Container assembly with paper-based end closure

Abstract

The present disclosure relates to recyclable composite container assemblies having improved properties resulting from the combination of raw materials, structural designs, systems, and methods for sealing paper-based closures (61) to paper-based container bodies (60). The container assemblies exhibit superior performance and sealing properties, such as very low oxygen transmission rates and high resistance to bulging and / or damage caused by high pressure differentials. The disclosed container assemblies have been optimized for high-speed manufacturing by extending the shelf life of food stored therein while minimizing the amount of any non-paper materials so that the container assemblies are suitable as recyclable single materials.

Description

[0001] Cross-reference application

[0002] This application claims priority to U.S. Patent Application No. 63 / 071,019, filed August 27, 2020, which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure generally relates to systems and methods for forming and sealing composite container assemblies using paper-based or composite closures. Background Technology

[0004] Rigid paper-based composite container assemblies are commonly used to package a variety of products, such as (for example) fast food and other food products. These container assemblies typically include a rigid container body (e.g., cylindrical) manufactured with openings at the top and bottom. The composite container body may include a rigid can made of sheet material (e.g., cardboard and / or linerboard) (e.g., spirally wound). Such container assemblies further include top and bottom closures. While the bottom closure (e.g., a metal end) is typically permanently attached (e.g., welded) to the bottom edge of the container body, the top closure is typically designed for easy removal by the consumer (e.g., a removable / replaceable top cap and / or peelable film). Typically, the film is first sealed to the top edge. Then, the product is filled into the container through the open bottom edge of the container body, and the metal closure is welded to the bottom edge of the container body.

[0005] The aforementioned process using a metal base hinders the recycling of container assemblies because welding the metal closure to the bottom of the container body makes it difficult to separate the metal closure from the container assembly after use. Because the paper-based body of the container assembly cannot be separated from the metal base, the container assembly cannot enter the paper or metal recycling stream. This leads to unnecessary waste and a negative environmental impact. Recyclable container assemblies are needed to increase the sustainability of end products.

[0006] One solution to the recyclability requirement is to produce container assemblies with paper-based end closures instead of metal ends. However, existing paper-based container assemblies and methods for attaching paper-based end closures to paper-based container bodies do not provide containers with acceptable sealing performance characteristics. Through ingenuity and hard work, the inventors have developed container assemblies with improved characteristics and methods for manufacturing such container assemblies.

[0007] For example, container assemblies produced from the raw materials, methods, and / or unique processing described herein have improved oxygen permeability (in some embodiments, less than about 0.05 cm). 3 / m 2( / day) and in some embodiments, it can withstand a pressure differential of more than about 10 inHg, which is a significant improvement over known paper-based container assemblies. Summary of the Invention

[0008] This disclosure generally relates to hermetically sealed paper-based container assemblies and methods for manufacturing such container assemblies.

[0009] In some embodiments, this disclosure relates to container assemblies (e.g., cylindrical) sealed with a paper-based bottom closure. In some embodiments, this disclosure relates to the resulting properties of the manufactured container assemblies. The container assemblies have properties superior to any previously known paper-based container assemblies, as described below.

[0010] In some embodiments, this disclosure relates to a paper-based container assembly having a top closure and a bottom closure (e.g., a paper-based disc) sealed to a container body. The paper-based container assembly may have a diameter of approximately 0.05 cm. 3 / m 2 / day or lower oxygen permeability and approximately 0.05g / m 2 / day or lower water vapor transmission rate. The container body may include at least one sidewall defining the interior of the container. The container body may further include a top edge defining the top end of the sidewall and a bottom peripheral edge defining the bottom end of the sidewall. The top closure may include a peelable film, a peelable barrier cap, a puncture-resistant film, or a notched openable film sealed to the top edge, or a recessed film sealed to the interior of the container body. The bottom closure may be recessed into the bottom end and may form a seal with the inner surface of the container body. The container body, peelable film, and bottom closure may each include multiple layers. The multiple layers may include one or more barrier layers and one or more paper base layers.

[0011] In some embodiments, the water vapor transmission rate of the paper-based container assembly may be approximately 0.5 g / m³. 2 / day or less. In some embodiments, the water vapor transmission rate of the paper-based container assembly may be about 0.05 g / m³. 2 / day or less. In some embodiments, the one or more paper base layers of the container body, peelable film, and bottom closure may comprise at least about 95% by weight of the paper-based container assembly.

[0012] In some embodiments, the plurality of layers may comprise one or more ionomer layers, wherein the one or more ionomer layers of at least one of the container body and the bottom closure have the same grade and form a seal between the bottom closure and the inner surface of the container body upon heating. In some embodiments, the plurality of layers may comprise one or more ionomer layers, wherein the one or more ionomer layers of at least one of the container body and the top closure have the same grade and form a seal between the top closure and the inner surface (i.e., the rolled edge) of the container body upon heating.

[0013] In some embodiments, at least one of the one or more ionomer layers may have a thickness in the range of about 2 to about 40 μm. In some embodiments, the one or more barrier layers of at least one of the container body, the peelable film, and the bottom closure may include aluminum, metallized polyethylene terephthalate (MPET) film, metallized polyethylene terephthalate (MPBT) film, and / or alumina (AlOx) coated polyethylene terephthalate (PET) film. In some embodiments, at least one of the one or more barrier layers may have a thickness in the range of about 2 to about 40 μm. In some embodiments, the one or more paper base layers of the bottom closure may include a flexible sheet and have a thickness in the range of about 0.1 to about 0.6 mm. In some embodiments, the multiple layers may include one or more adhesive layers. In some embodiments, the bottom closure may be recessed into the bottom end of the container body by a recess distance ranging from about 0.2 to 2 cm and protrude less than the recess distance under a pressure difference of about 10 inHg (about 34 kPa) with the interior of the container. In some embodiments, the seal between the inner surface of the container body and the bottom closure may be airtight. In some embodiments, the container assembly may be configured to store food within the container interior. In some embodiments, the container body may be cylindrical, having a height ranging from about 4 to 40 cm, and / or an inner diameter ranging from about 4 to 20 cm.

[0014] While the container of the present invention may be cylindrical, the invention is not limited thereto. In some embodiments, the container may have a square, rectangular, triangular, or irregular cross-section. The bottom closure of the present invention may have a shape and configuration related to the cross-section of the container. Thus, for a cylindrical container, the bottom closure may be circular or disc-shaped. However, for example, a container with a square cross-section may be fitted with a square bottom closure.

[0015] In some embodiments, this disclosure relates to a paper-based container assembly having a top closure and a bottom closure (e.g., a paper-based disc) sealed to a cylindrical container body. The paper-based container assembly may have a diameter of approximately 0.5 cm. 3 / m 2 / day or lower oxygen permeability and approximately 0.5g / m 2 / day or lower water vapor transmission rate. The cylindrical container body may include sidewalls defining the interior of the container. The cylindrical container body may further include a top edge defining the top end of the sidewall and a bottom peripheral edge defining the bottom end of the sidewall. The top closure may be sealed to the top edge. The bottom closure may be recessed into the bottom end and may form a seal with the inner surface of the cylindrical container body. The cylindrical container body, top closure, and bottom closure may include multiple layers comprising one or more paper base layers. The one or more paper base layers of the cylindrical container body, top closure, and bottom closure may include at least about 95% by mass of the paper-based container assembly.

[0016] In some embodiments, the water vapor transmission rate of the paper-based container assembly may be approximately 0.15 g / m³. 2 / day or less. In some embodiments, the water vapor transmission rate of the paper-based container assembly may be about 0.05 g / m³. 2 / day or less. In some embodiments, the plurality of layers may comprise one or more ionomer layers, wherein the one or more ionomer layers of at least one of the cylindrical container body and the bottom closure have the same grade and form the seal between the bottom closure and the inner surface of the cylindrical container body upon heating. In some embodiments, at least one of the one or more ionomer layers may have a thickness in the range of about 2 to about 40 μm. In some embodiments, the plurality of layers may comprise one or more barrier layers. The one or more barrier layers of at least one of the cylindrical container body, the top closure, and the bottom closure may comprise aluminum, metallized polyethylene terephthalate (MPET) film, metallized polyethylene terephthalate (MPBT) film, and / or alumina (AlOx) coated polyethylene terephthalate (PET) film. In some embodiments, at least one of the one or more barrier layers may have a thickness in the range of about 5 to about 20 μm. In some embodiments, the one or more paper base layers of the bottom closure may comprise a flexible sheet having a thickness ranging from about 0.1 to about 0.6 mm. In some embodiments, the multiple layers may comprise one or more adhesive layers. In some embodiments, the bottom closure may be recessed into the bottom end of the cylindrical container body with a recess distance ranging from about 0.2 to 2 cm and protrude less than the recess distance under a pressure difference of about 10 inHg (about 34 kPa) with the interior of the container. In some embodiments, the seal between the inner surface of the cylindrical container body and the bottom closure may be airtight. In some embodiments, the container assembly may be configured to store food within the container interior. In some embodiments, the cylindrical container body may have a height ranging from about 4 to 40 cm and / or an inner diameter ranging from about 3 to 20 cm.

[0017] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate one or more embodiments of this disclosure and, together with the “Detailed Description”, serve to explain the principles of this disclosure. Attached Figure Description

[0018] The specification with reference to the accompanying drawings sets forth a complete and advantageous disclosure for those skilled in the art, wherein:

[0019] Figure 1 A cross-section of an exemplary sealing system according to some embodiments of the present disclosure is shown;

[0020] Figure 2 A cross-section of an exemplary sealing system according to some embodiments of the present disclosure is shown;

[0021] Figure 3 A cross-section of an exemplary sealing system according to some embodiments of the present disclosure is shown;

[0022] Figure 4 A cross-section of an exemplary sealing system according to some embodiments of the present disclosure is shown;

[0023] Figure 5 A cross-section of an exemplary sealing system according to some embodiments of the present disclosure is shown;

[0024] Figure 6 A cross-section of an exemplary sealing system according to some embodiments of the present disclosure is shown;

[0025] Figure 7 A cross-section of an exemplary sealing system according to some embodiments of the present disclosure is shown;

[0026] Figure 8 A cross-section of an exemplary sealing system according to some embodiments of the present disclosure is shown;

[0027] Figure 9 A cross-section of an exemplary sealing system according to some embodiments of the present disclosure is shown;

[0028] Figure 10 A cross-section of an exemplary sealing system according to some embodiments of the present disclosure is shown;

[0029] Figure 11 A cross-section of an exemplary sealing system according to some embodiments of the present disclosure is shown;

[0030] Figure 12 A cross-section of an exemplary sealing system according to some embodiments of the present disclosure is shown;

[0031] Figure 13 A cross-section of an exemplary sealing system according to some embodiments of the present disclosure is shown;

[0032] Figure 14 A cross-section of an exemplary mold and vacuum system according to some embodiments of the present disclosure is shown;

[0033] Figure 15 This invention describes an exemplary mold and a vacuum system according to some embodiments of the present disclosure;

[0034] Figure 16 A cross-section of an exemplary mold and vacuum system according to some embodiments of the present disclosure is shown;

[0035] Figure 17A Exemplary container body, top closure and paper-based disk according to some embodiments of the present disclosure are shown in a top front view.

[0036] Figures 17B to 17D According to some embodiments of this disclosure Figure 17ACross-sectional views of the exemplary container body, top closure, and paper-based disc;

[0037] Figure 18 A cross-section of an exemplary hermetically sealed container assembly according to some embodiments of the present disclosure is shown; and

[0038] Figure 19 This describes the bottom end of an exemplary sealed container assembly with a recessed bottom closure according to some embodiments of the present disclosure.

[0039] Figure 20 An exemplary sealing system according to an embodiment of the present invention is described;

[0040] Figure 21 An exemplary sealing system according to an embodiment of the present invention is described;

[0041] Figure 22 An exemplary sealing system according to an embodiment of the present invention is described;

[0042] Figure 23 An exemplary sealing system according to an embodiment of the present invention is described;

[0043] Figure 24 An exemplary sealing system according to an embodiment of the present invention is described;

[0044] Figure 25 An exemplary mold and vacuum system according to an embodiment of the present invention are described;

[0045] Figure 26 An exemplary mold and vacuum system according to an embodiment of the present invention are described;

[0046] Figures 27 to 34 An exemplary mold and vacuum system according to an embodiment of the present invention are described;

[0047] Figures 35A to 35F An exemplary mold and vacuum system according to an embodiment of the present invention are described;

[0048] Figure 36 An exemplary mold and vacuum system according to embodiments of the present invention; and

[0049] Figure 37 Graphical comparison of leak detection in a paper bottom seal compared to a metal bottom seal.

[0050] The repeated use of reference characters in this specification and figures is intended to indicate the same or similar features or elements of this disclosure. Detailed Implementation

[0051] Reference will now be made to embodiments of the present disclosure, one or more of which are illustrated in the accompanying drawings. Each example is provided by way of explanation and not limitation of the disclosure. In fact, those skilled in the art will understand that modifications and variations may be made to the disclosure without departing from its scope or spirit. For example, features described or illustrated as part of one embodiment may be used in another embodiment to produce yet another embodiment. Therefore, it is intended that this disclosure cover such modifications and variations within the scope of the appended claims and their equivalents.

[0052] In some embodiments, this disclosure relates to high-barrier packaging for perishable products and methods for manufacturing such high-barrier packaging, such as, for example, hermetically sealed container assemblies for packaging moisture- and / or oxygen-sensitive solid foods. Container assemblies produced according to the apparatus and methods described herein are capable of maintaining various atmospheric conditions when full and closed. More specifically, hermetically sealed container assemblies are suitable for maintaining the freshness of crisp foods, such as, for example, snacks, potato chips, processed potato snacks, biscuits, nuts, and the like. As used herein, the term "hermetically sealed" refers to the property of maintaining oxygen (O2) content with barriers (e.g., seals, surfaces, and / or container assemblies). For example, the oxygen permeability of the container assembly is less than 50 cm⁻¹ when subjected to ambient conditions of about 22.7°C and about 0% relative humidity. 3 O2 / m 2 / day, the container assembly can be considered airtight.

[0053] In some embodiments, the systems and methods described herein can produce hermetically sealed container assemblies having a paper-based composite bottom closure, which may be a paper-based disc inserted into the open bottom end of a composite container body and sealed in a recessed position. Furthermore, the containers of this disclosure can maintain their hermetically sealed nature during worldwide transport (e.g., by truck, air, rail) even under varying atmospheric conditions (e.g., due to variations in temperature, humidity, and / or altitude). Such conditions can result in significant pressure differences between the interior and exterior of the hermetically sealed container assembly. Moreover, atmospheric conditions can cycle between relatively high and relatively low values. The containers and methods described herein can advantageously produce container assemblies that can be transported and / or stored under a wide range of climatic conditions (e.g., temperature, humidity, and / or pressure). Additionally, in some embodiments, the hermetically sealed container assemblies may be formed from raw materials having properties suitable for high-speed manufacturing.

[0054] As described above, the hermetically sealed container assembly may include a paper-based composite bottom closure. Similarly, the container body may include a paper-based composite material, thereby allowing the entire container assembly to be recycled in a single stream (e.g., unlike conventional container assemblies with metal bottoms). In some embodiments, the container assembly may have a paper content of about 90% by mass or more. In some embodiments, the container assembly may have a paper content of about 95% by mass or more. These percentages of paper content can advantageously make the container assembly suitable as a single material in certain countries, thereby allowing it to be accepted in recycling streams in most countries globally. In some embodiments, the term "single material" includes any material that can be collected and enters waste management processes to obtain raw materials from residues of unused applications.

[0055] As used herein, the term "coating" can mean any material that covers the substrate or surface of an object or layer. For example, a coating can be applied to a substrate, object, or layer as a liquid, gas, and / or solid. A coating can completely cover the substrate, object, or layer or may partially cover it. A coating can have decorative and / or functional properties.

[0056] As used herein, a "sealant" is a material that can be used to seal one layer or component to another layer or component. In embodiments, a sealant may include a heat-sealable material. In embodiments, a sealant may include a heat-sealable thermoplastic material. In embodiments, a sealant may include an ionomer, an adhesive, or an adhesive layer. In embodiments, a sealant may include a coating or a film.

[0057] As used herein, "adhesive layer" may include adhesives, sealants, or any other materials that bond, glue, or attach one layer to another. Adhesives discussed herein may be permanent, pressure-sensitive, peelable, or other.

[0058] Container assembly

[0059] Figures 17 to 19 illustrate exemplary embodiments of a paper-based container assembly. In such embodiments, a paper-based disk 50 is formed as an end closure 51 and sealed to a rigid paper-based composite container body 60. The container body 60, the top closure 61, and the bottom closure 51 together form a sealed container assembly 406. Although depicted as generally cylindrical, it should be understood that the container assembly 406 can be other shapes. For example, the container assembly 406 can be a square, rectangle, oval, ellipse, or any other cross-sectional shape known in the art. In some embodiments, for example, the container assembly 406 can have a height ranging from about 5 to 40 cm (about 2 to 16 inches).

[0060] Container assembly characteristics

[0061] Without being bound by theory, it can be assumed that the combination of raw materials used in the disclosed container assemblies, systems, and / or assembly methods imparts superior properties and performance to the resulting container assemblies. For example, a combination of a barrier layer and an ionomer layer can provide enhanced abrasion resistance and / or puncture resistance. Furthermore, in some embodiments, the container assembly undergoes an accelerated high-altitude test at approximately 10 inHg for at least approximately 10 minutes. Additionally, the seal between the container body 60 and the bottom closure 51 remains intact during high-speed assembly, resulting in a better seal using raw materials that can directly enter the paper recycling stream.

[0062] In some embodiments, for example, the container assemblies produced by the systems and methods of this disclosure can provide a shelf life in the range of about 6 to 24 months (e.g., the moisture increase per gram of the contained food is less than about 1%). This superior performance may be due to the low water vapor and / or oxygen permeability of the produced container assemblies. For example, in some embodiments, the water vapor permeability of container assembly 406 may be equal to or better than about 0.05 g / m³. 2 / day. In other embodiments, the water vapor transmission rate of the container assembly 406 may be equal to or better than about 0.15 g / m³. 2 / day. In other embodiments, the water vapor transmission rate of the container assembly 406 may be equal to or better than about 0.05 g / m³. 2 / day. These test results can be derived from weight measurements taken periodically throughout the day under ambient air conditions of approximately 38°C and approximately 90% relative humidity. In some embodiments, the oxygen permeability of the container assembly 406 may be equal to or better than approximately 0.5 cm. 3 / m 2 / day. These test results can be obtained from measurements taken after the container assembly has been subjected to ambient air conditions of approximately 22.7°C and approximately 0% relative humidity.

[0063] In some embodiments, for example, container assembly 406 can be made up to about 1 × 10 -7 Helium leak testing of high-barrier packaging (e.g., according to DIN EN 1179 or ASTM E493).

[0064] Container body

[0065] Figure 18This is a top front view of the example container body 60, top closure 61, and paper-based disk 50. In some embodiments, the container body 60 may include a rigid cylindrical container body having a sidewall 63 terminating in a bottom peripheral edge 205 at an open end. In such embodiments, the open end may include a bottom end 62 of the container body 60. In some embodiments, the open bottom end 62 may be sealed with a paper-based end closure (e.g., bottom closure 51). In some embodiments, the container body 60 may additionally have a second open end (e.g., top end 68) opposite the open bottom end 62, which may be sealed with a flexible membrane or other closure (e.g., top closure 61).

[0066] In some cylindrical embodiments, the container body 60 may have an inner diameter ranging from about 3 to 16 cm (about 1 to 8 inches). For example, the container body 60 may have an inner diameter of about 7.315 cm (about 2.880 inches). In some cylindrical embodiments, the container body 60 may have an outer diameter ranging from about 3 to 20 cm (about 1 to 8 inches). For example, the container body 60 may have an inner diameter of about 7.630 cm (about 3.004 inches). The open bottom end 62 of the container body 60 may be defined by a bottom peripheral edge 205 formed by the terminating edge of the sidewall 63 of the body forming the container body 60. The sidewall 63 may include an inner surface 66 facing the interior of the container and an outer surface 64 facing the exterior of the container body 60. The inner surface 66 may be the product-facing side of the sidewall 63 of the container body 60. In some embodiments, the product may be food, and the inner surface 66 may include a food safety layer, film, liner, and / or coating to help protect the integrity of the food contained within the container body 60. The outer surface 64 may include printing or other applied graphics for marking and / or advertising the product contained within the container body 60.

[0067] In some embodiments, the sidewall 63 of the container body 60 may have a thickness in the range of about 0.05 to 0.2 cm (about 0.02 to 0.787 inches) (e.g., measured from the inner surface 66 to the outer surface 64 of the container body 60). For example, the sidewall 63 of the container body 60 may have a thickness of about 0.157 cm (0.062 inches).

[0068] like Figure 17C As shown, in some embodiments, the rigid sidewall 63 of the container body 60 may comprise multiple layers, such as (for example) a paper base layer 60p, a barrier layer 60b, an ionomer layer 60i, and / or an adhesive layer 60t. Each component layer (paper base layer 60p, barrier layer 60b, ionomer layer 60i) may comprise a single layer or may comprise multiple layers.

[0069] The paper base layer 60p may include fiber-based and / or pulp materials, such as (for example) cardboard, paperboard, cabinet base paper, and / or offset printing paper. In some embodiments, the paper base layer 60p of the container body 60 may have a g / m³ content of about 200 to 600 g / m³. 2 The total area weight is within the range of [specific parameters]. In some embodiments, the paper substrate 60p may have a thermal conductivity in the range of about 0.04 to 0.3 W / (mK).

[0070] The paper base layer 60p may comprise a single layer or multiple layers bonded by one or more adhesive bonding layers (e.g., adhesive layer 60t). By way of example only, adhesive layer 60t may be applied to one or more paper layers (or any layers discussed herein) using any adhesive bonding lamination method known in the art (e.g., wet bonding, solvent, solvent-free) and / or may be applied via thin-gauge extrusion. As used herein, the term "adhesive layer" or "adhesive bonding layer" may include both adhesives and laminated extrusions.

[0071] In some embodiments, the adhesive layer 60t may comprise ionomer resin, polypropylene, polycarbonate, polyethylene (e.g., linear low-density polyethylene (LLDPE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), medium-density polyethylene), polyethylene terephthalate (PET), polypropylene, polystyrene, polyvinyl chloride, metallocene-catalyzed polyolefins, ethylene-methyl acrylate (EMA) and / or copolymers thereof, co-extrudeds and blends.

[0072] Barrier layer 60b can serve as a sufficient barrier against oxygen, moisture, and / or oil (e.g., mineral oil). In embodiments, barrier layer 60b may comprise a metal foil (e.g., aluminum foil) and / or a metallized film (e.g., metallized polyethylene, metallized polypropylene). For example, barrier layer 60b may comprise a metal portion 60bm (e.g., an aluminum coating or film) having a thickness of about 0.5 μm (about 0.02 mils) disposed on a film portion 60bf (e.g., polyethylene terephthalate (PET), oriented polypropylene, and / or homopolymer / copolymer variants and combinations thereof). In embodiments, for example, barrier layer 60b may comprise a metallized polyethylene terephthalate (MPET) film, an alumina (AlOx) coated polyethylene terephthalate (PET) film, aluminum foil, and / or a metallized polyethylene terephthalate (MPBT) film.

[0073] In some embodiments, the barrier layer 60b may have a thickness in the range of about 6 to 15 μm (about 0.2 to 0.6 mils). In some embodiments, the barrier layer 60b may have a thermal conductivity in the range of about 30 to 280 W / (mK).

[0074] In some embodiments, the ionomer layer 60i of the container body 60 may comprise a thermoplastic material suitable for forming a heat seal. In some embodiments, the ionomer layer 60i may be disposed over the entire inner surface 66 of the container body 60. In other embodiments, the inner surface 66 of the sidewall 63 may comprise an ionomer layer 60i disposed around the open bottom end 62 and / or the open top end 68, but not necessarily over the entire inner surface 66 of the container body 60. In some embodiments, the ionomer layer 60i may soften or melt upon heating and seal the assembled bottom closure 51 to the container body 60. In some embodiments, the ionomer layer 60i may be abrasion resistant.

[0075] In some embodiments, the ionomer layer 60i can be heat-sealed in a temperature range of about 90 to 300°C. In embodiments, the ionomer layer 60i may have a thermal conductivity in the range of about 0.3 to 0.6 W / (mK). The ionomer layer 60i may include, for example, ionomer-type resins, ionsomers, ionomers, ethylene-methacrylate (EMAA) salts (e.g., sodium, zinc), ethylene-acrylic acid (EAA), ethylene-vinyl acetate (EVA), ethylene-methyl acrylate (EMA), vinyl graft copolymers and / or copolymers thereof, co-extrudeds, and blends. In some embodiments, the ionomer layer 60i may comprise a co-extruded film structure, such as (for example) an ionomer / HDPE co-extruded compound, an LDPE / HDPE co-extruded compound, and the like.

[0076] In this embodiment, no ionomer layer 60i is disposed on the interior of the container body 60, such that the ionomer layer 50i of the paper-based disk 50 (discussed below) directly forms a seal with the barrier layer 60b of the sidewall 63 of the container body 60. Alternatively, the ionomer layer 60i of the inner surface 66 of the container body 60 may be of a different grade than that of the ionomer layer 50i of the paper-based disk 50, such that the ionomer layer 50i of the paper-based disk 50 softens or melts to form a seal with the container body 60, but the ionomer layer 60i of the container body 60 does not soften or melt (e.g., due to the higher melting temperature of the ionomer and / or the different grade).

[0077] In an embodiment, moving inward from the outer surface 64 of the container body 60, the paper base layer 60p of the sidewall 63 may include an outer sheet of paper (e.g., white). The paper base layer 60p may include a coating, marking sheet, liner, or other material (not shown) on its outer surface 64. In an embodiment, an ionomer may be disposed on the outer surface 64 of the body 60. In this embodiment, the ionomer may or may not be heat-sealed. In this embodiment, the ionomer may or may not be heat-sealed to anything. Advantageously, the ionomer applied to the outer surface 64 of the body 60 may increase the strength and abrasion resistance of the sidewall 63 of the container body 60. In an embodiment, the paper base layer 60p may include one or more additional sheets (not shown) of paper (e.g., brown cardboard, paperboard) adjacent to the outer sheet of paper. Thus, the paper base layer 60p of the sidewall 63 of the container body 60 may be a multilayer sheet. In some embodiments, an adhesive layer 60t may connect multiple paper base layers 60p to each other and / or a barrier layer 60b. The barrier layer 60b may have a thickness of approximately 0.0008 cm (approximately 0.0003 inches). In various embodiments, the barrier layer 60b may comprise one or more layers. For example, such as Figure 17C As shown, the barrier layer 60b includes a metal portion 60bm (e.g., alumina) coated on a film portion 60bf (e.g., polyethylene terephthalate (PET) film). In some embodiments, the ionomer layer 60i may comprise an ethylene glycol copolymer having acid groups partially neutralized by zinc or sodium ions. Other configurations are also possible. Any combination of layers (paper, metal, and / or sealant) may be used in the container body of this disclosure.

[0078] In some embodiments, the container body 60 may include a film, liner, and / or coating of polyethylene (e.g., low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), medium-density polyethylene, and / or mixtures thereof) on the inner surface 66 and / or outer surface 64 of the container body 60.

[0079] Bottom closure

[0080] In some embodiments, the paper-based disk 50 of this disclosure may be a paper-based end closure. In some embodiments, the paper-based disk 50 may be a generally flat circle sized to cover the circumference of the open bottom end 62 of the container body 60. In some embodiments, the paper-based disk 50 may be pre-stamped and / or pre-formed with specific structural features (not shown). The stamping and / or pressing process may include feeding flat closure material into a compression molding machine (e.g., a stamping press) and compressing the material between opposing dies. In any case, in embodiments with a cylindrical container body, the rotational / circumferential orientation of the paper-based disk 50 relative to the container body 60 may be ignored when the container body 60 and the paper-based disk 50 are uniform across all rotation angles. However, other shapes (e.g., rectangles, polygons with extended sides) are possible.

[0081] As discussed in this paper, the inner-facing side 54 and the outer-facing side 52 of the bottom closure 51 (also referred to in this paper as the lower surface 54 and upper surface 52 of the paper base layer 50p, respectively) Figure 2 (The inverted configuration shown) will be referenced in the context of the orientation when the paper-based disk 50 is applied to the open bottom end 62 of the container body 60. Here, as shown in FIG17, the container body 60 is oriented with respect to the paper-based disk 50, wherein the bottom peripheral edge 205 of the open bottom end 62 of the container body 60 faces downward so as to face the inward-facing side 54 of the paper-based disk 50. The inward-facing side 54 of the disk 50 faces upward and the outward-facing side 52 of the paper-based disk 50 faces downward. In embodiments where the open end of the container body 60 is the bottom of the container body 60, the outward-facing side 52 of the paper-based disk 50 will therefore face downward when the container assembly 406 is oriented upright. It should be understood that other orientations not depicted in this disclosure may be used to apply the paper-based disk 50 to the container body 60, but the outward-facing side 52 of the paper-based disk 50 may be the side facing outward (e.g., away from the container interior) when assembled as part of the end-product container assembly 406 (e.g., as...). Figure 19 (as shown in the image), and the inner side 54 is the side facing the product inside the container when assembled into a portion of the end product container assembly 406.

[0082] While the paper-based disk 50 may primarily comprise paper and / or other fiber-based materials, in embodiments it may also contain a non-fiber barrier layer made of metal and / or polymeric materials. In some embodiments, the disk 50 may comprise multiple layers of paper, barrier materials, and / or ionomers.

[0083] like Figure 17D As shown, in some embodiments, for example, the paper-based disk 50 may include a paper base layer 50p, a barrier layer 50b, an ionomer layer 50i, and / or an adhesive layer 50t. The paper base layer 50p may form the outer-facing side 52 of the paper-based disk 50. The adhesive layer 50t may adhesively bond the paper base layer 50p to the barrier layer 50b. The ionomer layer 50i may be disposed adjacent to the barrier layer 50b (opposite to the paper base layer 50p) to form the inner-facing side 54 of the paper-based disk 50.

[0084] The paper base layer 50p may include fiber-based and / or pulp materials, such as (for example) cardboard, paperboard, cabinet base paper, and / or offset printing paper. For example, in some embodiments, the paper base disc 50 may be a paper cup base paper and / or paperboard coated with a liner and / or layer of polyethylene (e.g., low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), medium-density polyethylene, and / or mixtures thereof). The paper base layer 50p may include a single layer or multiple layers bonded by one or more adhesive layers (e.g., adhesive layer 50t).

[0085] As discussed above regarding the container body 60, the adhesive layer 50t may comprise any material and may be applied by any method known in the art. In some embodiments, the adhesive layer 50t may comprise an ionomer resin, polypropylene, polycarbonate, polyethylene (e.g., linear low-density polyethylene (LLDPE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), medium-density polyethylene), polyethylene terephthalate (PET), polypropylene, polystyrene, polyvinyl chloride, metallocene-catalyzed polyolefins, ethylene-methyl acrylate (EMA) and / or copolymers thereof, co-extrudeds, and blends.

[0086] Barrier layer 50b can serve as a sufficient barrier against oxygen, moisture, and / or mineral oil. Barrier layer 50b may comprise a metal foil (e.g., aluminum foil) and / or a metallized film (e.g., metallized polyethylene, metallized polypropylene). For example, barrier layer 50b may comprise a metal portion 50bm (e.g., an aluminum coating or film) having a thickness of about 0.5 μm disposed on a film portion 50bf (e.g., polyethylene terephthalate (PET), oriented polypropylene, and / or homopolymer / copolymer variants and combinations thereof). In some embodiments, for example, barrier layer 50b may comprise a metallized polyethylene terephthalate (MPET) film, an alumina (AlOx) coated polyethylene terephthalate (PET) film, aluminum foil, and / or a metallized polyethylene terephthalate (MPBT) film.

[0087] In some embodiments, the barrier layer 50b may have a thickness in the range of about 6 to 15 μm. The barrier layer 50b may be a metal (e.g., aluminum) foil having a thickness of about 0.0008 cm (about 0.0003 inches). In some embodiments, the barrier layer 50b may have a thermal conductivity in the range of about 30 to 280 W / (mK).

[0088] The ionomer layer 50i of the paper-based disk 50 may include a thermoplastic material suitable for forming a heat seal. The thermoplastic material can be heat-sealed in a temperature range of about 90 to 300°C. For example, the thermoplastic material of the ionomer layer 50i may include ionomer-type resins, ionsomers, ionomers, ethylene-methacrylate (EMAA) salts (e.g., sodium, zinc), ethylene-acrylic acid (EAA), ethylene-vinyl acetate (EVA), ethylene-methyl acrylate (EMA), vinyl graft copolymers and / or copolymers thereof, co-extrudeds, and blends. In some embodiments, the thermoplastic material may include a co-extruded film structure, such as (for example) ionomer / HDPE co-extrudeds, LDPE / HDPE co-extrudeds, and the like. In some embodiments, the ionomer layer 50i may be abrasion-resistant.

[0089] In a particular embodiment, the paper base layer 50p of the paper-based disk 50 may comprise two sheets of paper (not shown). In some embodiments, an adhesive layer 50t may adhesively bond one or more paper base layers 50p to each other and / or the barrier layer 50b. In an embodiment, the ionomer layer 50i may comprise an ethylene glycol copolymer having acid groups partially neutralized by zinc or sodium ions. The ionomer layer 50i may be disposed on the barrier layer 50b and / or the outer-facing side 52 of the paper-based disk 50. Other configurations are also possible.

[0090] In embodiments where the barrier layer 50b is a single-layer metal foil, the metal foil layer may be coated with a heat-sealable material (e.g., an ionomer layer 50i). In such embodiments, the metal foil layer may facilitate induction heating or heat transfer heating, thereby causing the heat-sealable material to soften and / or melt and seal the bottom closure 51 to the container body 60.

[0091] The ionomer layer 60i of the container body 60 and / or the ionomer layer 50i of the bottom closure 51 can be heated to form a heat seal between the container body 60 and the bottom closure 51. In some embodiments, the ionomer layer 60i of the container body 60 and the ionomer layer 50i of the bottom closure 51 may have compatible chemical compositions (e.g., the same or similar grades of ionomers) such that an acceptable seal can be formed during heat sealing during assembly. In some embodiments, the ionomer layer 60i of the container body 60 and the peelable sealant layer 61i of the top closure 61 may have compatible chemical compositions (e.g., the same or similar grades of ionomers) such that an acceptable seal can be formed during heat sealing during assembly.

[0092] In some embodiments, when the paper-based disk 50 is configured to contact the inner surface 66 of the container body 60 (e.g., within the second deformable surface 55), the ionomer layer 50i may be disposed on the inward-facing side 54 of the paper-based disk 50, surrounding only the periphery of the disk 50. In other embodiments, the ionomer layer 50i may be applied to the entire inward-facing side of the paper-based disk 50 (e.g., Figure 2 (the lower surface 54 in the middle).

[0093] In some embodiments, after insertion, the disk 50 may have a second deformable surface 55 (e.g., as shown in the figure). Figure 18 (As shown in the image), it can be configured to abut against the inner surface 66 of the sidewall 63 of the container body 60 when inserted into the open bottom end 62 of the container body 60. The sealing area between the second deformable surface 55 of the bottom closure 51 and the inner surface 66 of the container body 60 can be sized to provide an airtight seal. The sealing area can also be sufficient to allow any creases that might create channels to be smoothed out or minimized. In some embodiments, the sealing area can be from about 5 to 15 cm². 2 (approximately 1 to 2 inches) 2Within the range of ), for example, the sealing area could be approximately 11.9 cm². 2 (approximately 1.85 inches) 2 ).

[0094] Advantageously, in some embodiments, the combined thickness of the ionomer layer 50i of the bottom closure 51 and the ionomer layer 60i of the container body 60 can be sufficiently large such that any food and / or other debris present between the ionomer layers 50i and 60i can be embedded and / or completely encapsulated without compromising the resulting seal strength. In some embodiments, the thickness of the ionomer layer 50i of the paper-based disc 50 can be in the range of about 8 to 50 μm. In some embodiments, the thickness of the ionomer layer 60i of the sidewall 63 of the container body 60 can be in the range of about 2 to 40 μm.

[0095] In some embodiments, for example, when measured by vacuum decay (e.g., according to DIN EN 1779 / ASTM Test Method E493), the hermetic seal between the ionomer layer 50i formed on the bottom closure 51 and the ionomer layer 60i on the container body 60 may have a leakage rate less than or equal to that of an pore having a diameter in the range of about 10 to 300 μm. Vacuum decay can determine the equivalent pore size of the hermetic seal by coating the non-sealed portion of the container assembly 406 with a leak-inhibiting material. Other testing methods may be used, including, for example, bubble leakage, blue dye, and / or helium leakage tests.

[0096] like Figure 18 As shown, the bottom closure 51 is recessed into the container body 60 such that the first deformable surface 53 of the bottom closure 51 is spaced apart from the bottom peripheral edge 205 of the container body 60 (e.g., recessed within the bottom peripheral edge 205 of the container body 60). The bottom closure 51 can be recessed by a predetermined distance “D”. r "Recessed into the container body 60. The recessed distance can be measured from the bottom peripheral edge 205 of the container body 60 to the first deformable surface 53 of the bottom closure 51." r In some embodiments, the recess distance "D" r "It can be in the range of approximately 0.2 to 2 cm (approximately 0.08 to 1.2 inches). For example, the recess distance 'D'..." r "It can be approximately 0.7 cm (approximately 0.275 inches). The recess distance is "D" r "It can be configured to minimize any protrusion of the first deformable surface 53 of the bottom closure 51 through the bottom peripheral edge 205 of the container body 60 when the container assembly 406 is exposed to a high pressure differential between the container interior and the external environment. For example, instance testing has shown that the recess distance of the bottom closure 51 'D'..." rThe depth of the recess 51 ensures that the bottom closure 51 will not over-expand through the bottom peripheral edge 205 of the container body 60 under a pressure differential exceeding approximately 10 inHg (approximately 34 kPa). These test results can be based on measurements performed using various pressure differential methods (e.g., according to ASTM Test Method D6653). In this way, the recess distance “D” r "The combination with the integrity of the airtight seal helps prevent the bottom closure 51 from swaying and / or other problems."

[0097] In some embodiments, the paper-based disk 50 may have a density of about 1 to 2.5 g / m³. 3 The density. In some embodiments, the paper-based disk 50 may have an elastic modulus of about 10 to 35 GPa. In some embodiments, the paper base layer 50p may have a thermal conductivity in the range of about 0.04 to 0.3 W / (mK). The paper base layer 50p of the bottom closure 51 may have a density of about 130 to 450 g / m³. 2 The total area weight within the range.

[0098] Top closure

[0099] like Figure 17A As shown, the top closure 61 may be a flat plate (e.g., a disc) to fit onto the open top 68 of the container body 60. The top closure 61 may have an outward-facing side 610 (in... Figure 17A The middle section is shown facing upwards) and the inner side 611 (in the middle section). Figure 17A (Seen in the middle as facing downwards). When the top closure 61 is applied to the top edge of the container body 60, the inward-facing side 611 is configured to seal to the top edge of the container body 60 and face the inside of the container.

[0100] like Figure 17B As shown, in some embodiments, the top closure 61 may comprise multiple layers, such as (for example) a paper base layer 61p, a barrier layer 61b, a peelable sealant layer 61i (which may be an ionomer material in some embodiments), and / or an adhesive layer 61t. The paper base layer 61p may form the outer-facing side 610 of the top closure 61. The adhesive layer 61t may adhesively bond the paper base layer 61p to the barrier layer 61b. The peelable sealant layer 61i may be adhesively or coated onto the barrier layer 61b to form the inner-facing side 611 of the top closure 61.

[0101] The paper base layer 61p may include fiber-based and / or pulp materials, such as (for example) cardboard, paperboard, cabinet base paper, and / or offset printing paper. In some embodiments, the paper base layer 61p may have a thermal conductivity in the range of about 0.04 to 0.3 W / (mK). The paper base layer 61p may include a single layer or multiple layers bonded by one or more adhesive layers (e.g., adhesive layer 61t).

[0102] As described above, adhesive layer 61t can utilize any adhesive bonding composition or method known in the art. In some embodiments, adhesive layer 61t may comprise ionomer resin, polypropylene, polycarbonate, polyethylene (e.g., linear low-density polyethylene (LLDPE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), medium-density polyethylene), polyethylene terephthalate (PET), polypropylene, polystyrene, polyvinyl chloride, metallocene-catalyzed polyolefins, ethylene-methyl acrylate (EMA) and / or copolymers thereof, co-extrudeds, and blends.

[0103] Barrier layer 61b can serve as a sufficient barrier against oxygen, moisture, and / or mineral oil. Barrier layer 61b may comprise a metal foil (e.g., aluminum foil) and / or a metallized film (e.g., metallized polyethylene, metallized polypropylene). For example, barrier layer 61b may comprise a metal portion 61bm (e.g., an aluminum coating or film) having a thickness of about 50 μm disposed on a film portion 61bf (e.g., polyethylene terephthalate (PET), oriented polypropylene, and / or homopolymer / copolymer variants and combinations thereof). Barrier layer 61b may comprise a metallized film, such as (for example) a metallized polyethylene terephthalate (MPET) film, an alumina (AlOx) coated polyethylene terephthalate (PET) film, an aluminum coated polyethylene terephthalate (PET) film, and / or a metallized polyethylene terephthalate (MPBT) film. In some embodiments, barrier layer 61b may comprise vacuum-deposited aluminum adjacent to peelable sealant layer 61i.

[0104] In some embodiments, the barrier layer 61b may have a thickness in the range of about 4 to 20 μm. In some embodiments, the barrier layer 61b may have a thermal conductivity in the range of about 40 to 280 W / (mK).

[0105] The peelable sealant layer 61i may include any peelable sealant known in the art for securing the top membrane closure to the container body. For example, the peelable sealant layer 61i may be a polyethylene-based sealant and / or an ionomer resin (e.g., (Polymer). In some embodiments, the peelable sealant layer 61i of the top closure 61 may have a thickness in the range of about 10 to 50 μm.

[0106] The top closure 61 can be sealed to the top edge of the container body 60 via a peelable sealant layer 61i. In some embodiments, the peelable sealant layer 61i may be modified with a polymeric material to promote additional adhesiveness to the container body 60. In some embodiments, the peelable sealant layer 61i may include a resealable material, allowing the container to be resealed.

[0107] A peelable sealant layer 61i provides a consumer-friendly opening mechanism. In some embodiments, the top closure 61 may be shaped to facilitate removal from the container assembly 406, for example, via a pull tab. In some embodiments, the top cap (not shown) may be configured to be removed before and reattached to the container body 60 after the membrane seal is removed.

[0108] Example Implementation

[0109] In some embodiments, the sidewall 63 of the container body 60 may include a paper base layer 60p bonded to a barrier layer 60b of a metallized polyethylene terephthalate (MPET) film via an adhesive layer 60t. An ionomer layer 60i may be formed adjacent to the barrier layer 60b.

[0110] In some embodiments, the sidewall 63 of the container body 60 may include a paper base layer 60p bonded via an adhesive layer 60t to a barrier layer 60b of an alumina (AlOx) coated polyethylene terephthalate (PET) film. In this embodiment, the film may be transparent. An ionomer layer 60i may be formed adjacent to and bonded to the barrier layer 60b.

[0111] In some embodiments, the sidewall 63 of the container body 60 may include a paper base layer 60p bonded to a barrier layer 60b of aluminum foil via an adhesive layer 60t. An ionomer layer 60i may be formed adjacent to and bonded to the barrier layer 60b. In this embodiment, the ionomer may be applied as a thin film rather than a coating.

[0112] In some embodiments, the sidewall 63 of the container body 60 may include a paper base layer 60p bonded to a barrier layer 60b of a metallized polybutylene terephthalate (MPBT) film via an adhesive layer 60t. An ionomer layer 60i may be formed adjacent to and bonded to the barrier layer 60b.

[0113] In some embodiments, the paper-based disk 50 may include a paper base layer 50p of the paper cup base paper bonded to a barrier layer 50b of a metallized polyethylene terephthalate (MPET) film via an adhesive adhesive layer 50t. An ionomer layer 50i may be formed adjacent to the barrier layer 50b.

[0114] In some embodiments, the paper-based disk 50 may include a paper base layer 50p of the paper cup base paper bonded to a barrier layer 50b of an alumina (AlOx) coated polyethylene terephthalate (PET) film via an adhesive adhesive layer 50t. An ionomer layer 50i may be formed adjacent to and bonded to the barrier layer 50b.

[0115] In some embodiments, the paper-based disk 50 may include a paper base layer 50p of the paper cup base paper bonded to a barrier layer 50b of aluminum foil via an adhesive bonding layer 50t. An ionomer layer 50i may be formed adjacent to and bonded to the barrier layer 50b.

[0116] In some embodiments, the paper-based disk 50 may include a paper base layer 50p of the paper cup base paper bonded to a barrier layer 50b of a metallized polybutylene terephthalate (MPBT) film via an adhesive bonding layer 50t. An ionomer layer 50i may be formed adjacent to and bonded to the barrier layer 50b.

[0117] In some embodiments, the top closure 61 may include a paper base layer 61p bonded to a barrier layer 61b of a metallized polyethylene terephthalate (MPET) film via an adhesive layer 61t. A peelable sealant layer 61i may be formed adjacent to the barrier layer 61b.

[0118] In some embodiments, the top closure 61 may include a paper base layer 61p bonded via an adhesive layer 61t to a barrier layer 61b of an alumina (AlOx) coated polyethylene terephthalate (PET) film. A peelable sealant layer 61i may be formed adjacent to and bonded to the barrier layer 61b.

[0119] In some embodiments, the top closure 61 may include a paper base layer 61p bonded via an adhesive layer 61t to a barrier layer 61b of an aluminum-coated polyethylene terephthalate (PET) film. A peelable sealant layer 61i may be formed adjacent to and bonded to the barrier layer 61b.

[0120] In some embodiments, the top closure 61 may include a paper base layer 61p bonded to a barrier layer 61b of a metallized polybutylene terephthalate (MPBT) film via an adhesive layer 61t. A peelable sealant layer 61i may be formed adjacent to and bonded to the barrier layer 61b.

[0121] The following provides a more complete explanation and description of an exemplary sealing system for sealing the paper-based end closures described herein to the paper-based container body described herein.

[0122] Sealing system

[0123] refer to Figures 1 to 11 The container described herein may be formed using the following sealing system 100 and / or according to the following methods. In some embodiments, the paper-based bottom may begin as a sheet or disc. For example, the composite sheet or paper-based disc 50 may be shaped to conform to the composite container body 60 via a cooperating mandrel assembly 200, a mold assembly 300, and a container support assembly (not shown). The mandrel assembly 200 may be used to stamp or press the paper-based disc 50 to form it as the composite bottom 51 (e.g., as shown in the image). Figures 10 to 11 (as shown in the image).

[0124] The mandrel assembly 200 may include an outer mandrel 210 (sometimes referred to as a "downholder" for its purpose of holding the disc 50 downward against the mold assembly 300) and an inner mandrel 220 (sometimes referred to as a "sealing punch" for its purpose of punching the disc 50 into the container 60 and sealing the sidewalls of the container 60 with the disc 50). The outer mandrel 210 and the inner mandrel 220 may each move independently along the Y-axis. The inner mandrel 220 may translate relative to the outer mandrel 210 to form the paper-based disc 50 as a bottom closure 51. Furthermore, the mold assembly 300 may cooperate with the mandrel assembly 200 to shape the paper-based disc 50 into the bottom closure 51 simultaneously or nearly simultaneously with the insertion of the closure 51 into the bottom end 62 of the composite body 60. The mold assembly 300 may typically include a mold 80 having a top surface 97, a positioning portion 90, a mold opening 98, and a sealing member 40, also referred to as a mold liner. The tube assembly can be configured to hold and move the composite body 60 relative to the mandrel assembly 200 and the mold assembly 300. For example, the tube assembly can move the composite body laterally so that the axis of the container body 60 is aligned with the axis of the mandrel assembly 200 and the mold assembly 300 and / or the composite body can be moved perpendicularly along the axis of the mandrel assembly 200 and the mold assembly 300.

[0125] In some embodiments, the mandrel assembly 200, the mold assembly 300, and the container support assembly may be aligned along the Y-axis at least during the method described herein, such that the paper-based disk 50 may be pushed by the inner mandrel 220 through the mold opening 98 and inserted into the bottom end 62 of the composite body 60 held by the tube support member.

[0126] Mold assembly

[0127] The die assembly 300 may be configured to receive and hold the paper-based disc 50 before it is inserted through the die opening 98 and into the container body 60. In some embodiments, the disc 50 is received from a separate disc feed assembly (not shown). In embodiments, the die assembly 300 may be configured to mate with or otherwise align with a feed assembly. For example, the die 80 may include a notch, ridge, or other alignment feature 302 on its upper portion, which allows it to mate with, align with, or receive corresponding mechanical elements of the feed assembly. This allows the disc 50 to be properly placed within the die 80.

[0128] More specifically, the mold assembly 300 may include a mold 80 (i.e., a mold bushing) having a positioning portion 90 (i.e., a chuck), the positioning portion 90 being configured to receive and align the paper-based disk 50 within the mold 80 before the disk 50 is formed into a recessed bottom closure 51. The positioning portion 90 may be positioned adjacent to the mold opening 98 to align the paper-based disk 50 with the mold opening 98.

[0129] The positioning portion 90 may include a ramp 96 connecting the top surface 97 of the mold 80 to the sidewall 94 of the positioning portion 90. The ramp 96 may be inclined downward toward the mold opening 98 and axis of the mold assembly 300. In some embodiments, the ramp 96 may allow the disk 50 to be guided into the positioning portion 90.

[0130] In some embodiments, the sidewall 94 of the positioning portion 90 may be vertical or substantially vertical. In some embodiments, the sidewall 94 of the positioning portion 90 may be longer than the thickness of the disk 50. In some embodiments, the outer diameter of the sidewall 94 of the positioning portion 90 may be substantially similar to the diameter of the disk 50. In another embodiment, the outer diameter of the sidewall 94 of the positioning portion 90 may be slightly larger than the diameter of the disk 50.

[0131] In some embodiments, the inclined surface 96 of the positioning portion 90 may have a larger perimeter closest to the top surface 97 of the mold 80 and a smaller perimeter closest to the sidewall 94. In some embodiments, the circumference of the outer edge of the inclined surface 96 of the positioning portion 90 may be larger than that of the paper-based disk 50. The inclined surface 96 may taper downward to allow gravity-assisted alignment of the paper-based disk 50 within the positioning portion 90. Once seated, the paper-based disk 50 may be positioned adjacent to the disk support surface 92 and the sidewall 94 of the positioning portion 90. In some embodiments, the disk support surface 92 and the sidewall 94 of the positioning portion 90 are connected at a 90-degree angle or substantially a 90-degree angle. In some embodiments, the disk support surface 92 may be horizontal or substantially horizontal. In some embodiments, the seated disk 50 is positioned such that its lower surface 54 (e.g., as shown in the image) is positioned such that its lower surface 54 ... Figure 2 (as shown in the image) adjacent to the disk support surface 92 (e.g., seated on top of the disk support surface 92). In some embodiments, the seated disk 50 is positioned such that its thickness is adjacent to the sidewall 94 of the positioning portion 90.

[0132] In some embodiments, the inner circumference of the disc support surface 92 is smaller than the circumference of the disc 50. In some embodiments, the inner circumference of the disc support surface 92 is adjacent to the mold opening 98. In some embodiments, the disc support surface 92 is positioned adjacent to the inner surface 99 of the mold opening. In some embodiments, the inner surface 99 of the mold opening may be vertical or substantially vertical. In some embodiments, the disc support surface 92 is positioned at right angles or nearly right angles to the inner surface 99 of the mold opening.

[0133] In use, the disc 50 is inserted into the mold assembly 300, positioned within the positioning portion 90, and seated on the disc support surface 92. In some embodiments, vacuum pressure may be applied from below to align the paper-based disc 50 within the positioning portion 90 of the mold 80.

[0134] Although the mold opening 98 is depicted as having a substantially circular cross-section, the mold opening 98 may have a substantially circular, triangular, rectangular, quadrilateral, pentagonal, hexagonal, or elliptical cross-section. In some embodiments, the mold opening 98 may be configured to receive the inner shaft 220, as discussed below. In some embodiments, the mold opening 98 may have a cross-section substantially similar to that of the inner shaft 220.

[0135] Air extraction assembly

[0136] In some embodiments, the vacuum assembly 400 is included in the system of the present invention. In some embodiments, the vacuum assembly 400 is at least partially disposed within the mold assembly 300. The vacuum assembly 400 may be designed to draw or evacuate a defined volume of gas from inside the container before or simultaneously with inserting the disc 50 into the container body 60.

[0137] The vacuum assembly 400 may include one or more valves 420 integrated into the mold assembly 300. In some embodiments, the valves 420 are disposed within the mold 80. More specifically, a port or bore 82 may be present through the interior of the mold 80, connecting the outer surface 89 of the mold to an internal channel 430. The valves 420 may be disposed within said port or bore 82. The port or bore 82 may connect the internal channel 430 to the upper surface of the mold, the lower surface of the mold, or the side / lateral surface of the mold. That is, the valves 420 may extend laterally within the mold and / or may extend vertically upward or downward within the mold.

[0138] In some embodiments, the inner bore 82 may be horizontally disposed within the mold 80. In some embodiments, the inner bore 82 may be located in the upper section 87 of the mold 80. In some embodiments, the inner bore 82 and at least a portion of the valve 420 may be located above the channel 430. In some embodiments, the valve 420 may have an opening within the inner bore 82 that leads downward toward the channel 430. That is, there may be direct gas communication between the valve 420 and the channel 430. In some embodiments, air may be drawn from the channel 430 via the valve 420.

[0139] In some embodiments, valve 420 may include any suction or vacuum valve known in the art. In some embodiments, valve 420 may have an open position and a closed position. In the open position, valve 420 may allow gas exchange, and in the closed position, valve 420 may not allow gas exchange. In some embodiments, valve 420 may include an elongated tube or pipe extending generally horizontally or vertically through the upper section 87 of mold 80, wherein a through-hole 422 is disposed at its proximal end (referring to the interior of mold 80). In this embodiment, through-hole 422 may be disposed adjacent to internal channel 430. In some embodiments, through-hole 422 may be disposed directly above at least a portion of internal channel 430. In some embodiments, manifold connector 426 may connect the inner bore 82 and channel 430. In some embodiments, through-hole 422 may be connected to and communicate with internal channel 430. Through-hole 422 may take any shape known in the art. In an exemplary embodiment, through-hole 422 is circular, but may be oval, square, rectangular, or any other shape known in the art.

[0140] In some embodiments, the internal channel 430 may be hollow. The channel 430 may be shaped or configured as needed, but in some embodiments, it may have a square, rectangular, circular, or semi-circular cross-section. In some embodiments, the channel 430 may be circumferentially or partially circumferentially positioned within the mold 80. In a particular embodiment, the channel 430 may include a recessed portion of the upper segment 87 of the mold 80. In this embodiment, the channel 430 may include at least one sidewall 432. In some embodiments, the channel 430 may include two opposing sidewalls 432, 434 and a top wall 436. In some embodiments, the bottom wall of the channel 430 may include the top surface 42 of the sealing member 40. That is, if the upper segment 87 of the mold 80 is separated from the sealing member 40, then the channel 430 will have an open bottom end.

[0141] The channel 430 may have one or more channel openings 440 disposed between the channel 430 and the inner surface 99 of the mold opening. In some embodiments, the channel openings 440 are disposed laterally inward from the channel 430, closer to the central axis of the container 60 to be sealed. In some embodiments, the channel openings 440 may connect the channel 430 to the interior of the mold 80, allowing gas exchange therebetween. That is, the channel openings 440 may provide gas communication between the channel 430 and the interior of the mold 80. The channel openings 440 may be shaped as needed, but in some embodiments, they may be square, rectangular, circular, oval, or semi-circular in cross-section. In certain embodiments, the openings 440 leading into the interior of the mold 80 may be square or rectangular. The number, size, and arrangement of the channel openings 440 may vary based on the amount of gas that must be evacuated.

[0142] In one embodiment, channel 430 may include a single channel opening 440. Channel opening 440 may extend circumferentially between channel 430 and inner surface 99 of mold opening. In another embodiment, channel opening 440 may extend partially or completely circumferentially around mold 80.

[0143] In other embodiments, channel 430 may include a plurality of channel openings 440. For example, in some embodiments, six channel openings 440 may be used. The channel openings 440 may vary in size from one another. The channel openings 440 may be equidistant from one another or may be spread out in any other manner known in the art. In embodiments, the channel openings 440 may be located on only one side of the mold assembly.

[0144] In some embodiments, the channel opening 440 may be located below the positioning portion 90 of the mold 80. More specifically, the channel opening 440 may be located below the disk support surface 92 of the positioning portion 90. Thus, when the disk 50 is in place, before insertion into the container 60, the channel opening 440 may be located below the disk 50 (see [link to relevant documentation]). Figure 33 In some embodiments, the channel opening 440 may be disposed within the inner surface 99 of the mold opening. In some embodiments, the channel 430 and the channel opening 440 may be disposed adjacent to the bottom surface 85 of the upper section 87 of the mold 80.

[0145] In some embodiments, the channel 430 is fully circular within the mold 80. In other embodiments, the channel 430 is partially circular within the mold 80. In some embodiments, the channel 430 includes a plurality of discontinuous channels within the mold 80.

[0146] In some embodiments, when the disk 50 is positioned within the positioning portion 90 of the mold 80, the channel 430 may be closed and not communicate with the atmosphere. In some embodiments, the vertical extension 212 of the outer mandrel 210 (discussed below) constrains the paper-based disk 50 during bottom formation (e.g., as shown below). Figure 4 (As shown in the diagram). In some embodiments, the pressure exerted by the vertical extension 212 of the outer mandrel 210 on the paper-based disk 50 can seal the channel 430 from the atmosphere. In this case, the vacuum assembly 400 can draw or evacuate air from inside the container, as will be further explained herein.

[0147] In some embodiments, valve 420 may be connected via a conduit or pipe 424 to a side-channel pump, blower, fan, or vacuum pump (not shown). Any side-channel pump, vacuum pump, or suction device known in the art may be used. Valve 420 may be connected to the conduit via a coupling connector 410. The coupling connector 410 may be integrated into mold 80. Alternatively, the coupling connector 410 may be screwed into mold 80. That is, at least a portion of the inner surface of the bore 82 may have threads that can align and interconnect with threads on the outer surface of the coupling connector 410.

[0148] The coupling connector 410 may have a distal end 412 configured to connect to a hose or pipe. The connection may be a snap-fit, twist, or any other configuration known in the art. In some embodiments, the coupling connector 410 may include a bend, thereby allowing the pipe to be attached and suspended in a vertical, horizontal, or any other position. In some embodiments, the coupling connector 410 may rotate about its axis to prevent pipe tangling.

[0149] In some embodiments, the extraction assembly 400 includes a plurality of valves 420, coupling connections 410, and pipes. In a particular embodiment, the extraction assembly 400 includes three valves 420 and three corresponding coupling connections 410 and pipes. In some embodiments, the number of valves 420 corresponds to the number of sealing members 40 (discussed below). In this embodiment, if there are three sealing members 40, then there are three valves 420, each disposed in one of the sealing members 40. In other embodiments, the number of valves 420 may be greater than the number of sealing members 40. For example, a sealing member 40 may include a single integral sealing member 40 but in which two or three valves 420 may be disposed. In some embodiments, a specific number of channel openings 440 are disposed in each valve section 414, 416, 418. For example, three, four, five, or six channel openings 440 may be disposed in each valve section.

[0150] In some embodiments, the pumping mechanism operates in a vacuum chamber that has been depressurized. However, in another embodiment, the pumping mechanism operates under standard atmospheric conditions without the need for a vacuum chamber.

[0151] mandrel assembly

[0152] As described above, the spindle assembly 200 may include an inner spindle 220 and an outer spindle 210. The inner spindle 220 and outer spindle 210 may translate independently of each other. In embodiments, the inner spindle 220 and outer spindle 210 translate parallel to each other, which may be perpendicular but is not necessarily perpendicular. For example, the system may provide an inner spindle 220 and outer spindle 210 that are translated horizontally or at an angle.

[0153] In some embodiments, the inner shaft 220 is movable a first distance and the outer shaft 210 is movable a second distance, wherein the first and second distances are different from each other. Similarly, the inner shaft 220 is movable at a first time and the outer shaft 210 is movable at a second time, wherein the first and second times are different from each other. In some embodiments, the inner shaft 220 and the outer shaft 210 may move together during a first time period. In some embodiments, the inner shaft 220 may have a first extension length and the outer shaft 210 may have a second extension length, wherein the first and second extension lengths are different from each other. In some embodiments, the outer shaft 210 may move together with both the inner shaft 220 and the ejector 30 until the shaft assembly 200 contacts the mold assembly 300. In some embodiments, each of the outer shaft 210, the inner shaft 220, and the ejector 30 may contact the mold assembly 300 simultaneously.

[0154] In some embodiments, the outer mandrel 210 may be generally cylindrical. In another embodiment, the outer mandrel 210 may include a vertically extending (e.g., downward) portion 212 and a radially outward guiding flange 214. In some embodiments, the vertically extending portion 212 may be perforated and / or may have a through hole 216 therein. In some embodiments, the vertically extending portion 212 and the radially outward guiding flange 214 may be joined at right angles or nearly right angles. In some embodiments, the flange 214 may be absent.

[0155] In some embodiments, the vertical extension 212 of the outer mandrel 210 may be sized to fit within the circumference of the positioning portion 90. In some embodiments, the vertical extension 212 of the outer mandrel 210 has a circumference larger than the circumference of the mold opening 98, such that the vertical extension 212 of the outer mandrel 210 cannot extend into the mold opening. More specifically, the vertical extension 212 of the outer mandrel 210 may be sized and / or configured such that, when fully extended, it is positioned adjacent to the positioning portion sidewall 94 and the disk support surface 92 of the positioning portion 90. In some embodiments, the vertical extension 212 of the outer mandrel 210 may extend after the disk 50 is seated within the positioning portion 90 and may be configured to secure the disk 50 in place (e.g., as shown in the image). Figure 4 (as shown in the image).

[0156] like Figure 12As shown, the inner shaft 220 may be generally cylindrical. In some embodiments, the inner shaft 220 may be sized to fit within the inner circumference of the vertical extension 212 of the outer shaft 210. In some embodiments, the inner shaft 220 may be configured to extend vertically below the vertical extension 212 of the outer shaft 210. In this embodiment, once the disk 50 is seated within the positioning portion 90 and constrained by the fully extended vertical extension 212 of the outer shaft 210, the inner shaft 220 may continue to move vertically downward, extending beyond the base of the vertical extension 212 of the outer shaft 210 and pushing / advancing the disk 50 into the open end 62 of the container body 60 (e.g., as shown). Figure 6 (as shown in the image).

[0157] The inner shaft 220 may include a first shaft surface 222 adjacent to the second shaft surface 224, in some embodiments (e.g., as shown in the figure). Figure 12 In the illustration, they are configured together to insert into and shape the paper-based disk 50. In some embodiments, the first mandrel surface 222 may engage the second mandrel surface 224 at a right angle or near a right angle. In some embodiments, the first mandrel surface 222 may be horizontal or substantially horizontal and may be disposed adjacent to the top surface of the disk 50. In some embodiments, the second mandrel surface 224 may be vertical or substantially vertical and may be configured to be adjacent to the inner surface of the vertical extension 212 of the outer mandrel 210 as the inner mandrel 220 passes through the outer mandrel 210. That is, the circumference of the second mandrel surface 224 may be smaller than the inner circumference of the vertical extension 212 of the outer mandrel 210.

[0158] It should be noted that although the first mandrel surface 222 and the second mandrel surface 224 are depicted in the figures as substantially flat (horizontal and vertical), the first mandrel surface 222 and the second mandrel surface 224 may be bent, contoured, or shaped. The inner mandrel 220 may further include a shaped portion disposed between the first mandrel surface 222 and the second mandrel surface 224. The shaped portion may be bent, chamfered, or include any other contour. It should be noted that although the inner mandrel 220 is depicted as having a substantially circular cross-section, the inner mandrel 220 may have a substantially circular, triangular, rectangular, quadrilateral, pentagonal, hexagonal, or elliptical cross-section.

[0159] As the inner axis 220 pushes the disk 50 into the container body 60 (e.g., as...), Figures 5 to 6As shown in the diagram, the disc is released from between the outer mandrel 210 and the positioning portion 90 of the mold assembly 300. The central portion 56 of the disc 50 can be pushed downward through the mold opening 98 into the open bottom end 62 of the container body 60, such that the central portion 56 (first deformable surface 53) remains flat or substantially flat (e.g., horizontal). During insertion of the disc 50 into the container body 60, in some embodiments, the peripheral portion 58 of the disc 50 can be bent at a right angle or near a right angle. Figure 11 The second deformable surface 55 is shown in the diagram. In such embodiments, the peripheral portion 58 of the disk 50 (which becomes the second deformable surface 55) may be forced adjacent to the second mandrel surface 224, thereby passing through the mold opening 98. The resulting second deformable surface 55 of the disk 50 (previously the peripheral portion 58) may be positioned vertically or nearly vertically adjacent to the inner surface 66 of the container body 60 at the open bottom end 62.

[0160] The disk 50 can be pushed into the container body 60 to any distance feasible within its domain. In some embodiments, the disk 50 becomes recessed into the composite bottom 51 (e.g., as shown in the image). Figure 11 (as shown in the diagram). In some embodiments, the peripheral edge 57 of the disk 50 is flush with the edge of the sidewall of the container body 60. In other embodiments, the peripheral edge 57 of the disk 50 is positioned inward relative to the peripheral edge of the sidewall 63 of the container body 60. In some embodiments, the first deformable surface 53 and the second deformable surface 55 are joined at right angles or near right angles within the container body 60.

[0161] In some embodiments, the mandrel heater may be configured to heat a first mandrel surface 222 and / or a second mandrel surface 224 of the inner mandrel 220. In some embodiments, the mandrel heater may be disposed within the inner mandrel 220. In some embodiments, the inner mandrel 220 may further include an insulating portion formed of a heat-insulating material configured to mitigate heat transfer.

[0162] Sealing components

[0163] The sealing member 40 can be configured to provide heat and pressure for heat sealing. The sealing member 40 can be positioned at a sealing location (e.g., as...). Figures 1 to 6 (as shown in the middle) and the opening location (e.g., such as Figures 7 to 11 (as shown in the figures). When in the sealed position, the sealing member 40 contacts the outer surface 64 of the container body 60, and when in the open position, the sealing member 40 does not contact the container body 60. In an embodiment, the sealing member 40 includes a segmented clamping bracket (generally shown in the figures).

[0164] In other embodiments, the sealing member 40 includes a non-segmented clamping ring (see...). Figures 20 to 23 ). Figure 20This invention describes a system with a non-segmented clamping ring, wherein the system is in its initial state. Figure 21 In the middle, the system moves to the appropriate position and the disk is clamped in the appropriate position. Figure 22 The system moves to the sealed position. Figure 23 Instructions: Remove the sealing punch after the ejector has supported the bottom of the paper in the proper position. Finally, Figure 24 This indicates that the ejector has been removed from the container. Figures 20 to 26 The connection to the extraction line is also described. In this embodiment, the sealing member may include a static mold liner. This type of sealing member can be particularly useful in ready-to-eat food handling equipment where food safety is a high concern.

[0165] In some embodiments (e.g., segmented clamping bracket embodiments), the sealing member 40 is rotatably coupled to the mold assembly 300. The sealing members 40 may be complementaryly shaped such that when in the sealed position, they substantially surround the workpiece in a jigsaw-like manner. In other embodiments, the sealing member 40 may comprise a single integral member (i.e., a closing ring) surrounding the container body 60 when the container is in place. When the paper-based disc 50 is sealed to the composite body 60, the sealing member 40 may compress the bottom end 62 of the composite body 60 along the substantially complete circumference of the outer surface 64. When the composite body 60 has a substantially circular cross-section, the circumference of the composite body 60 may be substantially uniformly compressed by the sealing member 40. In some embodiments, three sealing members 40 are present. In other embodiments, one sealing member 40 is present (i.e., a non-segmented clamping ring). However, it should be noted that any number of sealing members 40 may be used. For example, a sealing system may include from about one to about ten sealing members 40. In addition, the sealing member 40 may each cover substantially equal segments of the composite body or substantially unequal segments.

[0166] The sealing member 40 can be used to compress and heat the container body to perform a heat sealing operation. Each sealing member 40 can provide conductive heating to the workpiece up to about 300°C. Furthermore, the sealing member 40 can apply pressure to the workpiece up to about 30 MPa. The sealing members 40 can be adjacent to each other.

[0167] As the sealing member 40 contacts the outer surface 64 of the container body 60, the container body 60 and the composite closure 51 can be compressed between the second mandrel surface 224 and the sealing member 40. After applying compression and heat for a sufficient residence time, the sealing member 40 can be removed from the bottom end 62 of the container body 60, so that the sealing member 40 does not contact the container body 60 after the residence time has expired (e.g., as...). Figure 7 (as shown in the image).

[0168] Ejector

[0169] Once the sealing process is complete, in some embodiments, the mandrel assembly 200 is removed from the container body 60. In one embodiment, the outer mandrel 210 is released and translated away from the mold assembly 300 before the inner mandrel 220 is moved. In other embodiments, both the outer mandrel 210 and the inner mandrel 220 are released and translated away from the mold assembly 300 simultaneously.

[0170] In some embodiments, the ejector 30 is disposed inside the inner spindle 220 to facilitate removal of the spindle assembly 200 from the container body 60. In some embodiments, the ejector 30 may be spring-loaded. In other embodiments, the ejector 30 may not be spring-loaded. In some embodiments, the inner spindle 220 may or may not be spring-loaded. In another embodiment, the outer spindle 210 may or may not be spring-loaded. In certain embodiments, only the outer spindle 210 is spring-loaded.

[0171] The ejector 30 may have a circumference on its lower end 32 that is smaller than the circumference of the inner shaft 220. In this respect, the ejector 30 may be fitted within the inner circumference of the inner shaft 220 in its retracted position (e.g., as shown in the image). Figure 12 (As shown in the figure). In some embodiments, the base of the ejector 30 may include a cylindrical pyramid. In this embodiment, the interior of the inner shaft 220 may include a cylindrical pyramidal recess, allowing the ejector 30 to be fitted into the inner shaft 220. In embodiments, the ejector 30 may be perforated and / or may have through holes therein.

[0172] In another embodiment, the base of the ejector 30 may include a plurality of disc contact sections, each contacting the bottom closure 51 but separated from each other. For example, the ejector may include three or four tips that flatten at their contact surfaces with the closure 51 to avoid damaging the closure 51.

[0173] In some embodiments, the ejector has a bottom surface 34 designed to contact the bottom closure 51. In some embodiments, the ejector 30 may be a solid body spanning its bottom surface 34 from one side of its diameter to the other. In another embodiment, the ejector 30 may have a hollow interior, as shown in the figure. In such embodiments, the bottom contact surface 34 may have a circular cross-section. In some embodiments, the bottom surface 34 of the ejector 30 may contact at least a portion of the first deformable surface 53 of the composite closure 51. In some embodiments, the first deformable surface 53 of the closure 51 may include a countersunk portion of the closure 51. In some embodiments, the bottom surface 34 of the ejector 30 is circumferential and, when in its extended position, is positioned near the second deformable surface 55 of the composite closure 51 (e.g., as shown in the figure). Figure 13 (as shown in the image).

[0174] In some embodiments, when the ejector 30 is in its recessed position, the bottom surface 34 of the ejector 30 may be flush with the first (lower) surface 222 of the inner shaft 220 (e.g., as shown in the figure). Figure 12 (as shown in the diagram). In another embodiment, when the ejector is in its recessed position, the ejector 30 may be slightly recessed within the inner shaft 220, such that the bottom surface 34 of the ejector 30 is higher than the first (lower) surface 222 of the inner shaft 220.

[0175] In some embodiments, the ejector 30 and the inner shaft 220 (and / or the outer shaft 210) can each translate vertically relative to each other independently. That is, the inner shaft 220 can move a first distance and the ejector 30 can move a second distance, wherein the first and second distances are different from each other. Similarly, the inner shaft 220 can move at a first time and the ejector 30 can move at a second time, wherein the first and second times are different from each other. In some embodiments, the inner shaft 220 and the ejector 30 can move together during a first time period. In some embodiments, the inner shaft 220 may have a first extension length and the ejector 30 may have a second extension length, wherein the first and second extension lengths are different from each other.

[0176] In some embodiments, the inner shaft 220 (and / or outer shaft 210) initially retracts vertically from the container body 60, while the ejector 30 remains positioned adjacent to the composite closure 51 (e.g., as shown in the image). Figure 8 and 13 (as shown in the image), thereby maintaining the paper-based closure 51 within the container body 60. In such embodiments, a space may be provided between the outer circumference of the lower end 32 of the ejector 30 and the deformed portion 55 of the closure 51. This position (e.g., as shown in the image) Figure 8 and 13 (As shown in the diagram) This can be referred to as the extended position of the ejector 30. In this embodiment, once the inner shaft 220 retracts beyond the outer edge 205 of the container body 60, in some embodiments, the ejector 30 retracts vertically upward into the interior of the inner shaft 220.

[0177] In another embodiment, after the sealing process is complete, the ejector 30 may extend downwards further than it did during the sealing process to aid in the removal of the container 60 from the mold assembly 300. That is, the ejector 30 may push the container 60 downwards via pressure on the closure 51. Alternatively, the ejector 30 may not pressurize the closure 51, but may translate downwards together with the container 60 and the closure 51, in relation to the movement of the container assembly. In this embodiment, the ejector 30 may then retract from contact with the closure 51 and retract into the mandrel assembly 200.

[0178] In some embodiments, the ejector 30 includes a means for delivering a stream of controlled air directed toward the closure 51 simultaneously with or shortly before the ejector 30 retracts from the closure 51. In some embodiments, the delivery of pressurized air may include a nozzle mechanism disposed within the ejector 30. In an embodiment, the spindle assembly 200 includes an ejector coupling 201 and a spindle or sealing head coupling 202.

[0179] The ejector 30 of this disclosure avoids problems caused by the standard mandrel retraction process. That is, standard mandrel retraction involves pulling the mandrel out of the container assembly (or vice versa), resulting in friction between the mandrel and the paper-based closure. Any relative movement of the paper-based closure as the mandrel separates from the container assembly can cause folds, wrinkles, and / or air bubbles to form in the seal, thereby reducing or compromising the airtightness of the container assembly. The ejector 30 of this disclosure allows the paper-based closure to remain stable within the container body during the mandrel removal process (e.g., during discharge). The ejector 30 helps ensure an airtight seal between the closure 51 and the container body 60 throughout the complete cycle of the paper-based bottom sealing process.

[0180] After both the inner shaft 220 and the ejector 30 retract, the container can optionally be positioned vertically downwards. Figure 10 The inner spindle 220, ejector 30, and container can be removed from the mold assembly 300 and mandrel assembly 200. In an embodiment, the movement of the inner spindle 220, ejector 30, and container can be synchronized. In an embodiment, the inner spindle 220 and outer spindle 210 can then optionally be moved integrally. Figure 11 The mandrel assembly 200 retracts completely vertically upward from the mold assembly 300. In an embodiment, the mandrel assembly 200 and the mold assembly 300 are then positioned for another insertion, bottom closure formation, and sealing process.

[0181] Container support assembly

[0182] The container support assembly can be configured to retrieve and / or retain the composite body 60 and hold it in a desired position. The container support assembly may include a tubular support member shaped to receive the composite body 60. In some embodiments, the tubular support member may vertically lift the container body 60 to accommodate the mold assembly 300 and the mandrel assembly 200.

[0183] In one embodiment, container 60 is inserted into the mold assembly by lifting it upwards and by bringing the edge or edge of container 60 into contact with the lower surface of the mold opening 98 (see [link to mold assembly]). Figures 2 to 3 This is used to fix the container 60 in a vertical position within the mold assembly. The container 60 will be in a fixed position to prevent relative vertical movement of the container 60 as the inner shaft 220 moves in and out of the container assembly.

[0184] Paper-based disc and bottom closure

[0185] like Figure 2 As shown, in some embodiments, the paper-based disk 50 may have an upper surface 52 and a lower surface 54 defining the thickness of the sheet. In some embodiments, for example, the paper-based disk 50 may have a thickness in the range of about 0.01 to 0.6 cm.

[0186] In some embodiments, the paper-based disk 50 may include a layered structure. For example, the layered structure may include a paper base layer 50p, a barrier layer 50b, and / or an ionomer layer 50i (as discussed in more detail herein). In some embodiments, the ionomer layer 50i may form all or at least a portion of the lower surface 54 of the paper-based disk 50 (e.g., as shown in the image). Figure 17D (As shown in the image). The paper-based disk 50 may include a central portion 56 and a peripheral portion 58. In some embodiments, the central portion 56 and the peripheral portion 58 may be substantially flat. For example, the paper-based disk 50 may be cut or molded into a circular disk. In other instances, the paper-based disk 50 may be cut or formed into a dome disk (not depicted) such that the central portion 56 is offset from the peripheral portion 58 along the Y-axis.

[0187] After formation, the paper-based disk 50 becomes the bottom closure 51 (e.g., as shown in the image). Figure 11 (As shown in the diagram). The bottom closure 51 may have a first deformable surface 53 and a second deformable surface 55. In some embodiments, the first deformable surface 53 may be substantially horizontal. In some embodiments, the first deformable surface 53 includes a central portion 56 of the paper-based disk. In another embodiment, the second deformable surface 55 may be substantially vertical and / or may include a peripheral portion 58 of the paper-based disk. In some embodiments, the inward-facing side of the first deformable surface 53 (e.g., the lower surface 54 of the paper-based disk 50) may be adjacent to the container interior of the container body 60, and the inward-facing side of the second deformable surface 55 (e.g., the lower surface 54 of the paper-based disk 50) may be adjacent to the inner surface 66 of the sidewall 63 of the container body 60. As discussed in more detail herein, in some embodiments, the ionomer layer 50i of the paper-based disk 50 within the second deformable surface 55 may be thermally melted to form a seal with the inner surface 66 of the sidewall 63 of the container body 60.

[0188] method

[0189] In use, the sealing system 100 receives the disc 50 and seats it within the positioning portion 90 of the mold assembly 300, optionally using vacuum pressure to properly seat the disc. In some embodiments, the container body 60 is then raised toward the mold assembly 300 via a lifting plate until the peripheral edge 205 of the container body 60 contacts the lower surface of the mold 80. In such embodiments, the inner surface 66 of the container body 60 may be flush with the mold opening 98. In some embodiments, the outer mandrel 210 is then translated vertically downward toward the disc 50 until the outer mandrel 210 contacts the peripheral portion 58 of the disc 50, thereby securing it in place. More specifically, the vertical extension 212 of the outer mandrel 210 may be configured to hold the disc 50 in place (e.g., as shown in the image). Figure 4 (as shown in the image).

[0190] Once the disc 50 is clamped in place by the outer mandrel 210 (e.g., its vertical extension 212), the open end (bottom) of the container body 60 is isolated from the surrounding atmosphere. The force exerted by the outer mandrel 210 on the disc 50 can create a sealed or near-sealed condition within the container 60 and between the container 60 and the disc 50. Then, the gas valve is opened as needed, and air is evacuated from the container through the channel opening 440 and the channel 430, thereby creating a negative pressure condition inside the container. More specifically, a side-channel pump can be designed to draw a defined volume of gas from inside the container. The defined volume of gas can be related to the size and volume of the container 60 and the depth to which the disc 50 will be inserted into the container body 60 to seal it. More specifically, the defined volume of gas can be defined as the insertion depth of the formed paper bottom multiplied by the internal cross-sectional area of ​​the container. In any embodiment, the evacuation volume should be less than the volume that would cause the container 60 to collapse. In some embodiments, the rate of evacuation from the container can be adjusted. For example, some containers (such as those with large internal volumes) pose a significant risk of collapse when using high-speed evacuation processes. In some cases, the vacuum level can be adjusted. For instance, processes using higher vacuum pressures require lower flow rates for evacuation. Processes using lower vacuum pressures require higher flow rates for evacuation. Those skilled in the art should understand these variations.

[0191] In some embodiments, the evacuation process may occur within a period of about 60 milliseconds or less. In other embodiments, the evacuation process may occur within a period of about 40 milliseconds to about 50 milliseconds. In some embodiments, the evacuation process may occur within a period of about 200 milliseconds or less.

[0192] When the side channel pump is activated, air in the pipe, connector 410, and valve 420 can be drawn into the side channel pump. Additionally, air in channel 430, channel opening 440, and inside the container can be drawn into the side channel pump. Without releasing the pressure between the outer spindle 210 and the disc 50, the paper disc 50 is then immediately inserted (or perforated) into the container body 60 via the inner spindle 220 in a recessed manner. The drawing and insertion steps can occur simultaneously or almost simultaneously. That is, air can be drawn from inside the container within a fraction of a second before the disc 50 is inserted into the container body 60.

[0193] In some embodiments, insertion of the disc 50 into the container body 60 is accomplished via an inner shaft 220. In such embodiments, the inner shaft 220 and the ejector 30 may continue to translate vertically downward toward the disc 50. The inner shaft 220 and the ejector may then contact the disc 50 and push it downward through the mold opening 98 until the disc 50 deforms to have a flat central portion and deformed sidewalls 55 adjacent to the inner surface 66 of the container body 60. In one embodiment, pressure may be applied to the disc by a first mandrel surface 222 and / or a second mandrel surface 224 of the inner shaft 220 (e.g., by actuating the inner shaft 220 along the Y direction).

[0194] Next, the deformable composite closure 51 can be hermetically sealed to the container body 60. In some embodiments, this occurs without releasing the pressure of the inner shaft and mold (which maintains negative pressure conditions inside the container). Compression and heat can be applied to the deformable composite closure 51 and / or the container body 60, causing their respective sealant layers to form a hermetically sealed environment. In some embodiments, heat is provided via at least the sealing member 40. Similarly, the sealing member 40 and the second mandrel surface 224 of the inner shaft 220 can provide opposing pressure to the outer surface 64 of the container body 60 and / or the deformable sidewall 55 of the bottom closure 51.

[0195] The hermetic seal according to this disclosure can be formed by the sealing member 40 at a temperature greater than about 90°C, for example, from 120°C to about 280°C or from about 140°C to about 260°C. A suitable hermetic seal can be formed by keeping the sealing member 40 in contact with the bottom end 62 of the composite body 60 for any dwell time (e.g., less than about 5 seconds, from about 0.8 seconds to about 5.0 seconds, or from about 1 second to about 4 seconds) sufficient to heat the sealant layer to a temperature suitable for forming a hermetic seal. The bottom closure 51 and the bottom end 62 of the composite body 60 can be compressed between the sealing member 40 and the inner shaft 220 under any pressure less than about 30 MPa (e.g., from about 1 MPa to about 22 MPa).

[0196] After applying compression and / or heat for a sufficient residence time, the sealing member 40 can be removed from the bottom end 62 of the container body 60, such that the sealing member 40 does not come into contact with the composite body 60 after the residence time has expired (e.g., as shown in the image). Figure 7 (As shown in the diagram). Next, the inner shaft 220 retracts from the closure 51, while the ejector 30 remains in place. Once the inner shaft 220 has at least cleared the outer edge of the container body 60, the ejector 30 retracts, optionally accompanied by a burst of pressurized air to aid the retraction process. The ejector 30 then retracts completely into the inner shaft 220. The container body 60 is then removed from the mold assembly 300 and the mandrel assembly 200 before, during, or after the mandrel assembly 200 has fully retracted from the mold assembly 300.

[0197] In some embodiments, the systems and methods described herein can produce hermetically sealed container assemblies with a paper-based composite bottom closure inserted into and sealed in a recessed position within the composite container body, without the film seal (e.g., the top film seal) bulging due to internal container overpressure. Because the top sealing film does not bulge, there are no instability issues. The container assembly can stand stably upright (inverted) on its film end as it is conveyed to downstream packaging processes (e.g., from a sealing machine to a case packer). Furthermore, the top cap will be easily fitted onto the top of the container assembly above the top closure (e.g., a peelable film) because the top closure does not bulge.

[0198] Furthermore, the hermetic sealed container assembly of this disclosure can be transported worldwide by, for example, sea, air or rail, and subjected to different atmospheric conditions (e.g., due to temperature changes, humidity changes and altitude changes) without any unacceptable membrane cover protrusions.

[0199] In some embodiments, multiple composite container assemblies may be formed in a synchronized manner by a system or apparatus suitable for processing multiple paper-based discs, bottom closures, and composite container bodies. For example, a manufacturing system may include multiple mandrel assemblies, multiple mold assemblies, multiple vacuum assemblies, and multiple tube support assemblies operating in a coordinated manner. Specifically, a pylon-like device having multiple sub-assemblies (each sub-assembly including a mandrel assembly, mold assembly, vacuum assembly, and tube assembly) can accept and process discs simultaneously or synchronously. Depending on the complexity of the pylon-like device, hundreds of individual composite container assemblies may be manufactured in a coordinated manner per cycle. Therefore, any of the processes described herein may be performed simultaneously. For example, when each sub-assembly operates synchronously, each of the following may be performed simultaneously: a first paper-based disc may be positioned above a mold opening; a second paper-based disc may be constrained between a mandrel assembly and a mold assembly; a third paper-based disc may be formed as a first bottom closure by insertion into a first composite body; and the third bottom closure may be hermetically sealed to a second composite body. Alternatively, any of the operations described herein may be performed simultaneously by a device having multiple subassemblies, for example (say).

[0200] In some embodiments, the systems and methods of this disclosure allow the sealing system to operate at high speeds (e.g., more than 300 container assemblies per minute). In some embodiments, the systems and methods of this disclosure allow the sealing system to operate at a rate of at least 400 container assemblies per minute. In some embodiments, the systems and methods of this disclosure allow the sealing system to operate at a rate of at least 500 container assemblies per minute.

[0201] It should be understood that this disclosure provides hermetic-sealed container assemblies for packaging moisture-sensitive and / or oxygen-sensitive solid foods (e.g., crispy carbohydrate foods, salted foods, crispy foods, potato chips, processed potato snacks, nuts, and the like). Such hermetic-sealed container assemblies can provide hermetic sealing under a variety of climatic conditions, including high and low temperatures, high and low humidity, and high and low pressure. Furthermore, the hermetic-sealed container assemblies can be manufactured according to the methods described herein via processes involving heat transfer heating or conduction heating technologies with relatively low environmental pollution. The hermetic-sealed container assemblies described herein can be low in weight, have high structural stability, and be suitable for recycling.

[0202] In some embodiments, the systems and methods described herein can produce hermetically sealed container assemblies with a paper-based composite bottom closure, which may be a paper-based disc inserted into the open bottom end of the composite container body and sealed in a recessed position without causing the top closure (e.g., a peelable membrane) at the sealed tip to bulge. During the typical insertion process in which the paper-based disc transforms into the recessed bottom closure, the increased pressure inside the container (due to the insertion process itself) causes the top closure to expand outward or "bulge." In other words, when the bottom closure is inserted into the open bottom end of the container body and sealed in place, it pushes air inside the container into a smaller space to accommodate the recessed bottom closure. This increased pressure expands outward into the most flexible component (which is typically the top closure (e.g., a membrane cap)).

[0203] Not only are raised film caps unsightly, they can also cause certain manufacturing problems. For example, raised film can lead to instability. In some cases, container assemblies with raised film issues cannot stand stably on their film ends during transport to downstream packaging processes (e.g., from sealing machines to case packers) (inverted). Furthermore, if the top film is raised, the top cap cannot be fitted onto the container assembly, rendering the packaging unsellable.

[0204] Therefore, in some embodiments, the systems and methods disclosed herein provide a mechanism for applying a paper-based disc to a paper-based container body to form a recessed bottom closure without introducing an unacceptable degree of protrusion into the flexible top closure (e.g., a peelable film). More specifically, the systems and methods of this disclosure can allow evacuation to occur simultaneously with or shortly before the sealing process. In some embodiments, the methods and systems of the present invention allow for the evacuation of an adjustable, defined volume of gas from inside the container. In some embodiments, this defined volume of gas is directly related to the desired depth of the recessed bottom closure, thereby avoiding overpressure conditions inside the container.

[0205] Example

[0206] In the following examples, various properties of the paper-based bottom container (composite container, paper bottom, membrane lid, and top lid) of the present invention are tested. The paper bottom of the tested container comprises a paper layer (195 g / m²). 2 The flexible sheet (0.3mm thick) (i.e., the paper cup base paper), adhesive layer, aluminum foil (8μm) as a barrier layer, and ionomer layer (32g / m²) as a sealant layer 2 In some containers, a PET layer is included to protect the aluminum barrier layer. In other embodiments, an aluminum barrier layer is not included. All versions have been tested as indicated below.

[0207] Example 1

[0208] In high-altitude testing, the inventive container is placed in a sealed chamber and the pressure inside is increased to at least 11 inHg over a period of approximately 10 minutes. If the container can withstand up to 10 inHg (simulating atmospheric pressure when the container travels over the Rocky Mountains) for at least 10 minutes, then the container passes the test. If not, the container is classified as “fail.” As used herein, “observed rocker bottom” means a membrane and / or paper bottom that bulges due to overpressure conditions during vacuum chamber confinement, which is normal under such conditions. After removal from the container, the bulge returns to neutral. A bulge can be considered as the membrane or paper bottom moving outward from the inside of the container such that it extends beyond the relevant cut edge of the container. Failure or failure includes leakage, peeling of the membrane or paper bottom, twisting that remains after pressure release, splitting or delamination of the seam, bursting of the membrane or paper bottom, and / or another fault that will prevent the container from meeting the airtightness standard. If the membrane or paper bottom bulges inward into the can after pressure release, this indicates a leakage fault. The test results are stated below.

[0209] Table 1a. Results of High Altitude Test ("HAT")

[0210]

[0211]

[0212] The test results indicate a 99.4% success rate for the paper bottom described in this article, which is acceptable.

[0213] Table 1b. High-altitude test results

[0214]

[0215]

[0216] The test results indicate a 98% success rate for the standard overlay and a 100% success rate for the lightweight paper bottom described herein, which is acceptable.

[0217] Example 2

[0218] In this example, the inventive container underwent a helium leak test. Helium can be used as a tracer gas for detecting leaks because it constitutes only about 5 pmm of atmospheric helium, resulting in a very low background level. Helium also has a relatively low mass, making it mobile and completely inert / non-reactive. The sealed inventive container was placed in a sealed vacuum chamber, which was then filled with 130 mbar of helium. A sniffer / leak detector was connected to the container, allowing a gas sample from inside the container to be extracted and passed through a mass spectrometer to read the increase in the background reading of the helium level in the container. In this example, the helium leak limit was 2.3 x 10⁻⁶. -4mbar*l / s. A success rate of 99.8% was observed. This result is acceptable.

[0219] Table 2. Results of Helium Leakage Test ("HLT")

[0220]

[0221] Example 3

[0222] In this example, the inventive container underwent a container integrity test. The container was placed in a vacuum chamber at 200 mbar pressure, and vacuum decay was measured over a 20-second period. The method uses pressure change measurements to indirectly determine the flow rate from the container to the fixed-volume chamber. A mass extraction variant measures the flow rate required to maintain the vacuum at a fixed level (ASTM F2338 and ASTM F 3287). If the container leaks, it will reduce the expected vacuum inside the vacuum chamber. Vacuum drop or decay is measured per second. A success / failure threshold was set at 42 Pa / s. A success rate of 98.6% was observed. This result is acceptable.

[0223] Table 3. Container Integrity Test ("CIT") Results

[0224]

[0225]

[0226] Example 4

[0227] In this example, the inventive container underwent a container periodic test interval (“PTI”) test. The container was placed in a vacuum chamber at a pressure of 700 mbar, and vacuum decay was measured over a 20-second cycle. Vacuum drop or decay was measured per second. A success / failure threshold was set at 20 Pa / s. A success rate of 96% was observed. This result is acceptable.

[0228] Table 4. PTI Test Results

[0229] batch# batch PTI (700mbar, 20sec) Observed bottom of rocker arm Failure Types 1 26 containers 1 failed none none 2 25 containers 1 failed none none

[0230] Example 5

[0231] In this example, the inventors analyzed the simulated shelf life of the inventive container. The container, after being filled, sealed, and stored, had a residual oxygen content of 0.0%. The residual oxygen content of the container was then tested after 6 months and 9 months. A success / failure threshold was set to be less than or equal to 2.0% residual oxygen during these periods (a threshold of 4.0% to 4.5% is acceptable after approximately 18 months). A success rate of 92% was observed. This result is acceptable.

[0232] Table 5. Simulated shelf life results

[0233]

[0234] Example 6

[0235] In this example, the inventors used the vacuum decay method described herein to compare the leakage of a container with an inventive paper-bottom closure with that of a container with a metal-bottom closure. Pressure drop in the containers was measured in Pa / s. The “blue” and “green” containers are paper-bottom containers, while the “reference with metal end” includes metal-bottom containers. As can be seen, the paper-bottom container exhibits a smaller overall pressure drop during vacuum decay than the container with a metal bottom. Figure 37 The results are illustrated in graphs. In summary, the paper bottom of this invention is superior to the metal bottom in terms of consistency in preventing leakage.

Claims

1. A paper-based container assembly, comprising: The container body includes: At least one sidewall that defines the interior of the container. The top edge, which defines the top edge of the at least one sidewall, and The bottom peripheral edge defines the bottom end of the at least one sidewall; Top closure, which is attached to the top edge; and A bottom closure is recessed into the bottom end and forms a seal with the inner surface of the container body; At least one of the container body and the bottom closure includes multiple layers comprising one or more barrier layers and one or more paper base layers; and The paper-based container assembly has a diameter of 0.5 cm. 3 / m 2 / day or lower oxygen permeability and 0.5 g / m 2 / day or lower water vapor transmission rate; and The paper-based container assembly is capable of withstanding at least 10 inHg for at least 10 minutes without failure of the top or bottom closure.

2. The paper-based container assembly according to claim 1, wherein the oxygen permeability of the paper-based container assembly is 0.05 g / m³. 2 / day or lower.

3. The paper-based container assembly according to claim 1, wherein the water vapor transmission rate of the paper-based container assembly is 0.05 g / m³. 2 / day or lower.

4. The paper-based container assembly according to claim 1, wherein: The plurality of layers includes one or more ionomer layers within at least one of the container body and the bottom closure; and The one or more ionomer layers have the same grade and form a seal between the bottom closure and the inner surface of the container body when heated.

5. The paper-based container assembly of claim 1, wherein each of the container body, the top closure, and the bottom closure comprises a plurality of layers including one or more barrier layers and one or more paper base layers.

6. The paper-based container assembly of claim 5, wherein the one or more paper base layers of the container body, top closure and bottom closure comprise at least 95% of the mass of the paper-based container assembly.

7. The paper-based container assembly of claim 5, wherein the barrier layer of at least one of the container body, the top closure, and the bottom closure comprises metallized polyethylene terephthalate (MPET).

8. The paper-based container assembly of claim 5, wherein the barrier layer of at least one of the container body, the top closure, and the bottom closure comprises aluminum.

9. The paper-based container assembly of claim 5, wherein the barrier layer of at least one of the container body, the top closure, and the bottom closure comprises metallized polybutylene terephthalate (MPBT).

10. The paper-based container assembly of claim 5, wherein the one or more barrier layers of at least one of the container body, the top closure, and the bottom closure comprise alumina (AlOx) coated polyethylene terephthalate (PET).

11. The paper-based container assembly of claim 1, wherein the plurality of layers comprises one or more adhesive layers.

12. The paper-based container assembly of claim 1, wherein the bottom closure is recessed into the bottom end of the container body at a recess distance ranging from 0.2 to 2 cm.

13. The paper-based container assembly of claim 1, wherein the seal between the inner surface of the container body and the bottom closure is airtight.

14. The paper-based container assembly according to claim 1, wherein the container body is cylindrical.

15. The paper-based container assembly of claim 1, wherein the top closure comprises a peelable film sealed to the top edge.

16. A paper-based container assembly comprising: A cylindrical container body, comprising: At least one sidewall, wherein the at least one sidewall comprises: One or more paper base layers, which are adhesively bonded to one or more barrier layers; and one or more ionopolymer layers, which are adhesively bonded to the one or more barrier layers, wherein the one or more ionopolymer layers define the interior of the container; The top edge, which defines the top edge of the at least one sidewall, and The bottom outer edge defines the bottom end of the sidewall; A top closure that seals to the top edge, wherein the top closure comprises: One or more paper base layers, which are adhered to one or more barrier layers; and One or more peelable sealant layers, which are adhered to the one or more barrier layers; and A bottom closure, recessed into the bottom end and forming a seal with the inner surface of the cylindrical container body, wherein the bottom closure comprises: One or more layers of paper cup baseboard, which are glued to one or more barrier layers; and One or more ionomer layers, which are adhesively bonded to the one or more barrier layers. in: The one or more paper base layers of the cylindrical container body, top closure, and bottom closure comprise at least 95% of the mass of the paper-based container assembly, and The paper-based container assembly has a diameter of 0.5 cm. 3 / m 2 / day or lower oxygen permeability and 0.5 g / m 2 / day or lower water vapor transmission rate; and The paper-based container assembly is capable of withstanding at least 10 inHg for at least 10 minutes without failure of the top or bottom closure.

17. The paper-based container assembly of claim 16, wherein at least one barrier layer of the sidewall, at least one barrier layer of the top closure, and at least one barrier layer of the bottom closure each comprise metallized polyethylene terephthalate (MPET).

18. The paper-based container assembly of claim 16, wherein at least one barrier layer of the sidewall, at least one barrier layer of the top closure, and at least one barrier layer of the bottom closure each comprise metallized polybutylene terephthalate (MPBT).

19. The paper-based container assembly of claim 16, wherein at least one barrier layer of the sidewall, at least one barrier layer of the top closure, and at least one barrier layer of the bottom closure each comprise alumina (AlOx) coated polyethylene terephthalate (PET).

20. The paper-based container assembly of claim 16, wherein at least one barrier layer of the sidewall, at least one barrier layer of the top closure, and at least one barrier layer of the bottom closure each comprise aluminum.

21. A paper-based container assembly comprising: A cylindrical container body, comprising: At least one sidewall, wherein the at least one sidewall comprises: One or more paper substrates are adhesively bonded to one or more barrier layers, wherein the one or more barrier layers are selected from the group consisting of metallized polyethylene terephthalate (MPET), metallized polyethylene terephthalate (MPBT), alumina (AlOx) coated polyethylene terephthalate (PET), and aluminum; and One or more ionomer layers are bonded to the one or more barrier layers, wherein the one or more ionomer layers define the interior of the container; The top edge, which defines the top edge of the at least one sidewall, and The bottom outer edge defines the bottom end of the sidewall; A top closure that seals to the top edge, wherein the top closure comprises: One or more paper substrates are adhesively bonded to one or more barrier layers, wherein the one or more barrier layers are selected from the group consisting of metallized polyethylene terephthalate (MPET), metallized polyethylene terephthalate (MPBT), alumina (AlOx) coated polyethylene terephthalate (PET), and aluminum; and One or more peelable sealant layers, which are adhered to the one or more barrier layers; and A bottom closure, recessed into the bottom end and forming a seal with the inner surface of the cylindrical container body, wherein the bottom closure comprises: One or more paper cup base cardboard layers, glued to one or more barrier layers, wherein the one or more barrier layers are selected from the group consisting of metallized polyethylene terephthalate (MPET), metallized polyethylene terephthalate (MPBT), alumina (AlOx) coated polyethylene terephthalate (PET), and aluminum; and One or more ionomer layers, which are adhesively bonded to the one or more barrier layers. in: The one or more paper base layers of the cylindrical container body, top closure, and bottom closure comprise at least 95% of the mass of the paper-based container assembly, and The paper-based container assembly has a diameter of 0.5 cm. 3 / m 2 / day or lower oxygen permeability and 0.5 g / m 2 / day or lower water vapor transmission rate; and The paper-based container assembly is capable of withstanding at least 10 inHg for at least 10 minutes without failure of the top or bottom closure.

22. The paper-based container assembly of claim 21, wherein the paper-based container assembly has a diameter of 0.05 cm. 3 / m 2 / day or lower oxygen permeability and 0.05 g / m 2 / day or lower water vapor transmission rate.

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