METHOD TO MAKE A CONTAINER FOR CONSUMER GOODS AND CONTAINER FOR CONSUMER GOODS

Abstract

The invention relates to a method of making a container for consumer goods, the method comprising: - forming a first multi-layer (100), the first multi-layer comprising a first cellulose (30) based layer and a first polymeric layer (31); - folding the first multi-layer (100) to form a package (10) comprising a lid portion and a box portion, the box portion and the lid portion being divided by an opening line, the lid portion being hinged to the box portion, the package defining a housing for the consumer goods, wherein the first multi-layer is so folded that the first polymeric layer is provided on an outer side of the first cellulose based layer; - forming an outer wrapper (101), the outer wrapper comprising a second cellulose (40) based layer and a second polymeric (41) layer; - wherein one of the first polymeric layer (31) and second polymeric layer (41) is a moisture barrier layer and the other of the first polymeric layer (31) and second polymeric layer (41) is a heat sealable layer; - wrapping the package with the outer wrapper (101), the outer wrapper covering, at least in part, the opening line, wherein the wrapping is made so that the second polymeric layer (41) is provided on an inner side of the second cellulose based layer (40); - heating the package and the outer wrapper (101), to seal the outer wrapper on the package (10), forming the container.

Claims

1. A method of making a container for consumer goods, the method comprising: forming a first multi-layer, the first multi-layer comprising a first cellulose based layer and a first polymeric layer; folding the first multi-layer to form a package comprising a lid portion and a box portion, the box portion and the lid portion being divided by an opening line, the lid portion being hinged to the box portion, the package defining a housing for the consumer goods, wherein the first multi-layer is so folded that the first polymeric layer is provided on an outer side of the first cellulose based layer; forming an outer wrapper, the outer wrapper comprising a second cellulose based layer and a second polymeric layer; wherein one of the first polymeric layer and second polymeric layer is a moisture barrier layer and the other of the first polymeric layer and second polymeric layer is a heat sealable layer; wrapping the package with the outer wrapper, the outer wrapper covering, at least in part, the opening line, wherein the wrapping is made so that the second polymeric layer is provided on an inner side of the second cellulose based layer; heating the package and the outer wrapper, to seal the outer wrapper on the package, forming the container.

2. The method according to claim 1, wherein the first cellulose based layer defines an inner surface and an outer surface and wherein forming a first multi-layer comprises: coating the outer surface of the first cellulose based layer with the first polymer layer.

3. The method according to claim 1, wherein forming an outer wrapper comprises forming an outer wrapper including a third polymeric layer.

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

5. The method according to claim 1, comprising: forming a second weakened line on the portion of the outer wrapper covering the opening line.

6. The method according to claim 1, wherein forming a first multi-layer or forming an outer wrapper comprises forming the moisture barrier layer from an emulsion or dispersion of one or more of: a copolymer of styrene and acrylic esters; a copolymer of styrene and butadiene; a copolymer of ethylene and vinyl acetate; a copolymer of ethylene and acrylic or methacrylic acid; a polymer or copolymer of ethylene with propylene, 1-butene, isobutene, 1-octene, 1-hexene, norbornene; and a wax.

7. The method according to claim 1, wherein forming a first multi-layer or forming an outer wrapper comprises forming the heat sealable layer from an emulsion or dispersion of one or more of: a copolymer of ethylene; a copolymer of methacrylic acid; a copolymer of an ester of acrylic acid or methacrylic acid.

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

9. The container according to claim 8, wherein the outer wrapper comprises a third polymer layer.

10. The container according to claim 9, wherein the third polymer layer is a heat sealable layer.

11. The container according to claim 8, wherein the outer wrapper comprises a second weakened line formed on the portion of the outer wrapper covering the opening line.

12. The method according to claim 1, wherein the first cellulose based layer has a basis weight comprised between 180 grams per square meter and 270 grams per square meter.

13. The method according to claim 1, wherein the second paper material layer has a basis weight comprised between 40 grams per square meter and 60 grams per square meter.

14. The method according to claim 1, wherein the first polymeric layer or the third polymeric layer has a basis weight comprised between 4 grams per square meter and 6 grams per square meter, or wherein the second polymeric layer has a basis weight comprised between 5 grams per square meter and 12 grams per square meter.

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

16. The container of claim 8, wherein the second paper material layer has a basis weight comprised between 40 grams per square meter and 60 grams per square meter.

17. The container of claim 8, wherein the first polymeric layer or the third polymeric layer has a basis weight comprised between 4 grams per square meter and 6 grams per square meter, or wherein the second polymeric layer has a basis weight comprised between 5 grams per square meter and 12 grams per square meter.

Description

[0208] Examples will now be further described with reference to the figures in which:

[0209] FIG. 1 is a perspective schematic view of a component of a container according to the invention;

[0210] FIG. 2 is a front view of an element of the component of the container of FIG. 1;

[0211] FIG. 3 is an enlarged side view of the element of the component of FIG. 2;

[0212] FIG. 4 is a front view of an element of another component of the container according to the invention;

[0213] FIG. 5 is an enlarged side view of the element of FIG. 2;

[0214] FIGS. 6 - 13 are perspective views of steps of the method for the realization of the container of FIG. 1;

[0215] FIG. 14 is a graph showing comparative tests between the container of the invention and prior art container in a first condition;

[0216] FIG. 15 is a graph showing comparative tests between the container of the invention and prior art container in a first condition;

[0217] FIG. 16 is a schematic enlarged view of a detail of FIG. 6; and

[0218] FIG. 17 is a schematic enlarged view of a detail of FIG. 7.

[0219] FIG. 1 shows a package 10 in accordance with the present invention. The package 10 has the shape of a rectangular parallelepiped and includes a box portion 14 and a lid portion 16. The parallelepiped defines a back wall 21, a front wall 22, a left side wall 23, a right side wall 24, a bottom wall 25 and a top wall 26.

[0220] The lid portion 16 is hinged about a hinge line 17 extending across a back wall of the parallelepiped and is pivotable between an open position (shown in FIG. 1) and a closed position. Further, the package 10 defines a housing or inner volume 18 containing for example a group of aerosol generating articles (not shown in the drawings). When the package 10 is closed, the lid portion 16 and the box portion 14 defines an opening line 19 which is the separation line between the lid portion and box portion. The opening line 19 is the geometrical continuation of the hinge line 17. The opening line 19 is formed on the left side wall 23, right side wall 24 and on the front wall 22.

[0221] In a different embodiment (not depicted), the opening line is not a cut, it is for example perforated, and therefore the package cannot be opened (that is, the lid portion 16 cannot rotate around the hinge line, unless the opening line is broken).

[0222] The package 10 is formed from a sheet blank 100 depicted in FIGS. 2 and 3. As illustrated in the lateral view of FIG. 3, the sheet blank 100 comprises a first cellulose based layer 30 comprising a cellulosic material and a first polymeric layer 31 having either heat sealing properties, or moisture barrier properties, or both. The first polymeric layer 31 is provided on an outer side of the first cellulose based layer 30. In more detail, the first cellulose based layer 30 is formed from a sheet of a paper-based material. Preferably, the first polymeric layer is a heat sealable layer. Preferably, the first cellulose based layer 30 has a weight comprised between 180 gsm and 270 gsm. Preferably, the first polymeric layer 31 has a weight comprised between 4 gsm and 10 gsm.

[0223] The sheet blank 100 is folded in such a way that the first cellulose based layer 30 is the inner layer and the first polymeric layer 31 is the outer layer of the package 10.

[0224] The package 10 formed by suitably folding the sheet blank 100 is then wrapped using an outer wrapper in order to form a container 1 (shown in FIG. 13) to contain consumer goods (not shown) for containing aerosol generating articles.

[0225] The outer wrapper is formed from a sheet blank 101 depicted in FIGS. 4 and 5. As illustrated in FIG. 5, the sheet blank 101 comprises a second cellulose based layer 40 comprising a second cellulosic material, a second polymeric layer 41 having either heat sealing properties, or moisture barrier properties, or both, and a third polymeric layer 42 having either heat sealing properties, or moisture barrier properties, or both. The second polymeric layer 41 is provided on an inner side of the second cellulose based layer 40. The third polymeric layer 42 is provided on an inner side of the second polymeric layer 41. In more detail, the second cellulose based layer 40 is formed from a sheet of a paper-based material. Preferably, the third polymeric layer is a heat sealable layer and the second polymeric layer is a moisture barrier layer. Preferably, the second cellulose based layer 40 has a weight comprised between 40 gsm and 60 gsm. Preferably, the third polymeric layer has a weight comprised between 4 gsm and 10 gsm. Preferably, the second polymeric layer has a weight comprised between 6 gsm and 12 gsm. Preferably, the thickness of the second cellulose based layer is comprised between 30 micrometers and 50 micrometers.

[0226] In order to form the container 1, the outer wrapper formed by blank sheet 101 is wrapped around the package 10 as shown in FIGS. 6 - 13.

[0227] First, on the blank sheet 101, a second weakened line 45 is formed. The second weakened line 45 is formed on the blank sheet 101 in such a way that, when the black sheet 101 is wrapped around the package 10, the second weakened line 45 is congruent to the opening line 19, as it is visible in FIGS. 11 - 13.

[0228] The second weakened line 45 may be manufactured with a laser scoring process or partial mechanical cutting of the paper over its thickness without damaging the sealable and moisture barrier layers.

[0229] The second weakened line 45 is formed on the second cellulose based layer 40. The scoring is done on the side of the second cellulose based layer 40 which becomes the outer surface of the container 1. The depth of the scoring is controlled in order not to impact the moisture barrier properties of the second polymeric layer 41.

[0230] Considering the scoring tolerances for both laser and mechanical processes and to have good functionality (ease of opening), the scoring depth is preferably between 50 percent to 80 percent of the thickness of the second cellulose based layer. For laser scoring 1000 watts CO.sub.2 laser may be used. Beam control of the laser may take place through a scanner. Process may be reel-to-reel with speed of 200 meters/minute.

[0231] In case of mechanical scoring, a rotary cutting unit may be used. The operation is performed inserting the second cellulose based layer between knife of the cutting unit and a blind counter roller. Distance between knife and counter roller is between 15 micrometers to 30 micrometers depending on the substrate.

[0232] The sheet blank 101 of the outer wrapper is put in abutment with the right side wall 24 of the package 10 (see FIG. 6). The sheet blank 101 is positioned in such a way that the third polymeric layer 42 contacts the first polymeric layer at the right side wall 24. The third polymeric layer 42 is thus the inner layer of the outer wrapper and the second cellulose based layer 40 is the outer layer of the outer wrapper.

[0233] The enlarged view in FIG. 16 shows how blank 101 is applied to package 10, putting the blanck into contact with the package. Two fold lines 102, 103 are formed in the sheet blank 101, corresponding to the location of the two corners 27, 28 formed between the back wall 21 and the right side wall 24 and the front wall 22 and the right side wall 24, respectively. This is depicted in FIG. 7. The sheet blank 101 is then compressed against the side wall 24 as depicted by the arrows in the inlet of FIG. 17.

[0234] The blank sheet 101 is then folded at the two fold lines 102, 103, so that the front wall 22 and back wall 21 of the package 10 are also in contact with the outer wrapper. This is depicted in FIG. 8.

[0235] The package 10 is then preferably re-oriented in order to facilitate wrapping, for example the left side wall 23 may now face upwards, as shown in FIG. 9.

[0236] Two additional fold lines are then formed in the sheet blank 101, fold lines 104, 105, corresponding to the location of the two corners 29, 51 formed between the back wall 21 and the left side wall 23 and the front wall 22 and the left side wall 23, respectively. The sheet blank 101 is then folded at the two fold lines 104, 105 and two opposite flaps of the sheet blank overlaps on the left side wall 23. This is depicted in FIG. 10. A panel of sheet blank 101 is formed thus on the left side wall 23, right side wall 24, front wall 22 and back wall 21 of package 10. In this way, the whole opening line 19 and the hinge line 17 are covered by the outer wrapper.

[0237] The package 10 and outer wrapper are then preferably re-oriented, so that the front wall 22 now faces upwards, as in FIG. 11.

[0238] The sheet blank 101 is then folded in a known manner in order to cover top wall 26 and bottom wall 25 of the package 10. This is shown in FIGS. 12 and 13. In FIG. 13, the whole package 10 is covered by the outer wrapper, which form a panel on each wall of the package 10. The second weakened line 45 is located congruent to the opening line 19 located underneath.

[0239] Heat and pressure is applied to fix and join the outer wrapper to the package 10. For example, a temperature of 110° C., and a pressure of 1 Newton persquare centimetre (N/cm.sup.2) are applied for a time of 100 milliseconds. These conditions provides a satisfactory seal and high adhesion.

Example 1 Outer Wrapper

[0240] A first embodiment of sheet blank 101 is given.

[0241] The second cellulose based layer 40 is a 45 gsm paper layer.

[0242] The 45 gsm paper is coated with 10 gsm of wax modified styrene acrylic dispersion using a rod coater, forming the second polymeric layer 41.

[0243] The used dispersion is provided by Trueb Chemie under the trade name TB16. This dispersion is diluted with water to obtain a solid content of 40 percent.

[0244] The coating is dried with a convection oven at a temperature not exceeding 90° C. and sheet blank 101 is formed.

[0245] Instead of TB16, dispersions comprised of a paraffin wax having a melting point of 60° C. (°C) and a styrene acrylate latex obtained from the emulsion polymerization of styrene, butyl-acrylate, ethyl-hexyl metacrylate and acrylic acid can be used as the second polymeric layer. Preferred copolymers comprise 60-80 mol% of Styrene and up to 20% of acrylic esters.

[0246] The paraffin wax can be added either during the emulsion polymerization or on a premade emulsion, a typical wax content is 10 percent. Preferably, wax is below 15 percent with respect to polymer content because higher content of wax may lead to unstable dispersions. The resulting coated paperboard has a moisture permeability comprised between 20-30 g/m2/atm/day measured at 38° C. and 90RH according to ASTM F3299.

Example 2 Outer Wrapper

[0247] The sheet blank 101 of Example 1 is prepared.

[0248] An additional 4-5 gsm coating layer is applied on the second polymer layer for enhanced sealability and barrier. This coating is the third polymer layer and is formed by a dispersion of a low molecular weight ethylene acrylic acid copolymer (Primacor 5980I). This coating is applied from a water dispersion comprised of Primacor 5980I and 10 percent wt of wax (with respect to Primacor 5980I). The used dispersion had a solid content of 35 percent.

[0249] The drying of the resulting multi-layer comprising the second cellulose based layer, the second polymer layer and the third polymer layer is made at a temperature of 80° C. in a convection oven.

Example 3 Outer Wrapper

[0250] A 45 gsm calendered paper, as the second cellulose based layer, is coated with 10 gsm of a second polymer layer material described as follows.

[0251] A wax modified styrene acrylic dispersion is formed as described in example 1.

[0252] To this dispersion, inorganic pigments such as Kaolin, Vermiculite, Calcium Carbonate (CaCO3) are added to reach a 50/50 ratio by weight of pigment/polymer dispersion. The inorganic pigments may improve the moisture barrier properties of the so formed polymeric layer.

[0253] Water is added to keep the total solid content of the resulting dispersion below 55% wt. The resulting coated paper formed by the second cellulose based layer and second polymeric layer has a moisture permeability comprised between 20-35 g/m2/atm/day measured at 38° C. and 90RH according to ASTM F3299.

[0254] An additional 4-5 gsm sealable coating layer is applied for enhanced sealability and barrier. This coating as third polymeric layer is described in Example 2.

[0255] Blank sheet 101 according to Examples 2-3 may be printed with Brand information, health warnings and design on the uncoated surface of the second cellulose based layer.

[0256] The second cellulose based layer is laser scored to allow easy opening and tamper evidence. Care must be taken to have a laser scoring (etching) that will not cut more than 80 percent of the second cellulose based layer’s thickness, thus avoiding to damage the moisture barrier and sealable layers.

Example 4 - First Multi-layer

[0257] A 180-270 gsm paperboard is used as the first cellulose based layer.

[0258] The 180-270 gsm paperboard is coated with 10 gsm of wax modified styrene acrylic dispersion on the surface intended for the outer side of the package, forming the first polymeric layer. This dispersion is formed as described in Example 1.

[0259] This sheet blank 100 may be lacquered according to standard techniques in the field of cigarette packaging. Standard lacquering in a coating with a polymer layer which does not have heat sealable or moisture barrier properties. The basis weight of the standard lacquering layer is less than 4 gsm.

[0260] The resulting multi-layer has a moisture permeability comprised between 10-20 g/m2/ day measured at 38° C. and 90RH according to ASTM F3299.

Example 5 - First Multi-layer

[0261] A 180-220 gsm paperboard is used as the first cellulose based layer.

[0262] The 180-220 gsm paperboard is coated with 10 gsm of wax modified styrene acrylic dispersion realized according to Example 1, forming the first polymeric layer.

[0263] The resulting multi-layer has a moisture permeability between 10-20 g/m2/atm/day measured at 38C and 90RH according to ASTM F3299.

[0264] An additional 4-5 gsm coating layer is applied for enhanced sealability and barrier and it comprises a dispersion of a low molecular weight ethylene acrylic acid copolymer (Primacor 5980I from SK Chemicals). This coating is applied from a water dispersion the same and 10% wt of wax (with respect to Primacor 5980I). The used dispersion had a solid content of 35%. This layer, a forth polymeric layer, is applied on the first polymeric layer.

[0265] Preferred polymers from which a water dispersion is made to form the first polymeric layer or the third polymeric layer or both with heat sealable properties are:

TABLE-US-00001 Tradename Description Use Primacor 5980I Copolymer of ethylene and acrylic acid Moisture Barrier Layer with excellent sealability. Especially if mixed with paraffin TECSEAL E-799/35 Waterborne EAA-copolymer dispersion containing paraffin Moisture Barrier Layer with excellent sealing properties Aquaseal X-2258 Aqueous dispersion of ethylene copolymer and paraffin wax Moisture Barrier and sealing layer

[0266] Preferred polymers from which a water dispersion is made to form the second polymeric layer with moisture barrier properties are:

TABLE-US-00002 Tradename Description Use TECRYL PB-16 Waterborne styrene acrylate-copolymer dispersion containing paraffin Moisture Barrier Layer, limited sealing properties Aquaseal X-2088 Propylene Copolymer Dispersion, can be combined with paraffin Moisture Barrier and sealing layer Aquaseal X-2200 Aqueous dispersion of ethylene copolymer Moisture Barrier and sealable layer

[0267] These polymers are to be combined with a wax.

Comparative Examples

[0268] Comparative Examples have been made comparing the performances of the container 1 according to the invention with the following:

[0269] Comparative container A (BOPP film): 20 cigarettes hinge lid packages formed by a lacquered 180-270 gsm paperboard and wrapped with 16 microns BOPP film. This container A is represented as a dashed line in the FIGS. 14 and 15.

[0270] Comparative container B (No Film): 20 cigarettes hinge lid packages formed by a lacquered 180-270 gsm paperboard without wrapping film (no barrier). This container B is represented as a dotted line in the FIGS. 14 and 15.

[0271] Container of the invention (Paper Barrier): 20 cigarettes packages were prepared with hinge lid packages made of the sheet blank 100 of Example 4, and wrapped with sheet blank 101 realized according to Example 2. This container C is represented as a continuous line in the FIGS. 14 and 15.

[0272] Containers A and B and the container C of the invention were placed in climatic chambers to simulate extreme environmental conditions (called in the drawings and in the following Jungle and Desert), humidity uptake or loss was monitored via Oven Volatiles Method. The graphs of FIGS. 14 and 15 show that the containers according to the invention have a moisture intake or loss similar to comparative container A (cigarettes packed in BOPP film). Oven Volatiles (OV in the drawings) were measured according to method: DETERMINATION OF MOISTURE CONTENT (OVEN VOLATILES) OF TOBACCO AND TOBACCO PRODUCTS, CORESTA Recommended Method No. 76 (published in July 2017 https://www.coresta.org/sites/default/files/technical documents/main/CRM 76-July2017.

[0273] The results are shown in FIGS. 14 and 15.

[0274] In FIG. 14, the conditions “jungle” are applied. The containers A, B and container C of the invention are kept at a temperature of 32° C. and a relative humidity of 85 percent. In the container B, the moisture in the container immediately increases. Container A and container C of the invention, as shown by the solid line and dashed line, have a very similar behaviour, that is the oven volatiles slowly increase within 90 days.

[0275] In FIG. 15, the conditions “desert” are applied. The containers A, B and of the invention are kept at a temperature of 43° C. and a relative humidity of 15 percent. In the container B, the moisture in the container immediately disappears. Container A and container of the invention, as shown by the solid line and dashed line, have a very similar behaviour, that is the oven volatiles slowly decrease within 90 days.

[0276] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term “about”. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 10 percent of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A represents. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.