the web of multi-layer material having a first layer and a second layer comprising cellulosic material, the second layer being a moisture barrier layer comprising the moisture barrier material. Example 64: 64. The method of example 63, wherein the moisture barrier comprises at least one of: a copolymer of styrene and an acrylic ester; a copolymer of styrene and butadiene; a copolymer of ethylene and vinyl acetate; a copolymer of ethylene and acrylic acid or methacrylic acid; a polymer or copolymer of ethylene and propylene, 1-butene, isobutene, 1-octene, 1-hexene, or norbornene; and a wax. Example 65: 65. The method of example 63 or 64, wherein the second layer has a thickness of less than 20 micrometers, preferably less than 18 micrometers, preferably less than 16 micrometers, preferably less than 14 micrometers, preferably less than 12 micrometers, preferably less than 10 micrometers. Example 66: 66. The method of example 63, 64, or 65, wherein providing a web of cellulosic material comprises feeding the web of cellulosic material through a rotary bar slot die coater at a speed of at least 100 meters / minute, preferably at least 125 meters / minute, preferably at least 150 meters / minute, preferably at least 175 meters / minute, preferably at least 200 meters / minute. Example 67: 67. The method of any of Examples 63-66, wherein a rotary bar slot die coater applies the moisture barrier material at a temperature less than 200 degrees Celsius. Example 68: The method of any of examples 63-67, wherein the second layer has a basis weight of less than 20 grams per square meter, preferably less than 15 grams per square meter, preferably less than 10 grams per square meter, preferably less than 5 grams per square meter. Example 69: 69. The method of any of Examples 63-68, wherein the moisture barrier has a composition comprising at least 5 weight percent of one or more waxes, preferably at least 10 weight percent of one or more waxes, preferably at least 30 weight percent of one or more waxes, and the rotating bar slot die coater applies the moisture barrier at a kinematic viscosity of less than 40,000 millipascal-seconds, preferably less than 20,000 millipascal-seconds, preferably less than 10,000 millipascal-seconds, preferably less than 5,000 millipascal-seconds. Example 70: 70. The method of any of Examples 63-69, wherein the web of cellulosic material comprises a paper web or a paperboard web. Example 71: 71. The method of any of Examples 63-70, further comprising the step of calendering the second layer comprising a polymeric material to increase the smoothness of the second layer, preferably wherein the calendering step is carried out at a temperature below the melting point of the polymeric material. Example 72: A web of multilayer material produced using the method of any of Examples 63-71. Example 73: 1. A method of manufacturing a package of consumer goods, the method comprising: forming a web of multi-layer material using the method of any of Examples 63-71; cutting layered blanks from a web of multi-layer material; and folding the layered blank to form a package of consumer goods. Example 74: 1. A method of manufacturing a package of consumer goods, the method comprising: Providing a web of multilayer material produced using the method of any one of Examples 63 to 70; cutting layered blanks from a web of multi-layer material; and folding the layered blank to form a package of consumer goods. Example 75: 75. The method of claim 73 or 74, wherein the moisture barrier forms an interior surface of a package for the consumer product. Example 76: 76. The method of example 73, 74 or 75, further comprising providing one or more consumer goods, and wherein folding the layered blank comprises folding the layered blank around the one or more consumer goods. Example 77: 77. The method of claim 76, wherein the one or more consumer goods include a plurality of aerosol-generating articles. Example 78: The method of example 76, wherein the one or more consumer goods comprise a bundle of packages of aerosol-generating articles. Example 79: The method of Example 78, wherein each package of aerosol-generating articles is produced using the method of Example 76. Example 80: A consumer goods package produced using the method of any one of Examples 73-79.

[0137] The invention will now be further described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0138] [Figure 1] FIG. 1 shows a flow chart illustrating steps in a method of forming a web of multi-layer material according to an embodiment of the present invention. [Figure 2] FIG. 2 illustrates a first exemplary apparatus for carrying out the method of FIG. [Figure 3] FIG. 3 shows a first side of a first embodiment of a web of multi-layer material produced according to the method of FIG. 1 using the apparatus of FIG. [Figure 4] FIG. 4 shows the second side of the web of multi-layer material of FIG. [Figure 5]FIG. 5 shows a cross-sectional view of the web of multi-layer material of FIG. 4 taken along line 3-3. [Figure 6] FIG. 6 shows a second exemplary apparatus for carrying out the method of FIG. [Figure 7] FIG. 7 shows a first side of a second embodiment of a web of multi-layer material produced according to the modified method of FIG. 1 using the apparatus of FIG. [Figure 8] FIG. 8 shows the second side of the web of multi-layer material of FIG. [Figure 9] FIG. 9 shows a cross-sectional view of the web of multi-layer material of FIG. 7 taken along line 7-7. [Figure 10] FIG. 10 illustrates a third exemplary apparatus for carrying out the method of FIG. [Figure 11] FIG. 11 shows a first side of a third embodiment of a web of multi-layer material produced according to the modified method of FIG. 1 using the apparatus of FIG. [Figure 12] FIG. 12 shows the second side of the web of multi-layer material of FIG. [Figure 13] FIG. 13 shows a cross-sectional view of the web of multi-layer material of FIG. 11 taken along line 11-11. DETAILED DESCRIPTION OF THE INVENTION

[0139] FIG. 1 shows a flow chart illustrating steps in a method for forming a web of multi-layer material according to an embodiment of the present invention. The method includes a first step 10 of unwinding a web of cellulosic material from a bobbin. In a second step 20, the web of cellulosic material is perforated on a first side of the web of cellulosic material to form a perforated web of cellulosic material. Preferably, the web of cellulosic material comprises paper or paperboard. In embodiments in which the web of multi-layer material is used to form multiple layered blanks that are folded to form a package of consumer goods, the perforations may facilitate consumer opening of the package. For example, the perforated web of cellulosic material may include perforation lines that form tear lines or tear tapes when layered blanks cut from the web of multi-layer material are folded to form a package of consumer goods.

[0140] In a third step 30, the perforated cellulosic web is inverted in preparation for a fourth step 40, in which a first polymeric material is applied to a second side of the perforated cellulosic web. Preferably, the first polymeric material is a moisture barrier. Advantageously, applying the moisture barrier after the perforation step facilitates the formation of a uniform and effective moisture barrier. Applying the moisture barrier to the side of the perforated cellulosic web opposite the side on which the perforations are formed may facilitate improving the appearance of the perforations when the side of the multilayer web with the moisture barrier forms the interior surface of the folded layered blank. However, those skilled in the art will understand that the third step 30 can be omitted if it is desired to apply the first polymeric material to the first side of the perforated cellulosic web.

[0141] In a fifth step 50, the apertured cellulosic web containing the first polymeric material is again inverted, after which, in a sixth step 60, a second polymeric material is applied to the first side of the apertured cellulosic web. The second polymeric material may comprise a heat seal material. The fifth step 50 may be omitted if it is desired to apply the second polymeric material to the same side of the apertured cellulosic web as the first polymeric material. Furthermore, if application of a second polymeric material is not required, both steps 50 and 60 may be omitted.

[0142] After step 40 (and optionally after steps 50 and 60), the perforated web of cellulosic material and the layer of first polymeric material are bonded together to form a web of multi-layer material. In optional step 70, the web of multi-layer material may be slit to form multiple webs of multi-layer material. Finally, in step 80, one or more webs of multi-layer material may be rewound onto one or more bobbins for storage or transfer to another manufacturing line.

[0143] Figure 2 shows a schematic cross-sectional view of an apparatus 100 suitable for carrying out the method of Figure 1. The apparatus includes a supply station 110 for unwinding a web 112 of cellulosic material from a bobbin 114 in an unwinding process 10.

[0144] The web of cellulosic material 112 is fed to a perforation station 120 that includes a die cutter 122 disposed to perforate the web of cellulosic material 112 from a first side of the web in step 20. A first turn bar 130 then turns the perforated web of cellulosic material 112 in step 30.

[0145] The inverted perforated cellulosic web 112 then advances to a first polymer application station 140, step 40, which includes a rotary bar slot die coater 142 and a plurality of chill rollers 144, for applying a first polymer to a second side of the perforated cellulosic web 112. The inventors have recognized that the use of a rotary bar slot die coater facilitates the application of a thin, uniform layer of a first polymer to the perforated cellulosic web at relatively high web speeds that are not achievable with conventional slot die coaters. This is particularly advantageous in embodiments in which the first polymer comprises a moisture barrier, since a uniform coating that is substantially free of defects is required to provide optimal moisture barrier performance.

[0146] The inventors have observed improved performance of the rotary bar slot die coater compared to a conventional slot die coater during testing with the following moisture-resistant formulations: Formulation 1: Propylene homopolymer in an amount of 70 weight percent of the moisture barrier, propylene-ethylene copolymer in an amount of 14 weight percent of the moisture barrier, hydrogenated aromatic hydrocarbon resin in an amount of 10 weight percent of the moisture barrier, and paraffin wax in an amount of 6 weight percent of the moisture barrier, the paraffin wax having a melting point of 60 degrees Celsius. Formulation 2: A propylene-ethylene copolymer plastomer in an amount of 45 weight percent of the moisture barrier, a hydrogenated aromatic hydrocarbon resin in an amount of 15 weight percent of the moisture barrier, and paraffin wax in an amount of 40 weight percent of the moisture barrier, the paraffin wax having a melting point of 60 degrees Celsius. Formulation 3: A low molecular weight polyethylene in an amount of 45 weight percent of the moisture barrier, a hydrogenated aromatic hydrocarbon resin in an amount of 10 weight percent of the moisture barrier, a Fischer-Tropsch polyethylene wax in an amount of 10 weight percent of the moisture barrier, and paraffin wax in an amount of 35 weight percent of the moisture barrier, the paraffin wax having a melting point of 60 degrees Celsius.

[0147] During testing, 50 grams per square meter of calendered paper was coated with 15 grams per square meter of each of Formulations 1, 2, and 3. The materials were cooled to allow the coating to solidify after application by a cooling roller at a temperature of 15 degrees Celsius or by using an additional Teflon-coated calendering roller. The first cooling roller facilitates cooling of the coating from the exposed side of the paper, while the calendering roller facilitates more rapid cooling by direct contact with the molten polymer layer applied from the slot die. The resulting coated paper was visually evaluated for defects, such as lines and coating uniformity, and for water vapor or moisture transmission rate (WVTR) measured at 38 degrees Celsius and 90 percent relative humidity using a PERMATRAN-W 3 / 34 H from Ametek Mocon, according to ASTM F1249 standard. The test results are shown in Tables 1 and 2 below. [Table 1] [Table 2]

[0148] As shown in Table 1, the performance of the rotary bar slot die coater and conventional slot die coater in depositing moisture-barrier coatings was nearly equivalent at a low web speed of 10 meters / min. However, at a production speed of 100 meters / min, the conventional slot die coater showed a clear decrease in the WVTR of the deposited coating. Furthermore, coatings applied at a web speed of 100 meters / min using the conventional slot die coater exhibited visible irregularities in the coating, such as lines or other defects, as indicated by asterisks in Table 1. On the other hand, the rotary bar slot die coater did not show a significant change in the WVTR of the applied coating when the web speed was increased from 10 meters / min to 100 meters / min. At a web speed of 100 meters / min, the rotary bar slot die coater retained its ability to deposit a substantially defect-free coating, demonstrating sufficient moisture-barrier performance.

[0149] The effect of the cooling calendering process is also noteworthy (see Table 2). The improvement in moisture barrier performance is likely a result of the additional smoothing effect of the calender rollers. Furthermore, rapid cooling of the molten polymer coating may reduce the growth of microcrystals composed of polymer or wax, further improving barrier performance.

[0150] Returning to the apparatus 100 of Figure 2, the apparatus 100 further includes a second turn bar 150 disposed to turn over the coated, perforated web of cellulosic material 112 in step 50 of the method of Figure 1. Next, in step 60, a second polymer application station 160 including a pattern coater 162 is used to apply a second polymer material, e.g., a heat seal material, to a first side of the perforated web of cellulosic material 112. Next, in step 70, the coated and perforated web of cellulosic material 112, forming a web of multi-layer material, is slit at a slitting station 170 including a slitter 172. Finally, in step 80, a plurality of the webs of multi-layer material 174 are fed to a winding station 180 and wound onto separate bobbins 182, 184.

[0151] Figures 3 and 4 show perspective views of the first and second sides of a portion of web of multi-layer material 174 produced using the method of Figure 1 on the apparatus of Figure 2. Figure 5 shows a cross-sectional view of web of multi-layer material 174 taken along line 3-3. Web of multi-layer material 174 includes a first layer 200 comprising perforated web of cellulosic material 112. Perforated web of cellulosic material 112 includes a plurality of perforation lines 202 each extending across the entire width of web of cellulosic material 112. A plurality of indicia 204 have been pre-printed on the first side of web of cellulosic material 112 in a separate printing process.

[0152] A second polymeric material including a moisture barrier is applied as a continuous coating on the second surface of the web of cellulosic material 112. The continuous coating of moisture barrier forms the second layer 206 of the web 174 of multi-layer material.

[0153] A third polymeric material comprising a heat seal material is applied in a repeating pattern on the first surface of the web of cellulosic material 112. The repeating pattern of heat seal material forms the third layer 208 of the web 174 of multi-layer material.

[0154] The marks 204, perforation lines 202, and third layer 208 of heat seal material are arranged in a repeating pattern in the machine direction of the web 174 of multi-layer material, allowing multiple layered blanks to be cut from the web 174 of multi-layer material in separate downstream processes.

[0155] Figure 6 shows a schematic cross-sectional view of a second apparatus 300 suitable for carrying out the improved method for producing a web of multi-layer material. As discussed above with reference to Figure 1, step 50, which involves the second inversion of the apertured cellulosic web 112, is an optional step. Thus, the apparatus 300 of Figure 6 is identical to the apparatus 100 of Figure 2 (like reference numbers are used to indicate like parts), except that the second turn bar 150 has been removed. Otherwise, operation of the apparatus 300 of Figure 6 is the same as that of the apparatus 100 of Figure 2, resulting in the production of an improved web of multi-layer material 374.

[0156] Figures 7 and 8 show perspective views of the first and second faces of a portion of a web of multi-layer material 374 produced using the modified method of Figure 1 (with step 50 eliminated) on the apparatus 300 of Figure 6. Figure 5 shows a cross-sectional view of the web of multi-layer material 374 taken along line 7-7.

[0157] Web 374 of multi-layer material of Figures 7-9 is similar to web 174 of multi-layer material of Figures 3-5, and like reference numerals are used to indicate like parts. The difference between the two webs is the location of third layer 308 of second polymeric material, which is disposed on the second side of web 112 of cellulosic material, above second layer 206 of first polymeric material. The placement of the second polymeric material on either the first side or the second side of web 112 of cellulosic material may depend on the intended use of the multi-layer material web.

[0158] Figure 10 shows a schematic cross-sectional view of a third apparatus 400 suitable for carrying out a further improved method for producing a web of multi-layer material. As described above with reference to Figure 1, both step 50, which involves the second inversion of the perforated cellulosic web 112, and step 60, which involves the application of a second polymeric material, are optional steps. Thus, the apparatus 400 of Figure 10 is identical to the apparatus 300 of Figure 6 (like reference numerals are used to indicate like parts), except that the second polymeric application station 160 has been removed. Otherwise, operation of the apparatus 400 of Figure 10 is the same as that of the apparatus 300 of Figure 6, resulting in the production of an improved web of multi-layer material 474.

[0159] Figures 11 and 12 show perspective views of the first and second faces of a portion of a web of multi-layer material 474 produced using the modified method of Figure 1 (with steps 50 and 60 eliminated) on the apparatus 400 of Figure 11. Figure 13 shows a cross-sectional view of the web of multi-layer material 474 taken along line 11-11.

[0160] The web 474 of multilayer material of Figures 11-13 is similar to the web 374 of multilayer material of Figures 7-9, and like reference numerals are used to indicate like parts. The difference between the two webs relates to the nature of the second layer 406. Specifically, the first polymer application station 140 of the apparatus 400 is used to apply a polymer mixture containing both a moisture barrier and a heat seal material. Thus, the second layer 406 forms both a moisture barrier layer and a heat seal layer. In this manner, the improved method of Figure 1, performed using the apparatus 400 of Figure 10, can eliminate the need to separately apply a moisture barrier and a heat seal material to the perforated web 112 of cellulosic material.

Claims

1. 1. A method for producing a web of multi-layer material, said method comprising: Providing a web of cellulosic material; perforating the web of cellulosic material to form an apertured web of cellulosic material; applying a polymeric material to a surface of the apertured cellulosic web to form a web of multi-layer material, the web of multi-layer material having an apertured first layer comprising the cellulosic material and a second layer comprising the polymeric material; A method wherein the layer of polymeric material covers, fills, or covers and fills the perforations on the surface of the web of cellulosic material to which the polymeric material is applied.

2. 2. The method of claim 1, wherein the web of cellulosic material has a first side and a second side opposite the first side, the step of perforating the web of cellulosic material comprises perforating the web of cellulosic material from the first side, and the step of applying a polymeric material comprises applying the polymeric material to the second side of the web of cellulosic material.

3. The method of claim 1 , wherein the web of cellulosic material includes at least one of text, graphics, logos, and indicia on a surface of the web of cellulosic material.

4. 4. The method of claim 3, further comprising the step of printing at least one of the text, graphics, logos, and indicia onto the web of cellulosic material, the printing step being performed before the perforating step.

5. The method of any of claims 1 to 4, wherein the step of perforating the web of cellulosic material comprises perforating the web of cellulosic material using a rotary die cutter.

6. The method of any of claims 1 to 5, wherein the step of applying the polymeric material comprises applying the polymeric material to the cellulosic material using a slot die coater.

7. The method of claim 6 , wherein the slot die coater is a rotary bar slot die coater.

8. The method of claim 7 , wherein the rotary bar slot die coater comprises at least one chill roller.

9. The method of claim 8 , wherein the at least one cooling roller comprises a water cooling circuit disposed inside the cooling roller.

10. The method of claim 9 , wherein the cooling circuit has a helical shape.

11. The method of any of claims 1 to 10, wherein the second layer comprising the polymeric material is a moisture barrier layer.

12. 12. The method of any of claims 1 to 11, wherein the polymeric material comprises at least one of a homopolymer of ethylene, propylene, 1-butene, isobutene, 1-octene, or 1-hexene; a copolymer of at least two monomers selected from ethylene, propylene, 1-butene, isobutene, 1-octene, 1-hexene, and styrene; a copolymer of ethylene and vinyl acetate; a copolymer of ethylene and an ester of acrylic acid or methacrylic acid; a copolymer of ethylene and acrylic acid or methacrylic acid; a copolymer of styrene, ethylene, and propylene; a hydrogenated copolymer of styrene and butadiene; a hydrogenated copolymer of styrene and isoprene; a copolymer of styrene and isobutene; and a wax.

13. 13. The method of any of claims 1 to 12, wherein the polymeric material is a first polymeric material, and the method further comprises applying a second polymeric material to form a third layer comprising the second polymeric material.

14. The method of claim 13 , wherein the step of applying the second polymeric material is performed after the step of applying the first polymeric material.

15. 15. The method of claim 13 or 14, wherein the third layer comprising the second polymeric material is a heat seal layer.

16. 16. The method of claim 13, 14, or 15, wherein the second polymeric material comprises at least a homopolymer of ethylene, propylene, 1-butene, isobutene, 1-octene, or 1-hexene; a copolymer of at least two monomers of ethylene, propylene, 1-butene, isobutene, 1-octene, 1-hexene, or styrene; a copolymer of ethylene and vinyl acetate; a copolymer of ethylene and an ester of acrylic acid or methacrylic acid; a copolymer of ethylene and acrylic acid or methacrylic acid; a copolymer of styrene, ethylene, and propylene; a hydrogenated copolymer of styrene and butadiene; a hydrogenated copolymer of styrene and isoprene; or a copolymer of styrene and isobutene.

17. 17. The method of any one of claims 1 to 16, further comprising at least one step of calendering the web of multi-layer material, preferably wherein said at least one calendering step is carried out using at least one roller, optionally operating said at least one roller at room temperature, and optionally cooling said at least one roller to a temperature below room temperature.

18. 18. The method of claim 17 in combination with any of claims 13 to 16, wherein the at least one step of calendering the web of multi-layer material comprises a first calendering step after the step of applying the first polymeric material and a second calendering step after the step of applying the second polymeric material.

19. 18. The method of claim 17 in combination with any of claims 13 to 16, wherein the at least one step of calendering the web of multi-layer material comprises a single calendering step after the step of applying the first polymeric material and the step of applying the second polymeric material.

20. A web of multi-layer material produced using the method of any preceding claim.

21. 1. A method of manufacturing a package of consumer goods, said method comprising: forming a web of multi-layer material using a method according to any one of claims 1 to 19; cutting layer blanks from the web of multi-layer material; and folding the layered blank to form a package of consumer goods.

22. 22. The method of claim 21, wherein the second layer comprising the polymeric material forms an interior surface of a package for the consumer good.

23. 23. The method of claim 21 or 22, further comprising the step of providing one or more consumer goods, and wherein said step of folding said layered blank comprises folding said layered blank around said one or more consumer goods.

24. A multi-layer material, comprising: a first layer comprising a cellulosic material; a second layer comprising a polymeric material; and a plurality of perforations, each perforation passing through only the first layer; A multi-layer material wherein the layer of polymeric material covers, fills, or covers and fills the perforations on the surface of the layer of cellulosic material to which the polymeric material is applied.

25. A package of consumer goods, said package comprising: a folded layered blank formed from the multi-layer material of claim 24; and one or more consumer goods contained within said folded layered blank.

26. 1. An apparatus for producing a web of multi-layer material, said apparatus comprising: a feeding station for feeding a web of cellulosic material; a perforation station for perforating the web of cellulosic material to form an apertured web of cellulosic material; a polymer application station for applying a polymer material to a surface of the perforated web of cellulosic material to form a web of multi-layer material, the web of multi-layer material having a perforated first layer comprising the cellulosic material and a second layer comprising the polymer material, the layer of polymer material covering, filling, or covering and filling the perforations on the surface of the web of cellulosic material to which the polymer material is applied.

27. 1. A method for producing a web of multi-layer material, said method comprising: Providing a web of cellulosic material; using a rotary bar slot die coater to apply a moisture barrier material to a surface of the web of cellulosic material to form a web of multi-layer material, the web of multi-layer material having a first layer and a second layer comprising the cellulosic material, the second layer being a moisture barrier layer comprising the moisture barrier material.

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