Container assembly having paper-based end closures

Abstract

The present disclosure is directed to a recyclable composite container assembly having improved features resulting from a combination of raw materials, structural designs, systems, and methods for sealing a paper-based closure (61) to a paper-based container body (60). The container assembly demonstrates superior performance and sealing characteristics, such as very low oxygen transmission rates and high resistance to bulging and / or damage due to high pressure differentials. Manufactured at high speeds, the disclosed container assembly is optimized by increasing the shelf life of food products stored therein while minimizing any non-paper materials, thereby qualifying the container assembly as a single-material recyclable.

Description

[Technical Field]

[0001] This application claims priority to U.S. Patent Application No. 63 / 071,019, filed on 27 August 2020, which is incorporated herein by reference in its entirety.

[0002] This disclosure generally relates to systems and methods for forming and sealing composite container assemblies having a paper base or composite closure. [Background technology]

[0003] Rigid paper-based composite container assemblies are often used to package a variety of products, such as snacks and other food items. These container assemblies often comprise a rigid (e.g., cylindrical) container body manufactured with open top and bottom ends. The composite container body may comprise a rigid can made from sheet material (e.g., spirally wound) such as corrugated cardboard and / or paperboard. Such container assemblies further include top and bottom closures. The bottom closure (e.g., a metal end) is usually permanently attached to the bottom rim of the container body (e.g., seamed), while the top closure is often designed to be easily removed by the consumer (e.g., a removable / replaceable overcap and / or peelable film). Typically, the film is first sealed to the top rim. The inside of the container is then filled with product through the open bottom end of the container body, and the metal closure is seamed to the bottom rim of the container body.

[0004] The process described above, which uses a metal bottom edge, interferes with the recyclability of the container assembly. This is because seaming the metal closure to the bottom of the container body makes it very difficult to separate the metal closure from the container assembly itself after use. Since the paper-based body of the container assembly cannot be separated from the metal bottom, the container assembly cannot enter the paper or metal recycling stream. This can result in unnecessary waste and negative environmental impacts. There is a need for recyclable container assemblies to increase the sustainability of the final product.

[0005] One solution to the need for recyclability is to produce container assemblies with paper-based end closures instead of metal ones. 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 considerable effort, the inventors have developed container assemblies with improved characteristics and methods for producing such container assemblies.

[0006] For example, a container assembly resulting from the untreated material, method, and / or unique tooling process described herein has an oxygen permeability of (in some embodiments, about 0.05 cm²). 3 / m 2 It has been improved (to less than 10 inHg / day) and in some embodiments can withstand pressure differences greater than about 10 inHg—that is, a significant improvement over known paper-based container assemblies. [Overview of the project]

[0007] This disclosure generally relates to sealed paper-based container assemblies and methods for manufacturing such container assemblies.

[0008] In some embodiments, this disclosure relates to container assemblies (e.g., cylindrical) sealed with a paper-based bottom closure. In certain embodiments, this disclosure relates to the resulting features of a manufactured container assembly. The container assembly has superior features to any conventionally known paper-based bottom container assembly, as described below.

[0009] In some embodiments, the disclosure relates to a paper-based container assembly having a top closure and a bottom closure (e.g., a paper-based disc) sealed to the container body. The paper-based container assembly is approximately 0.05 cm 3 / m 2 Oxygen permeability of less than / day and approximately 0.05 g / m³ 2 It can have a water vapor transmission rate of less than or equal to 1 / day. The container body may comprise at least one side wall defining the interior of the container. The container body may further comprise an upper rim defining the upper end of the side wall and a bottom peripheral edge defining the bottom end of the side wall. The upper closure may include a peelable film, a peelable barrier cap, a puncturable film, or a perforated opening film sealed to the upper rim, or a recessed film sealed inside the container body. The bottom closure may be recessed inward from the bottom end to form a seal with the inner surface of the container body. The container body, peelable film, and bottom closure may each comprise multiple layers. The multiple layers may include one or more barrier layers and one or more paper-based layers.

[0010] In certain embodiments, the water vapor transmission rate of a paper-based container assembly is approximately 0.5 g / m³. 2 It can be less than / day. In certain embodiments, the water vapor transmission rate of the paper-based container assembly is approximately 0.05 g / m³. 2 This can be less than / day. In certain embodiments, one or more paper-based layers of the container body, peelable film, and bottom closure may constitute at least about 95% by mass of the paper-based container assembly.

[0011] In certain embodiments, the layers may comprise one or more ionomer layers, where at least one of the ionomer layers of the container body and the bottom closure is of the same grade, and when heated, forms a seal between the bottom closure and the inner surface of the container body. In certain embodiments, the layers may comprise one or more ionomer layers, where at least one of the ionomer layers of the container body and the top closure is of the same grade, and when heated, forms a seal between the top closure and the inner surface of the container body (i.e., the roll-up rim).

[0012] In certain 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 certain embodiments, one or more barrier layers of the container body, peelable film, and at least one of the bottom closure may include aluminum, metallized polyethylene terephthalate (MPET) film, metallized polybutylene terephthalate (MPBT) film, and / or aluminum oxide (AlOx) coated polyethylene terephthalate (PET) film. In certain 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 certain embodiments, one or more paper-based layers of the bottom closure may comprise a flexible board and have a thickness in the range of about 0.1 to about 0.6 mm. In certain embodiments, the multiple layers may include one or more tie layers. In certain embodiments, the bottom closure is recessed inward from the bottom edge of the container body by a recess distance in the range of about 0.2 to 2 cm and protrudes by a distance less than the recess distance at a pressure difference of about 10 inHg (about 34 kPa) with respect to the inside of the container. In certain embodiments, the seal between the inner surface of the container body and the bottom closure can be airtight. In certain embodiments, the container assembly can be configured to store food products inside the container. In certain embodiments, the container body can be cylindrical, have a height in the range of about 4 to about 40 cm, and / or have an inner diameter in the range of about 4 to about 20 m.

[0013] The container of the present invention can be cylindrical, but the present invention should not be limited thereto. In certain embodiments, the container can have a square, rectangular, triangular, or irregular cross-section. The bottom closure of the present invention can have a shape and configuration that correlates with the cross-section of the container. Thus, in the case of a cylindrical container, the bottom closure can be circular or disk-shaped. However, a container having a square cross-section can, for example, be provided with a square bottom closure.

[0014] In some embodiments, the present disclosure is directed to a paper-based container assembly having a top closure and a bottom closure (e.g., a paper-based disk) sealed to a cylindrical container body. The paper-based container assembly can have an oxygen transmission rate of about 0.5 cm 3 / m 2 / day or less and a water vapor transmission rate of about 0.5 g / m 2 / day or less. The cylindrical container body can include sidewalls that define the interior of the container. The cylindrical container body can further include an upper rim that defines the upper end of the sidewalls and a bottom peripheral edge that defines the bottom end of the sidewalls. The top closure can be sealed to the upper rim. The bottom closure can be recessed inwardly from the bottom end to form a seal with the inner surface of the cylindrical container body. The cylindrical container body, the top closure, and the bottom closure can include a plurality of layers including one or more paper-based layers. One or more paper-based layers of the cylindrical container body, the top closure, and the bottom closure can include at least about 95% by mass of the paper-based container assembly.

[0015] In certain embodiments, the water vapor transmission rate of the paper-based container assembly can be about 0.15 g / m 2 / day or less. In certain embodiments, the water vapor transmission rate of the paper-based container assembly can be about 0.05 g / m 2It can be less than or equal to 1 day. In certain embodiments, the plurality of layers can include one or more ionomer layers, and one or more ionomer layers of at least one of the cylindrical container body and the bottom closure can be of the same grade and form a seal between the bottom closure and the inner surface of the cylindrical container body when heated. In certain embodiments, at least one of the one or more ionomer layers can have a thickness within the range of about 2 to about 40 μm. In certain embodiments, the plurality of layers can include one or more barrier layers. One or more barrier layers of at least one of the cylindrical container body, the upper closure, and the bottom closure can include aluminum, metallized polyethylene terephthalate (MPET) film, metallized polybutylene terephthalate (MPBT) film, and / or aluminum oxide (AlOx)-coated polyethylene terephthalate (PET) film. In certain embodiments, at least one of the one or more barrier layers can have a thickness within the range of about 5 to about 20 μm. In certain embodiments, one or more paper-based layers of the bottom closure can comprise a flexible board and can have a thickness within the range of about 0.1 to about 0.6 mm. In certain embodiments, the plurality of layers can include one or more tie layers. In certain embodiments, the bottom closure is recessed inward from the bottom end of the cylindrical container body by a recess distance within the range of about 0.2 to 2 cm and protrudes by a distance less than the recess distance at a pressure difference with the interior of the container of about 10 inHg (about 34 kPa). In certain embodiments, the seal between the inner surface of the cylindrical container body and the bottom closure can be airtight. In certain embodiments, the container assembly can be configured to store a food product within the interior of the container. In certain embodiments, the cylindrical container body can have a height within the range of about 4 to about 40 μm and / or an inner diameter within the range of about 3 to 20 cm.

[0016] [[ID=第3]] The accompanying drawings, which are incorporated herein and constitute a part of this specification, illustrate one or more embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0017] It should be noted that there seems to be an error in the original text where "円筒形容器本体および底閉鎖部の少なくとも一方の1つまたは複数のアイオノマー層は" is a bit unclear in its structure. Also, in the translation of "円筒形容器本体は、約4~約40μmの範囲内の高さ", it's not clear if the unit "μm" is correct as it might be more reasonable for height to be in a larger unit like centimeters in the context. But the translation is done based on the provided text.A complete and practicable disclosure for those skilled in the art is described herein and reference is made to the accompanying drawings.

Brief Description of the Drawings

[0018] [Figure 1] FIG. is a cross-sectional view of an exemplary sealing system according to some embodiments of the present disclosure. [Figure 2] FIG. is a cross-sectional view of an exemplary sealing system according to some embodiments of the present disclosure. [Figure 3] FIG. is a cross-sectional view of an exemplary sealing system according to some embodiments of the present disclosure. [Figure 4] FIG. is a cross-sectional view of an exemplary sealing system according to some embodiments of the present disclosure. [Figure 5] FIG. is a cross-sectional view of an exemplary sealing system according to some embodiments of the present disclosure. [Figure 6] FIG. is a cross-sectional view of an exemplary sealing system according to some embodiments of the present disclosure. [Figure 7] FIG. is a cross-sectional view of an exemplary sealing system according to some embodiments of the present disclosure. [Figure 8] FIG. is a cross-sectional view of an exemplary sealing system according to some embodiments of the present disclosure. [Figure 9] FIG. is a cross-sectional view of an exemplary sealing system according to some embodiments of the present disclosure. [Figure 10] FIG. is a cross-sectional view of an exemplary sealing system according to some embodiments of the present disclosure. [Figure 11] FIG. is a cross-sectional view of an exemplary sealing system according to some embodiments of the present disclosure. [Figure 12] FIG. is a cross-sectional view of an exemplary sealing system according to some embodiments of the present disclosure. [Figure 13] FIG. is a cross-sectional view of an exemplary sealing system according to some embodiments of the present disclosure. [Figure 14] FIG. is a cross-sectional view of an exemplary die and gas exhaust system according to some embodiments of the present disclosure. [Figure 15]This figure shows an exemplary die and gas exhaust system according to some embodiments of the present disclosure. [Figure 16] This is a cross-sectional view illustrating an exemplary die and gas exhaust system according to several embodiments of the present disclosure. [Figure 17A] This is a perspective view of an exemplary container body, top closure, and paper-based disc according to some embodiments of the present disclosure. [Figures 17B-17D] Figure 17A shows an exemplary cross-sectional view of the container body, top closure, and paper-based disc according to some embodiments of the present disclosure. [Figure 18] This is a cross-sectional view of an exemplary sealed container assembly according to several embodiments of the present disclosure. [Figure 19] This figure shows the bottom end of an exemplary sealed container assembly having a recessed bottom closure, according to some embodiments of the present disclosure. [Figure 20] This figure shows an exemplary sealing system according to one embodiment of the present disclosure. [Figure 21] This figure shows an exemplary sealing system according to one embodiment of the present invention. [Figure 22] This figure shows an exemplary sealing system according to one embodiment of the present invention. [Figure 23] This figure shows an exemplary sealing system according to one embodiment of the present invention. [Figure 24] This figure shows an exemplary sealing system according to one embodiment of the present invention. [Figure 25] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 26] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 27] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 28] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 29] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 30] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 31] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 32] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 33] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 34] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 35A] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 35B] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 35C] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 35D] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 35E] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 35F] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 36] This figure shows an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 37] This figure shows a graph comparison of leak detection in the paper-bottom closure of the present invention compared with that of a metal-bottom closure. [Modes for carrying out the invention]

[0019] The repeated use of reference letters in this specification and drawings is intended to indicate the same or similar features or elements of the present disclosure.

[0020] Herein, references are made in detail to embodiments of the present disclosure, and one or more examples of such embodiments are shown in the accompanying drawings. Each example is provided as a description of the present disclosure, and not as a limitation of the present disclosure. In practice, it will be apparent to those skilled in the art that modifications and variations can be made in the present disclosure without departing from the scope or spirit of the present disclosure. For example, a feature shown or described as part of one embodiment can be used for another embodiment to give rise to further embodiments. Therefore, the present disclosure is intended to cover such modifications and variations that fall within the scope of the accompanying claims and their equivalents.

[0021] In some embodiments, this disclosure relates to high-barrier packaging for perishable products, such as hermetically sealed container assemblies for packaging humidity and / or oxygen-sensitive solid food products, and methods for producing such high-barrier packaging. Container assemblies produced according to the devices and methods described herein, once filled and sealed, can be capable of maintaining a variety of atmospheric conditions. More specifically, hermetically sealed container assemblies can be suitable for maintaining the freshness of crisp food products such as snack foods, potato chips, processed potato snacks, cookies, nuts, and the like. As used herein, the term “hermetically sealed” refers to the property of a barrier, such as a seal, surface, and / or container assembly, that maintains oxygen (O2) levels. For example, when exposed to ambient conditions of air at about 22.7°C and about 0% relative humidity, the oxygen permeability of a container assembly is 50 cm⁻¹. 3 O2 / m 2 When the value is less than / day, the container assembly can be considered hermetically sealed.

[0022] In some embodiments, the systems and methods described herein can produce hermetically sealed container assemblies having a paper-based composite bottom closure, which can 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 state while being transported worldwide (e.g., by truck, air, rail) even when subjected to fluctuating atmospheric conditions (e.g., caused by variations in temperature, humidity, and / or altitude). Such conditions may result in a considerable pressure difference between the inside and outside of the hermetically sealed container assembly. Furthermore, atmospheric conditions may circulate between relatively high and relatively low values. The containers and methods described herein can advantageously provide container assemblies that can be transported and / or stored under vastly different climatic conditions (i.e., temperature, humidity, and / or pressure). Furthermore, in some embodiments, the hermetically sealed container assemblies can be formed from untreated materials having suitable characteristics for rapid manufacturing.

[0023] As stated, the hermetically sealed container assembly may include a paper-based composite bottom closure. Similarly, the container body may include a paper-based composite material, allowing the entire container assembly to be recycled in a single stream (unlike, for example, conventional container assemblies with a metal bottom). In some embodiments, the container assembly may have a paper content of about 90% or more per mass. In some embodiments, the container assembly may have a paper content of about 95% or more per mass. These paper content percentages may favorably qualify the container assembly as a mono-material in certain countries, allowing the container assembly to be accepted in the recycling streams of most countries worldwide. In some embodiments, the term “mono-material” includes any material that can be collected and entered into a waste management flow in order to obtain unprocessed material from residues for different applications.

[0024] 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 a substrate, object, or layer, or it can partially cover it. A coating can have decorative and / or functional properties.

[0025] As used herein, “sealant” is a material that can be used to seal one layer or component to another layer or component. In one embodiment, a sealant may include a heat-sealable material. In one embodiment, a sealant may include a heat-sealable thermoplastic material. In one embodiment, a sealant may include an ionomer material, an adhesive, or a tie layer. In one embodiment, a sealant may include a coating or a film.

[0026] As used herein, “tie layer” may include adhesives, sealants, or any other material that bonds, adheres, or glues one layer to another. Adhesives as discussed herein may be permanent, pressure-sensitive, peelable, or otherwise.

[0027] "Container assembly" Exemplary embodiments of paper-based container assemblies are shown in Figures 17–19. In such embodiments, a paper-based disc 50 is molded into an end closure 51 and sealed into 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 shown as cylindrical overall, it should be understood that the container assembly 406 can be molded in other ways. For example, the container assembly 406 may be square, rectangular, oval, elliptical, or any other cross-sectional shape known in the art. In some embodiments, the container assembly 406 may have a height ranging, for example, from about 5 to 40 cm (about 2 to 16 inches).

[0028] • Features of the container assembly While not bound by theory, the combination of untreated materials, systems, and / or assembly methods used in the disclosed container assemblies is expected to give the resulting container assemblies superior characteristics and performance. For example, a combination of a barrier layer and an ionomer layer can provide improved abrasion and / or puncture resistance. Furthermore, in some embodiments, the container assemblies pass accelerated high-altitude testing at approximately 10 inHg for at least approximately 10 minutes. In addition, the seal between the container body 60 and the bottom closure 51 can be left undisturbed during high-speed assembly and results in a better seal by using untreated materials that can enter a paper recycling stream directly.

[0029] In some embodiments, container assemblies resulting from the systems and methods of the present disclosure can provide a shelf life of, for example, in the range of about 6 to 24 months (e.g., less than 1% moisture gain per gram of the contained food product). This excellent performance can be attributed to the low water vapor and / or oxygen permeability of the produced container assembly. For example, in some embodiments, the water vapor permeability of container assembly 406 is about 0.5 g / m³. 2It can be equal to or lower than / day. In other embodiments, the water vapor transmission rate of the container assembly 406 is about 0.15 g / m³. 2 It can be equal to or lower than / day. In yet another embodiment, the water vapor transmission rate of the container assembly 406 is about 0.05 g / m³. 2 This can be equal to or lower than / day. These test results can be said to be from gravimetric measurements taken periodically over the course of a day under ambient conditions of approximately 38°C air and approximately 90% relative humidity. In some embodiments, the oxygen permeability of the container assembly 406 is approximately 0.5 cm³. 3 / m 2 This can be equal to or lower than / day. These test results can be said to be from measurements taken after the container assembly has been exposed to ambient conditions of approximately 22.7°C air and approximately 0% relative humidity.

[0030] In some embodiments, the container assembly 406 is, for example, up to about 1 × 10 -7 The high-barrier packaging can pass helium leak tests (e.g., according to DIN EN 1179 or ASTM E493).

[0031] • Container body Figure 17A is a perspective view of an exemplary container body 60, an upper closure 61, and a paper-based disc 50. In some embodiments, the container body 60 may comprise a rigid cylindrical container body having side walls 63 terminating at a bottom peripheral edge 205 of the open end. In such embodiments, the open end may comprise 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., a bottom closure 51). In some embodiments, the container body 60 may further have a second open end (e.g., an upper end 68) opposite the open bottom end 62, and the second open end may be sealed with a flexible membrane or other closure (e.g., an upper closure 61).

[0032] In some cylindrical embodiments, the container body 60 may have an inner diameter in the range of approximately 3 to 16 cm (approximately 1 to 8 inches). For example, the container body 60 may have an inner diameter of approximately 7.315 cm (approximately 2.880 inches). In some cylindrical embodiments, the container body 60 may have an outer diameter in the range of approximately 3 to 20 cm (approximately 1 to 8 inches). For example, the container body 60 may have an outer diameter of approximately 7.630 cm (approximately 3.004 inches). The open bottom end 62 of the container body 60 may be bounded by a bottom peripheral edge 205 formed by the terminal edges of the side walls 63 that form the body of the container body 60. The side walls 63 may include an inner surface 66 facing inward and an outer surface 64 facing outward from the container body 60. The inner surface 66 may be the product-facing side of the side wall 63 of the container body 60. In some embodiments, the product(s) may be food products, and the internal surface 66 may include a food safety layer, film, liner, and / or coating to help protect the integrity of the food product(s) contained within the container body 60. The external surface 64 may include printing or other applied graphics for labeling and / or advertising the product(s) contained within the container body 60.

[0033] In some embodiments, the side walls 63 of the container body 60 may have a thickness in the range of approximately 0.05 to 0.2 cm (approximately 0.02 to 0.787 inches) (for example, measured from the inner surface 66 to the outer surface 64 of the container body 60). For example, the side walls 63 of the container body 60 may have a thickness of approximately 0.157 cm (0.062 inches).

[0034] As shown in Figure 17C, in some embodiments, the rigid sidewall 63 of the container body 60 may include multiple layers, such as a paper-based layer 60p, a barrier layer 60b, an ionomer layer 60i, and / or a tie layer 60t. Each component layer (paper-based layer 60p, barrier layer 60b, ionomer layer 60i) may consist of a single layer or multiple layers.

[0035] The paper-based layer 60p may include, for example, fiber-based and / or pulpable materials such as corrugated cardboard, paperboard, cupboard stock, and / or lithographic paper. In some embodiments, the paper-based layer 60p of the container body 60 is approximately 200-600 g / m². 2 The total basis weight can be within the range of [value]. In some embodiments, the paper-based layer 60p can have a thermal conductivity in the range of about 0.04 to 0.3 W / (mK).

[0036] The paper-based layer 60p may comprise a single layer or multiple layers bonded together by one or more adhesive tie layers (e.g., tie layer 60t). The tie layer 60t may be applied to one or more paper layers (or any layers discussed herein) using any adhesive tie lamination method known in the art (e.g., wet bond, solvent, solvent-free) and / or by thin-gauge extrusion. As used herein, the terms “tie layer” or “adhesive tie layer” may include adhesives and lamination extrusions.

[0037] In some embodiments, the tie layer 60t may include ionomer resins, 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, co-extrudes, and blends thereof.

[0038] The barrier layer 60b can act as a sufficient barrier against oxygen, moisture, and / or oil (e.g., mineral oil). In one embodiment, the barrier layer 60b may include a metal foil (e.g., aluminum foil) and / or a metallized film (e.g., metallized polyethylene, metallized polypropylene). For example, the barrier layer 60b may include a metal portion 60bm (e.g., an aluminized coating or film) having a thickness of about 0.5 μm (about 0.02 mil) disposed on a film portion 60bf (e.g., polyethylene terephthalate (PET), oriented polypropylene, and / or homopolymer / copolymer deformations, and combinations thereof). In one embodiment, the barrier layer 60b may comprise, for example, a metallized polyethylene terephthalate (MPET) film, an aluminum oxide (AlOx) coated polyethylene terephthalate (PET) film, an aluminum foil, and / or a metallized polybutylene terephthalate (MPBT) film.

[0039] 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 mil). In some embodiments, the barrier layer 60b may have a thermal conductivity in the range of about 30 to 280 W / (mK).

[0040] In one embodiment, the ionomer layer 60i of the container body 60 may include a thermoplastic material suitable for forming a heat seal. In some embodiments, the ionomer layer 60i may be distributed throughout the entire inner surface 66 of the container body 60. In other embodiments, the inner surface 66 of the side wall 63 may include an ionomer layer 60i distributed around the open bottom end 62 and / or open top end 68, although not necessarily throughout the entire inner surface 66 of the container body 60. In some embodiments, the ionomer layer 60i may soften or melt under heat to seal the assembled bottom closure 51 to the container body 60. In some embodiments, the ionomer layer 60i may be abrasion resistant.

[0041] The ionomer layer 60i can be heat-sealable in some embodiments within a temperature range of about 90 to 300°C. In one embodiment, the ionomer layer 60i can have a thermal conductivity in the range of about 0.3 to 0.6 W / (mK). The ionomer layer 60i can include, for example, ionomer-type resins, ionsomers, ionomer polymers, ethylene methacrylic acid (EMAA), ethylene acrylic acid (EMA), ethylene vinyl acetate (EVA), ethylene methyl acrylate (EMA), ethylene-based graft copolymers, and / or copolymers thereof, co-extrusions, and salts of blends (e.g., sodium, zinc). In some embodiments, the ionomer layer 60i can include co-extruded film structures such as ionomer / HDPE co-extrusion, LDPE / HDPE co-extrusion, and similar structures.

[0042] In some embodiments, the ionomer layer 60i is not disposed inside the container body 60, thereby the ionomer layer 50i of the paper-based disc 50 (discussed below) directly seals with the barrier layer 60b of the side wall 63 of the container body 60. Alternatively, the ionomer layer 60i on the inner surface 66 of the container body 60 can be of a different grade than the ionomer layer 50i of the paper-based disc 50, thereby the ionomer layer 50i of the paper-based disc 50 softens or dissolves to form a seal with the container body 60, while the ionomer layer 60i of the container body 60 does not soften or dissolve (for example, due to the higher melting temperature of the ionomer and / or a different grade).

[0043] In one embodiment, moving inward from the outer surface 64 of the container body 60, the paper-based layer 60p of the side wall 63 may comprise an outer ply of paper (e.g., white). The paper-based layer 60p may comprise a coating, label ply, liner, or other material (not shown) on its outer surface 64. In one embodiment, an ionomer material may be disposed on the outer surface 64 of the body 60. In this embodiment, the ionomer material may be heat-sealable or not. In this embodiment, the ionomer material may be heat-sealable or not to any of the materials. Advantageously, the ionomer material applied to the outer surface 64 of the body 60 can increase the strength and abrasion resistance of the side wall 63 of the container body 60. In one embodiment, the paper-based layer 60p may comprise one or more further plies of paper (not shown) (e.g., brown corrugated cardboard, paperboard) directly adjacent to the outer ply of paper. Therefore, the paper-based layer 60p of the side wall 63 of the container body 60 can be made of multiple plies. In some embodiments, a tie layer 60t can connect multiple paper-based layers 60p to each other and / or to a barrier layer 60b. The barrier layer 60b can have a thickness of about 0.0008 cm (about 0.0003 inches). In various embodiments, the barrier layer 60b can consist of one or more layers. For example, as shown in Figure 17C, the barrier layer 60b may comprise a metal portion 60bm (e.g., aluminum oxide) coated on a film portion 60bf (e.g., polyethylene terephthalate (PET) film). In some embodiments, the ionomer layer 60i may include an ethylene acid copolymer having acid groups partially neutralized with zinc or sodium ions. Other configurations are also possible. Any combination of layers (paper, metal, and / or sealant) can be used in the container body of the present disclosure.

[0044] 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.

[0045] ·Bottom closure In some embodiments, the paper-based disc 50 of the present disclosure may be a paper-based end closure. In some embodiments, the paper-based disc 50 may be a generally flat circle sized to overlap around the open bottom end 62 of the container body 60. In some embodiments, the paper-based disc 50 may be pre-pressed and / or pre-formed to have certain structural features (not shown). The pressing and / or pressing process may include feeding the flat closure material into a die press (e.g., a press-forming press) and compressing the material between opposing dies. In any case, in embodiments having a cylindrical container body, the rotational / circumferential orientation of the paper-based disc 50 relative to the container body 60 may be ignored if the container body 60 and the paper-based disc 50 are uniform throughout all rotation angles. However, other shapes (e.g., rectangles, polygons with extended sides) are possible.

[0046] As discussed herein, the inward-facing side surface 54 and the outward-facing side surface 52 of the bottom closure 51 (also referred to herein as the lower surface 54 and upper surface 52 of the paper-based layer 50p, respectively, as shown in the inverted configuration in Figure 2) are referred to in the context of the orientation of the paper-based disc 50 when applied to the open bottom end 62 of the container body 60. Here, as shown in Figure 17, the container body 60 is oriented with respect to the paper-based disc 50 with the bottom peripheral edge 205 of the open bottom end 62 of the container body 60 facing downwards in order to face the inward-facing side surface 54 of the paper-based disc 50. The inward-facing side surface 54 of the disc 50 faces upwards, and the outward-facing side surface 52 of the paper-based disc 50 faces downwards. In embodiments where the open end of the container body 60 is the bottom of the container body 60, the outward-facing side surface 52 of the paper-based disc 50 will therefore face downwards when the container assembly 406 is oriented upright. Other orientations not shown in this disclosure are possible for applying the paper-based disc 50 to the container body 60, but it should be understood that the outward-facing side 52 of the paper-based disc 50 can be a side facing outward (e.g., from the inside of the container outward) when assembled as part of the final product container assembly 406 (e.g., as shown in Figure 19), and the inward-facing side 54 can be a side facing the product(s) inside the container when assembled as part of the final product container assembly 406.

[0047] The paper-based disc 50 may primarily include paper and / or other fiber-based materials, but in one embodiment, the paper-based disc 50 may also include a non-fiber barrier layer made from a metal and / or polymer material. In some embodiments, the disc 50 may comprise multiple layers of paper, barrier material, and / or ionomer material.

[0048] As shown in Figure 17D, in some embodiments, the paper-based disc 50 may include, for example, a paper-based layer 50p, a barrier layer 50b, an ionomer layer 50i, and / or a tie layer 50t. The paper-based layer 50p can form the outward-facing side surface 52 of the paper-based disc 50. The tie layer 50t can adhere the paper-based layer 50p to the barrier layer 50b. The ionomer layer 50i may be disposed adjacent to the barrier layer 50b (facing the paper-based layer 50p) to form the inward-facing side surface 54 of the paper-based disc 50.

[0049] The paper-based layer 50p may include, for example, fiber-based and / or pulpable materials such as corrugated cardboard, paperboard, cupboard stock, and / or lithographic paper. For example, in some embodiments, the paper-based disc 50 may be cupboard stock 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-based layer 50p may comprise a single layer or multiple layers bonded together by one or more adhesive tie layers (e.g., tie layer 50t).

[0050] As discussed above with respect to the container body 60, the tie layer 50t can contain any material and can be applied by any method known in the art. In some embodiments, the tie layer 50t may contain ionomer resins, 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, co-extrudes, and blends thereof.

[0051] The barrier layer 50b can act as a sufficient barrier against oxygen, moisture, and / or mineral oil. The barrier layer 50b may include a metal foil (e.g., aluminum foil) and / or a metallized film (e.g., metallized polyethylene, metallized polypropylene). For example, the barrier layer 50b may include a metal portion 50bm (e.g., an aluminized 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 deformations, and combinations thereof). In some embodiments, the barrier layer 50b may comprise, for example, a metallized polyethylene terephthalate (MPET) film, an aluminum oxide (AlOx) coated polyethylene terephthalate (PET) film, aluminum foil, and / or a metallized polybutylene terephthalate (MPBT) film.

[0052] 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).

[0053] The ionomer layer 50i of the paper-based disc 50 may include a thermoplastic material suitable for forming a heat seal. The thermoplastic material can be heat-sealable within a temperature range of about 90 to 300°C. The thermoplastic material of the ionomer layer 50i may include, for example, ionomer-type resins, ionsomers, ionomer polymers, ethylene methacrylic acid (EMAA), ethylene acrylic acid (EAA), ethylene vinyl acetate (EVA), ethylene methyl acrylate (EMA), ethylene-based graft copolymers, and / or copolymers, co-extrusions, and salts of blends thereof (e.g., sodium, zinc). In some embodiments, the thermoplastic material may include co-extruded film structures such as ionomer / HDPE co-extrusion, LDPE / HDPE co-extrusion, and similar structures. In some embodiments, the ionomer layer 50i may be abrasion resistant.

[0054] In certain embodiments, the paper base layer 50p of the paper base disc 50 may comprise two plies of paper (not shown). In some embodiments, the tie layer 50t may adhere one or more paper base layers 50p to each other and / or to the barrier layer 50b. In one embodiment, the ionomer layer 50i may include an ethylene acid copolymer having acid groups partially neutralized with zinc or sodium ions. The ionomer layer 50i may be disposed on the barrier layer 50b and / or on the outward-facing side surface 52 of the paper base disc 50. Other configurations are also possible.

[0055] In embodiments where the barrier layer 50b is a single layer of 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 be used for induction heating or heat transfer heating, causing the heat-sealable material to soften and / or melt, thereby sealing the bottom closure 51 to the container body 60.

[0056] 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 thermal seal between the container body 60 and the bottom closure 51. In some embodiments, the ionomer layer 60i of the container body 60 and / or the ionomer layer 50i of the bottom closure 51 may have a compatible chemical (e.g., the same or similar grade of ionomer) so that an acceptable seal can be formed when heat-sealed 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 a compatible chemical (e.g., the same or similar grade of ionomer) so that an acceptable seal can be formed when heat-sealed during assembly.

[0057] In some embodiments, the ionomer layer 50i may be disposed on the inward-facing side surface 54 of the paper-based disc 50 only around the outer circumference of the disc 50 (e.g., within the second deformed surface 55) where the paper-based disc 50 is configured to contact the inner surface 66 of the container body 60. In other embodiments, the ionomer layer 50i may be applied to the entire inward-facing side surface of the paper-based disc 50 (e.g., the lower surface 54 in Figure 2).

[0058] In some embodiments, after insertion, the disc 50 may have a second deformed surface 55 (as shown, for example, in Figure 18), which may be configured to press against the inner surface 66 of the side wall 63 of the container body 60 when inserted into the open bottom end 62 of the container body 60. The seal area between the second deformed surface 55 of the bottom closure 51 and the inner surface 66 of the container body 60 may be sized to provide an airtight seal. The seal area may also be sufficient to allow any wrinkles that could result in a channel to be smoothed out or minimized. In some embodiments, the seal area is approximately 5–15 cm 2 (approximately 1-2 inches) 2The range can be within ). For example, the seal area is approximately 11.9 cm. 2 (Approximately 1.85 inches) 2 ) can be done as follows.

[0059] Advantageously, in some embodiments, the bonding thickness between the ionomer layer 50i of the bottom closure 51 and the ionomer layer 60i of the container body 60 can be sufficiently large so that any food product and / or other debris present between the ionomer layers 50i and 60i can be captured and / or completely sealed without reducing 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 8 to 50 μm. In some embodiments, the thickness of the ionomer layer 60i of the side wall 63 of the container body 60 can be in the range of 2 to 40 μm.

[0060] In some embodiments, the airtight seal formed between the ionomer layer 50i of the bottom closure 51 and the ionomer layer 60i of the container body 60 can have a leakage rate smaller than or equivalent to a hole with a diameter in the range of about 10 to 300 μm, as measured, for example, by the vacuum decay method (e.g., according to DIN EN 1779 / ASTM test method E493). The vacuum decay method can determine the equivalent hole diameter of the airtight seal by coating the unsealed portion of the container assembly 406 with a leak-inhibiting material. Other test methods can be utilized, for example, including foam leak, blue dye, and / or helium leak tests.

[0061] As shown in Figure 18, the bottom closure portion 51 can be recessed inward from the container body 60, thereby separating the first deformed surface 53 of the bottom closure portion 51 from the bottom peripheral edge 205 of the container body 60 (for example, recessed within it). The bottom closure portion 51 is recessed inward from the container body 60 by a predetermined recess distance "D r It can be indented at "D". Indentation distance "D rThe recess distance "D" can be measured from the bottom peripheral edge 205 of the container body 60 to the first deformed surface 53 of the bottom closing portion 51. In some embodiments, the recess distance "D" can be measured from the bottom peripheral edge 205 of the container body 60 to the first deformed surface 53 of the bottom closing portion 51. r The "deep recess distance" can be within the range of approximately 0.2 to 2 cm (approximately 0.08 to 1.2 inches). r The recess distance "Dr" can be approximately 0.7 cm (approximately 0.275 inches). The recess distance "Dr" can be configured to minimize any protrusion of the first deformed surface 53 of the bottom seal 51 passing through the bottom peripheral edge 205 of the container body 60 when the container assembly 406 is subjected to a higher pressure difference between the inside of the container and the external environment. For example, exemplary tests have shown that the depth of the recess distance "Dr" of the bottom seal 51 can ensure that the bottom seal 51 does not over-expand passing through the bottom peripheral edge 205 of the container body 60 at pressure differences exceeding approximately 10 inHg (≒34 kPa). These test results can be based on measurements made using various pressure difference methods (e.g., according to ASTM test method D6653). Thus, the recess distance "Dr", combined with the integrity of the airtight seal, can help prevent locking and / or other problems of the bottom seal 51.

[0062] In some embodiments, the paper-based disc 50 has a density of approximately 1 to 25 g / cm². 3 It can have a density of . In some embodiments, the paper-based disk 50 can have an elastic modulus of about 10 to 35 GPa. In some embodiments, the paper-based layer 50p can have a thermal conductivity in the range of about 0.04 to 0.3 W / (mK). The paper-based layer 50p of the bottom closure portion 51 has a density of about 130 to 450 g / m 2 It can have a total basis within the range.

[0063] ·Top closure As shown in Figure 17A, the upper closure portion 61 can be a flat sheet molded (for example, as a disc) to fit snugly onto the open upper end 68 of the container body 60. The upper closure portion 61 can have an outward-facing side surface 610 (shown facing upward in Figure 17A) and an inward-facing side surface 611 (shown facing downward in Figure 17A). When the upper closure portion 61 is applied to the upper rim of the container body 60, the inward-facing side surface 611 is configured to seal the upper rim of the container body 60 and face inward into the container.

[0064] As shown in Figure 17B, in some embodiments, the upper closure 61 may include multiple layers, such as a paper-based layer 61p, a barrier layer 61b, a peelable sealant layer 61i (which may be an ionomer material in some embodiments), and / or a tie layer 61t. The paper-based layer 61p may form the outward-facing side surface 610 of the upper closure 61. The tie layer 61t may adhere the paper-based layer 61p to the barrier layer 61b. The peelable sealant layer 61i may be adhered to or coated on the barrier layer 61b to form the inward-facing side surface 611 of the upper closure 61.

[0065] The paper-based layer 61p may include, for example, a fiber-based and / or pulpable material such as corrugated cardboard, paperboard, cupboard stock, and / or lithographic paper. In some embodiments, the paper-based layer 61p may have a thermal conductivity in the range of about 0.04 to 0.3 W / (mK). The paper-based layer 61p may consist of a single layer or multiple layers bonded together by one or more adhesive tie layers (e.g., tie layer 61t).

[0066] As described above, the tie layer 61t can utilize any adhesive tie composition or method known in the art. In some embodiments, the tie layer 61t may include ionomer resins, 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, co-extrusions, and blends thereof.

[0067] The barrier layer 61b can act as a sufficient barrier against oxygen, moisture, and / or mineral oil. The barrier layer 61b may include a metal foil (e.g., aluminum foil) and / or a metallized film (e.g., metallized polyethylene, metallized polypropylene). For example, the barrier layer 61b may include a metal portion 61bm (e.g., an aluminized coating or film) having a thickness of about 0.5 μm disposed on a film portion 61bf (e.g., polyethylene terephthalate (PET), oriented polypropylene, and / or homopolymer / copolymer deformations, and combinations thereof). The barrier layer 61b may comprise a metallized film such as, for example, a metallized polyethylene terephthalate (MPET) film, an aluminum oxide (AlOx) coated polyethylene terephthalate (PET) film, an aluminum coated polyethylene terephthalate (PET) film, and / or a metallized polybutylene terephthalate (MPBT) film. In some embodiments, the barrier layer 61b may include vacuum-deposited aluminum adjacent to the peelable sealant layer 61i.

[0068] 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).

[0069] The peelable sealant layer 61i may include any peelable sealant known in the art for fixing the upper 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., SURLYN® polymer). In some embodiments, the peelable sealant layer 61i of the upper closure 61 may have a thickness in the range of about 10 to 50 μm.

[0070] The upper closure portion 61 can be sealed to the upper rim of the container body 60 by a peelable sealant layer 61i. In some embodiments, the peelable sealant layer 61i can be modified with a polymer material to promote further adhesion to the container body 60. In certain embodiments, the peelable sealant layer 61i may comprise a resealable material, thereby making the container resealable.

[0071] The peelable sealant layer 61i can provide an opening mechanism that is easy for consumers to use. In some embodiments, the upper closure 61 can be molded to facilitate removal from the container assembly 406, for example, by a pull tab. In some embodiments, an overcap (not shown) can be configured for removal and reattachment to the container body 60 before and after the membrane seal is removed, respectively.

[0072] • Exemplary embodiments In some embodiments, the side wall 63 of the container body 60 may comprise a paper-based layer 60p attached to a barrier layer 60b of metallized polyethylene terephthalate (MPET) film by an adhesive tie layer 60t. An ionomer layer 60i may be formed adjacent to the barrier layer 60b.

[0073] In some embodiments, the side walls 63 of the container body 60 may comprise a paper-based layer 60p attached to a barrier layer 60b of an aluminum oxide (AlOx) coated polyethylene terephthalate (PET) film by an adhesive tie layer 60t. In this embodiment, the film may be transparent. An ionomer layer 60i may be formed adjacent to and attached to the barrier layer 60b.

[0074] In some embodiments, the side walls 63 of the container body 60 may comprise a paper-based layer 60p attached to an aluminum foil barrier layer 60b by an adhesive tie layer 60t. An ionomer layer 60i may be formed adjacent to and attached to the barrier layer 60b. In this embodiment, the ionomer may be applied as a film rather than a coating.

[0075] In some embodiments, the side wall 63 of the container body 60 may comprise a paper-based layer 60p attached to a barrier layer 60b of a metallized polybutylene terephthalate (MPBT) film by an adhesive tie layer 60t. An ionomer layer 60i may be formed adjacent to and attached to the barrier layer 60b.

[0076] In some embodiments, the paper-based disc 50 may comprise a paper-based cup stock layer 50p attached to a barrier layer 50b of a metallized polyethylene terephthalate (MPET) film by an adhesive tie layer 50t. An ionomer layer 50i may be formed adjacent to the barrier layer 50b.

[0077] In some embodiments, the paper-based disc 50 may comprise a paper-based cup stock layer 50p attached to a barrier layer 50b of an aluminum oxide (AlOx) coated polyethylene terephthalate (PET) film by an adhesive tie layer 50t. An ionomer layer 50i may be formed adjacent to and attached to the barrier layer 50b.

[0078] In some embodiments, the paper-based disc 50 may comprise a paper-based cup stock layer 50p attached to an aluminum foil barrier layer 50b by an adhesive tie layer 50t. An ionomer layer 50i may be formed adjacent to and attached to the barrier layer 50b.

[0079] In some embodiments, the paper-based disc 50 may comprise a paper-based cup stock layer 50p attached to a barrier layer 50b of a metallized polybutylene terephthalate (MPBT) film by an adhesive tie layer 50t. An ionomer layer 50i may be formed adjacent to and attached to the barrier layer 50b.

[0080] In some embodiments, the upper closure portion 61 may comprise a paper-based layer 61p attached to the barrier layer 61b of a metallized polyethylene terephthalate (MPET) film by an adhesive tie layer 61t. A peelable sealant layer 61i may be formed adjacent to the barrier layer 61b.

[0081] In some embodiments, the upper closure portion 61 may comprise a paper-based layer 61p attached to a barrier layer 61b of an aluminum oxide (AlOx) coated polyethylene terephthalate (PET) film by an adhesive tie layer 61t. A peelable sealant layer 61i may be formed adjacent to and attached to the barrier layer 61b.

[0082] In some embodiments, the upper closure portion 61 may comprise a paper-based layer 61p attached to the barrier layer 61b of an aluminum-coated polyethylene terephthalate (PET) film by an adhesive tie layer 61t. A peelable sealant layer 61i may be formed adjacent to and attached to the barrier layer 61b.

[0083] In some embodiments, the upper closure portion 61 may comprise a paper-based layer 61p attached to the barrier layer 61b of a metallized polybutylene terephthalate (MPBT) film by an adhesive tie layer 61t. A peelable sealant layer 61i may be formed adjacent to and attached to the barrier layer 61b.

[0084] Below, exemplary sealing systems for sealing the paper-based end closures described herein to the paper-based container bodies described herein are described in more detail.

[0085] "Sealing System" Referring to Figures 1 to 11, the containers described herein can be formed using the following sealing system 100 and / or according to the following methods. In some embodiments, the paper-based bottom can begin as a sheet or a disc. For example, a composite sheet or paper-based disc 50 can be molded to fit into a composite container body 60 by a mandrel assembly 200, a die assembly 300, and a container support assembly (not shown) that work together. The mandrel assembly 200 can be used to press or press the paper-based disc 50 to form the composite bottom 51 (for example, shown in Figures 10-11).

[0086] The mandrel assembly 200 may include an outer mandrel 210 (sometimes called a “downholder” because of its purpose of holding the disc 50 downward relative to the die assembly 300) and an inner mandrel 220 (sometimes called a “sealing punch” because of its purpose of punch-drawing the disc 50 into the container 60 and sealing the disc 50 against the sidewall of the container 60). The outer mandrel 210 and the inner mandrel 220 can each move independently along the Y-axis. The inner mandrel 220 can be translated relative to the outer mandrel 210 to form the paper-based disc 50 into the bottom closure 51. Furthermore, the die assembly 300 can work in conjunction with the mandrel assembly 200 to form the paper-based disc 50 into the bottom closure 51 and insert the closure 51 into the bottom end 62 of the composite body 60 simultaneously or nearly simultaneously. The die assembly 300 may generally comprise a die 80 having an upper surface 97, a positioning portion 90, a die opening 98, and a sealing member(s) 40 also known as a die bushing. The tube assembly may be configured to maintain and move the composite body 60 relative to the mandrel assembly 200 and the die assembly 300. For example, the tube assembly may move the composite body laterally and / or vertically along the axes of the mandrel assembly 200 and the die assembly 300 to align the container body 60 with the axes of the mandrel assembly 200 and the die assembly 300.

[0087] In some embodiments, the mandrel assembly 200, the die assembly 300, and the container support assembly can be aligned along the Y-axis, at least during the method described herein, so that the paper-based disc 50 can be biased through the die opening 98 by the inner mandrel 220 and inserted into the bottom end 62 of the composite body 60, which is held by the tube support member.

[0088] "Die assembly" The die assembly 300 may be configured to house and hold the paper-based disc 50 prior to its insertion into the container body 60 through the die opening 98. In some embodiments, the disc 50 is received from a separate disc feeding assembly (not shown). In one embodiment, the die assembly 300 may be configured to engage with or otherwise align with the feeding assembly. For example, the die 80 may have a notch, ridge, or other alignment feature 302 at its upper end, which allows the die 80 to engage with, align with, or house a corresponding mechanical element of the feeding assembly. This allows for proper placement of the disc 50 within the die 80.

[0089] More specifically, the die assembly 300 may include a die 80 (i.e., a die bush ring) having a positioning portion 90 (i.e., a collet sheet) configured to receive and align the paper-based disc 50 within the die 80 prior to forming the disc 50 into a recessed bottom end closure 51. The positioning portion 90 is positioned adjacent to the die opening 98 so as to align the paper-based disc 50 with the die opening 98.

[0090] The positioning portion 90 may include an inclined surface 96 that connects the upper surface 97 of the die 80 to the side wall 94 of the positioning portion 90. The inclined surface 96 may be inclined downward toward the axis of the die opening 98 and the die assembly 300. In some embodiments, the inclined surface 96 may allow the disk 50 to be guided into the positioning portion 90.

[0091] In some embodiments, the side walls 94 of the positioning portion 90 can be vertical or substantially vertical. In some embodiments, the side walls 94 of the positioning portion 90 can be longer than the thickness of the disk 50. In some embodiments, the outer diameter of the side walls 94 of the positioning portion 90 can be substantially similar to the diameter of the disk 50. In another embodiment, the outer diameter of the side walls 94 of the positioning portion 90 can be slightly larger than the diameter of the disk 50.

[0092] In some embodiments, the inclined surface 96 of the positioning portion 90 may have a larger perimeter closest to the upper surface 97 of the die 80 and a smaller perimeter closest to the side wall 94. In some embodiments, the perimeter of the outer edge of the inclined surface 96 of the positioning portion 90 may be larger than that of the paper base disc 50. The inclined surface 96 may be tapered downward to allow gravity assistance for the alignment of the paper base disc 50 within the positioning portion 90. Once seated, the paper base disc 50 may be positioned adjacent to the disc support surface 92 and the side wall 94 of the positioning portion 90. In some embodiments, the disc support surface 92 and the side wall 94 of the positioning portion 90 connect at a 90-degree angle or substantially at a 90-degree angle. In some embodiments, the disc support surface 92 may be horizontal or substantially horizontal. In some embodiments, the seated disc 50 is positioned such that its lower surface 54 is adjacent to (e.g., seated on) the disc support surface 92 (e.g., as shown in Figure 2). In some embodiments, the seated disc 50 is positioned such that its thickness is adjacent to the side wall 94 of the positioning portion 90.

[0093] In some embodiments, the inner circumference of the disk support surface 92 is smaller than the perimeter of the disk 50. In some embodiments, the inner circumference of the disk support surface 92 is adjacent to the die opening 98. In some embodiments, the disk support surface 92 is positioned adjacent to the inner surface 99 of the die opening. In some embodiments, the inner surface 99 of the die opening can be vertical or substantially vertical. In some embodiments, the disk support surface 92 is positioned perpendicular or nearly perpendicular to the inner surface 99 of the die opening.

[0094] During use, the disc 50 is inserted into the die assembly 300, positioned within the positioning portion 90, and seated on the disc support surface 92. In some embodiments, vacuum pressure is applied to the paper-based disc 50 from below to align the paper-based disc 50 within the positioning portion 90 of the die 80.

[0095] The die opening 98 is shown as having a substantially circular cross-section, but the die opening 98 may have a cross-section that is substantially circular, triangular, rectangular, quadrilateral, pentagonal, hexagonal, or elliptical. In some embodiments, the die opening 98 may be configured to receive the inner mandrel 220, which will be discussed below. In some embodiments, the die opening 98 may have a cross-section that is substantially similar to the cross-section of the inner mandrel 220.

[0096] "Gas exhaust assembly" In some embodiments, a gas exhaust assembly 400 is included in the system. In some embodiments, the gas exhaust assembly 400 is at least partially disposed within the die assembly 300. The gas exhaust assembly 400 may be designed to draw or vacuum a specified volume of gas from inside the container prior to or simultaneously with the insertion of the disc 50 into the container body 60.

[0097] The gas exhaust assembly 400 may include one or more valves 420 integrated within the die assembly 300. In some embodiments, the valves 420 are located within the die 80. More specifically, there may be ports or bores 82 passing through the interior of the die 80, connecting the outer surface 89 of the die to an internal channel 430. The valves 420 may be located within the ports or bores 82. The ports or bores 82 may connect the internal channel 430 to the upper surface of the die, the lower surface of the die, or the side / lateral surface of the die. That is, the valves 420 may extend laterally within the die and / or vertically upward or downward within the die.

[0098] In some embodiments, the bore 82 can be configured horizontally throughout within the die 80. In some embodiments, the bore 82 can be located within the upper section 87 of the die 80. In some embodiments, the bore 82 and at least a portion of the valve 420 can be located above the channel 430. In some embodiments, the valve 420 can have an opening facing downward within the bore 82 toward the channel 430; that is, a direct gas communication can exist between the valve 420 and the channel 430. In some embodiments, air can be drawn from the channel 430 by the valve 420.

[0099] In some embodiments, the valve 420 may be any suction or vacuum valve known in the art. In some embodiments, the valve 420 may have an open position and a closed position. In the open position, the valve 420 may allow gas exchange, and in the closed position, the valve 420 may not allow gas exchange. In some embodiments, the valve 420 may be an elongated tube or pipe extending horizontally or vertically throughout the upper section 87 of the die 80, with a through-hole 422 disposed at its proximal end (relative to the interior of the die 80). In this embodiment, the through-hole 422 may be disposed adjacent to the internal channel 430. In some embodiments, the through-hole 422 may be disposed just above at least a portion of the internal channel 430. In some embodiments, a manifold connection 426 may connect the bore 82 and the channel 430. In some embodiments, the through-hole 422 may connect to and communicate with the internal channel 430. The through-hole 422 can take any shape known in the art. In one exemplary embodiment, the through-hole 422 is circular, but it can be oval, square, rectangular, or any other shape known in the art.

[0100] The internal channel 430 can be hollow in some embodiments. The channel 430 can be molded or configured as desired, but in some embodiments, its cross-section can be square, rectangular, circular, or semicircular. In some embodiments, the channel 430 can be disposed circumferentially or partially circumferentially within the die 80. In certain embodiments, the channel 430 can comprise a recessed portion of the upper section 87 of the die 80. In this embodiment, the channel 430 can comprise at least one side wall 432. In some embodiments, the channel 430 can comprise two opposing side walls 432, 434 and an upper wall 436. In some embodiments, the bottom wall of the channel 430 can comprise the upper surface 42 of the sealing member(s) 40. That is, when the upper section 87 of the die 80 is separated from the sealing member(s) 40, the channel 430 will have an open bottom end.

[0101] The channel 430 may have one or more channel openings 440 disposed between the channel 430 and the inner surface 99 of the die opening. In some embodiments, the channel openings 440 are disposed laterally inward of the channel 430, closer to the central axis of the container 60 to be sealed. In some embodiments, the channel openings 440 can connect the channel 430 to the interior of the die 80, thereby allowing gas to be exchanged between the channel 430 and the interior of the die 80. That is, the channel openings 440 can provide gas communication between the channel 430 and the interior of the die 80. The channel openings 440 can be molded as desired, but in some embodiments, the cross-section can be square, rectangular, circular, oval, or semicircular. In certain embodiments, the channel openings 440 into the interior of the die 80 can 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 exhausted.

[0102] In one embodiment, the channel 430 may comprise a single channel opening 440. The channel opening 440 may extend circumferentially between the channel 430 and the inner surface 99 of the die opening. In one embodiment, the channel opening 440 may extend circumferentially partially or completely around the die 80.

[0103] In other embodiments, the channel 430 may comprise a plurality of channel openings 440. For example, six channel openings 440 may be utilized in some embodiments. The channel openings 440 may vary in size from one another. The channel openings 440 may be equidistant from one another or distributed in any other manner known in the art. In one embodiment, the channel openings 440 may be located on only one side of the die assembly.

[0104] In some embodiments, the channel opening 440 can be located beneath the positioning portion 90 of the die 80. More specifically, the channel opening 440 can be located beneath the disk support surface 92 of the positioning portion 90. Thus, when the disk 50 is in a predetermined position before insertion into the container 60, the channel opening 440 can be located beneath the disk 50 (see Figure 33). In some embodiments, the channel opening 440 can be located within the inner surface 99 of the die opening. In some embodiments, the channel 430 and the channel opening 440 can be located adjacent to the bottom surface 85 of the upper section 87 of the die 80.

[0105] In some embodiments, the channel 430 is completely circumferential within the die 80. In other embodiments, the channel 430 is partially circumferential within the die 80. In some embodiments, the channel 430 comprises multiple discontinuous channels within the die 80.

[0106] In some embodiments, the channel 430 can seal off access to the atmosphere once the disk 50 is positioned within the positioning portion 90 of the die 80. In some embodiments, a vertically extending portion 212 (discussed below) of the outer mandrel 210 restrains the paper-based disk 50 during bottom end formation (for example, as shown in Figure 4). In some embodiments, the pressure exerted by the vertically extending portion 212 of the outer mandrel 210 on the paper-based disk 50 can seal off the channel 430 from access to the atmosphere. At such a point, the gas exhaust assembly 400 can draw or vacuum gas from inside the container, as further described herein.

[0107] In some embodiments, the valve 420 can be connected via piping or tubing 424 to a side channel pump, blower or fan, or vacuum pump (not shown). Any side channel pump, vacuum pump, or suction device known in the art can be used. The valve 420 can be connected to the tubing via a coupling connector 410. The coupling connector 410 can be integrated with the die 80. Alternatively, the coupling connector 410 can be screwed into the die 80. That is, threads can be present on at least a portion of the inner surface of the bore 82, which can align and interconnect with threads on the outer surface of the coupling connector 410.

[0108] The coupling connector 410 may have a distal end 412 configured to connect to a hose or tube. The connector may be a snap-fit, twist-fit, or any other configuration known in the art. In some embodiments, the coupling connector 410 may include an elbow joint, allowing the tubing to be mounted and suspended vertically, horizontally, or in any other position. In some embodiments, the coupling connector 410 may rotate around its axis to prevent tangling of the tubing.

[0109] In some embodiments, the exhaust assembly 400 comprises a plurality of valves 420, coupling connections 410, and tubing. In a particular embodiment, the exhaust assembly 400 comprises three valves 420 and three corresponding coupling connections 410 and tubing. 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, there are three valves 420, each disposed within 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, the sealing member 40 may comprise a single, integrated sealing member 40, but may have two or three valves 420 disposed within it. In some embodiments, a certain number of channel openings 440 are disposed within each valve section 414, 416, 418. For example, three, four, five, or six channel openings 440 may be disposed within each valve section.

[0110] In some embodiments, the gas exhaust mechanism operates within a depressurized vacuum chamber. In other embodiments, however, the gas exhaust mechanism operates under standard atmospheric conditions without using a vacuum chamber.

[0111] "Mandrel Assembly" As described above, the mandrel assembly 200 may comprise an inner mandrel 220 and an outer mandrel 210. The inner mandrel 220 and the outer mandrel 210 may be translated separately from each other. In one embodiment, the inner mandrel 220 and the outer mandrel 210 may be translated parallel to each other, and it may be perpendicular, but not necessarily perpendicular. For example, the system may provide an inner mandrel 220 and an outer mandrel 210 that are translated horizontally or angularly.

[0112] In one embodiment, the inner mandrel 220 can move a first distance and the outer mandrel 210 can move a second distance, with the first and second distances being different from each other. Similarly, the inner mandrel 220 can move in a first time and the outer mandrel 210 can move in a second time, with the first and second times being different from each other. In some embodiments, the inner mandrel 220 and the outer mandrel 210 can move together during a first period. In some embodiments, the inner mandrel 220 can have a first extension length and the outer mandrel 210 can have a second extension length, with the first and second extension lengths being different from each other. In one embodiment, the outer mandrel 210 can move together with both the inner mandrel 220 and the ejector 30 until the mandrel assembly 200 contacts the die assembly 300. In one embodiment, the outer mandrel 220, the inner mandrel 210, and the ejector 30 each simultaneously contact the die assembly 300.

[0113] The outer mandrel 210 can be cylindrical overall in some embodiments. In another embodiment, the outer mandrel 210 may comprise a vertically extending portion 212 (e.g., downward) and a radially outward-facing flange 214. The vertically extending portion 212 can be perforated and / or have a through hole 216 disposed inside in some embodiments. In some embodiments, the vertically extending portion 212 and the radially outward-facing flange 214 can be joined at a right angle or nearly a right angle. The flange 214 may be absent in some embodiments.

[0114] In some embodiments, the vertically extending portion 212 of the outer mandrel 210 can be sized to fit within the inner circumference of the positioning portion 90. In some embodiments, the vertically extending portion 212 of the outer mandrel 210 has a perimeter longer than the perimeter of the die opening 98, thereby preventing the vertically extending portion 212 from extending into the die opening. More specifically, the vertically extending portion 212 of the outer mandrel 210 can be sized and / or configured so 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 vertically extending portion 212 of the outer mandrel 210 can be extended after the disk 50 has seated within the positioning portion 90 (for example, as shown in Figure 4), and can be configured to secure the disk 50 in place.

[0115] As shown in Figure 12, the inner mandrel 220 can be cylindrical overall. In some embodiments, the inner mandrel 220 can be sized to fit onto the inner circumference of the vertically extending portion 212 of the outer mandrel 210. In some embodiments, the inner mandrel 220 can be configured to extend vertically downward beyond the vertically extending portion 212 of the outer mandrel 210. In this embodiment, once the disc 50 is seated within the positioning portion 90 and constrained by the fully extended vertically extending portion 212 of the outer mandrel 210, the inner mandrel 220 can continue to move vertically downward (for example, as shown in Figure 6), extending beyond the base of the vertically extending portion 212 of the outer mandrel 210, pressing / biasing the disc 50 into the open end 62 of the container body 60.

[0116] The inner mandrel 220 may, in some embodiments (for example, as shown in Figure 12), comprise a first mandrel surface 222 adjacent to a second mandrel surface 224, which together are configured to insert and form a paper-based disc 50. In some embodiments, the first mandrel surface 222 may be coupled to the second mandrel surface 224 at a right angle or nearly right angle. In some embodiments, the first mandrel surface 222 may be horizontal or substantially horizontal and may be positioned adjacent to the upper surface of the disc 50. In some embodiments, the second mandrel surface 224 may be vertical or substantially vertical and may be configured adjacent to the inner surface of a vertically extending portion 212 of the outer mandrel 210 as the inner mandrel 220 passes through the outer mandrel 210. That is, the perimeter of the second mandrel surface 224 may be smaller than the inner circumference of the vertically extending portion 212 of the outer mandrel 210.

[0117] Although the first mandrel surface 222 and the second mandrel surface 224 are shown in the figure as substantially flat (horizontal and vertical), it should be noted that the first mandrel surface 222 and the second mandrel surface 224 can be curved, contoured, or shaped. The inner mandrel 220 may further comprise a shaped portion disposed between the first mandrel surface 222 and the second mandrel surface 224. The shaped portion can be curved, chamfered, or have any other contour. Although the inner mandrel 220 is shown as having a substantially circular cross-section, it should be noted that the inner mandrel 220 may have a cross-section that is substantially circular, triangular, rectangular, quadrilateral, pentagonal, hexagonal, or elliptical.

[0118] As the inner mandrel 220 pushes the disc 50 into the container body 60 (for example, as shown in Figures 5-6), the disc 50 is released from between the outer mandrel 210 and the positioning portion 90 of the die assembly 300. The central portion 56 of the disc 50 can be pushed downward through the die opening 98 into the open bottom end 62 of the container body 60, thereby keeping the central portion 56 (first deformed surface 53) 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 nearly a right angle, shown as the second deformed surface 55 in Figure 11. In such embodiments, the peripheral portion 58 of the disc 50 (which becomes the second deformed surface 55) can be forced through the die opening 98 to be adjacent to the second mandrel surface 224. The resulting second deformed surface 55 (formerly the peripheral portion 58) of the disk 50 can be positioned perpendicularly or nearly perpendicularly adjacent to the inner surface 66 of the container body 60 at the open bottom end 62.

[0119] The disc 50 can be pressed into the container body 60 by any distance deemed practical in the art. In some embodiments, the disc 50 becomes a recessed composite bottom 51 (as shown, for example, in Figure 11). In some embodiments, the peripheral edge 57 of the disc 50 is coplanar with the edge of the side wall of the container body 60. In other embodiments, the peripheral edge 57 of the disc 50 is positioned inward with respect to the peripheral edge of the side wall 63 of the container body 60. In some embodiments, the first deformed surface 53 and the second deformed surface 55 are joined at a right angle or nearly right angle within the container body 60.

[0120] In some embodiments, the mandrel heater may be configured to heat the first mandrel surface 222 and / or the 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 comprise an insulating portion formed from an insulating material configured to reduce heat transfer.

[0121] "Sealing member" The sealing member(s) 40 can be configured to provide heat and pressure for thermal sealing. The sealing member(s) 40 can be positionable between a sealing position (e.g., shown in Figures 1-6) and an open position (e.g., shown in Figures 7-11). When in the sealing position, the sealing member(s) 40 is in contact with the outer surface 64 of the container body 60, and when in the open position, the sealing member(s) 40 is not in contact with the container body 60. In one embodiment, the sealing member(s) 40 includes a compartmentalized clamping bracket (see figures for details).

[0122] In other embodiments, the sealing member 40 comprises a non-divided tightening ring (see Figures 20-24). Figure 20 shows the system of the present invention having a non-divided tightening ring, and the system is in its initial state. In Figure 21, the system moves to a position where the disc is tightened in place. In Figure 22, the system moves to the sealing position. Figure 23 shows the removal of the sealing punch while the ejector supports the paper bottom in place. Finally, Figure 24 shows the ejector moving away from the container. Figures 20-26 further show the connections to the exhaust line. In this embodiment, the sealing member may comprise a static die bushing ring. This type of sealing member can be particularly useful in ready-to-eat food processing equipment where food safety is of particular interest.

[0123] In several embodiments, for example, in the embodiment of a compartmentalized clamping bracket, the sealing member(s) 40 can be rotatably coupled to the die assembly 300. The sealing member(s) 40 can be molded complementaryly to one another so that when the sealing member(s) 40 are in the sealing position, they substantially surround the workpiece in a puzzle-like manner. In other embodiments, the sealing member(s) 40 may comprise a single, integrated member (i.e., a closing ring) that surrounds the container body 60 when the container is in a predetermined position. When sealing a paper-based disc 50 to the composite body 60, the sealing member(s) 40 can compress the bottom edge 62 of the composite body 60 along the substantially complete outer circumference of the outer surface 64. When the composite body 60 has a substantially circular cross-section, the periphery of the composite body 60 can be compressed substantially evenly by the sealing member(s) 40. In some embodiments, there are three sealing member(s) 40. In other embodiments, there is one sealing member(s) 40 (i.e., a non-compartmentalized clamping ring). However, it should be noted that any number of sealing members 40 can be used. For example, the sealing system may comprise about 1 to about 10 sealing members 40. Furthermore, each sealing member 40 may cover substantially equal or substantially unequal portions of the composite body.

[0124] The sealing members (multiple) 40 can be used to compress and heat the container body in order to perform a heat sealing operation. Each sealing member 40 can provide conductive heating of up to approximately 300°C to the workpiece. Furthermore, the sealing members (multiple) 40 can apply a pressure of up to approximately 30 MPa to the workpiece. The sealing members (multiple) 40 can be adjacent to each other.

[0125] Since the sealing member(s) 40 are in contact with 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(s) 40. After compression and heat have been applied for a sufficient residence time, the sealing member(s) 40 can separate from the bottom end 62 of the container body 60, thereby so that the sealing member(s) 40 are no longer in contact with the container body 60 after the residence time has ended (for example, as shown in Figure 7).

[0126] "Ejector" 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 translated outward, away from the die assembly 300, prior to the movement of the inner mandrel 220. In other embodiments, the outer mandrel 210 and the inner mandrel 220 are translated outward, away from the die assembly 300 simultaneously.

[0127] In some embodiments, the ejector 30 is located inside the inner mandrel 220 to assist in the removal of the mandrel 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 mandrel 220 may be spring-loaded or not. In further embodiments, the outer mandrel 210 may be spring-loaded or not. In certain embodiments, only the outer mandrel 210 is spring-loaded.

[0128] The ejector 30 may have a circumference shorter than the circumference of the inner mandrel 220 at its lower end 32. In this regard, the ejector 30 can be fitted onto the inner circumference of the inner mandrel 220 in its retracted position (for example, as shown in Figure 12). In some embodiments, the base of the ejector 30 may comprise a cylindrical pyramid. In such embodiments, the interior of the inner mandrel 220 may comprise a recess that is a cylindrical pyramid, thereby allowing the ejector 30 to be fitted onto the inner mandrel 220. In one embodiment, the ejector 30 may be perforated and / or have a through hole disposed inside.

[0129] In another embodiment, the base of the ejector 30 may comprise a plurality of disk contact sections, each contacting the bottom closure 51 but separated from one another. For example, the ejector may comprise three or four prongs that are flattened at the contact surface with the closure 51 to avoid damage to the closure 51.

[0130] In some embodiments, the ejector has a bottom surface 34 designed to contact the bottom closure 51. In some embodiments, the ejector 30 can be solid from one side of the diameter to the other side of the diameter along its bottom surface 34. In another embodiment, the ejector 30 can have a hollow interior portion, as shown in the figure. In such embodiments, the bottom contact surface 34 can have a circular cross-section. In some embodiments, the bottom surface 34 of the ejector 30 can contact at least a portion of the first deformed surface 53 of the composite closure 51. In some embodiments, the first deformed surface 53 of the closure 51 can comprise the 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 (for example, as shown in Figure 13), is positioned near the second deformed surface 55 of the composite closure 51.

[0131] In some embodiments, the bottom surface 34 of the ejector 30 can be coplanar with the first (lower) surface 222 of the inner mandrel 220 when the ejector 30 is in its recessed position (for example, as shown in Figure 12). In another embodiment, the ejector 30 can be slightly recessed into the inner mandrel 220, thereby the bottom surface 34 of the ejector 30 is higher than the first (lower) surface 222 of the inner mandrel 220 when the ejector is in its recessed position.

[0132] In some embodiments, the ejector 30 and the inner mandrel 220 (and / or outer mandrel 210) can each be translated vertically and separately from one another. That is, the inner mandrel 220 can move a first distance and the ejector 30 can move a second distance, with the first and second distances being different from each other. Similarly, the inner mandrel 220 can move in a first time and the ejector 30 can move in a second time, with the first and second times being different from each other. In some embodiments, the inner mandrel 220 and the ejector 30 can move together for a first period of time. In some embodiments, the inner mandrel 220 can have a first extension length and the ejector 30 can have a second extension length, with the first and second extension lengths being different from each other.

[0133] In some embodiments, the inner mandrel 220 (and / or outer mandrel 210) first retracts vertically from the container body 60, while the ejector 30 remains positioned adjacent to the composite closure 51 (as shown, for example, in Figures 8 and 13), maintaining the position of 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 (as shown, for example, in Figures 8 and 13) may be called the extended position of the ejector 30. In this embodiment, once the inner mandrel 220 retracts beyond the peripheral edge 205 of the container body 60, the ejector 30 then retracts vertically upward, returning to the interior of the inner mandrel 220.

[0134] In another embodiment, after the sealing process is complete, the ejector 30 can extend further downward than it did during the sealing process to assist in removing the container 60 from the die assembly 300. That is, the ejector 30 can push the container 60 downward by pressure against the closure 51. Alternatively, the ejector 30 can translate downward together with the container 60 and the closure 51 in coordination with the movement of the container assembly, rather than being able to apply pressure to the closure 51. In this embodiment, the ejector 30 can then retract from contact with the closure 51 and retract into the mandrel assembly 200.

[0135] In some embodiments, the ejector 30 includes means for delivering a controlled blast of air directed toward the closure 51 simultaneously with or immediately before the ejector 30 retracts from the closure 51. In some embodiments, the delivery of pressurized air may include a showerhead mechanism disposed within the ejector 30. In one embodiment, the mandrel assembly 200 includes an ejector coupling 201 and a mandrel or sealing head coupling 202.

[0136] The ejector 30 of this disclosure avoids problems caused by a standard mandrel retraction process. Specifically, a standard mandrel retraction involves pulling the mandrel out of the container assembly (or vice versa), causing friction between the mandrel and the paper-based closure. Because the mandrel and container assembly are separated, any relative movement of the paper-based closure can cause creases, wrinkles, and / or bubbles to form within the seal, reducing or destroying the airtightness of the container assembly. The ejector 30 of this disclosure allows for stabilization of the position of the paper-based closure within the container body during the process of removing the mandrel (e.g., during outfeeding). The ejector 30 helps ensure the airtightness of the seal between the closure 51 and the container body 60 throughout the entire cycle of the paper-based bottom sealing process.

[0137] After both the inner mandrel 220 and the ejector 30 have retracted, the container can optionally be removed from the die assembly 300 and mandrel assembly 200 in a vertical downward manner (Figure 10). In one embodiment, the movements of the inner mandrel 220, the ejector 30, and the container can be synchronous. In one embodiment, the inner mandrel 220 and the outer mandrel 210 can then optionally be completely retracted vertically upward from the die assembly 300 in a one-piece manner (Figure 11). In one embodiment, the mandrel assembly 200 and the die assembly 300 are then positioned for further insertion, bottom closure formation, and sealing processes.

[0138] "Container support assembly" The container support assembly may be configured to remove and / or hold the composite body 60 and to hold the composite body 60 in a desired position. The container support assembly may include a tube support member molded to receive the composite body 60. In some embodiments, the tube support member can lift the container body 60 vertically upward so that it contacts the die assembly 300 and the mandrel assembly 200.

[0139] In one embodiment, the container 60 is inserted into the die assembly by being lifted upward, and is fixed in a vertical position within the die assembly by bringing the rim or edge of the container 60 into contact with the lower surface of the die opening 98 (see Figures 2-3). The container 60 remains fixed in place to avoid relative vertical movement of the container 60 while the inner mandrel 220 moves in and out of the container assembly.

[0140] "Paper-based disc and bottom closure" As shown in Figure 2, in some embodiments, the paper-based disc 50 may have an upper surface 52 and a lower surface 54 that define the sheet thickness. In some embodiments, the paper-based disc 50 may have a thickness in the range of, for example, about 0.01 to 0.6 cm.

[0141] The paper-based disc 50 may have a layered structure in some embodiments. For example, the layered structure may comprise a paper-based layer 50p, a barrier layer 50b, and / or an ionomer layer 50i (as will be 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 disc 50 (as shown, for example, in Figure 17D). The paper-based disc 50 may comprise 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 disc 50 may be cut or formed into a circular disc. In other embodiments, the paper-based disc 50 may be cut or formed to be a dome-shaped disc (not shown), thereby offsetting the central portion 56 from the peripheral portion 58 along the Y-axis.

[0142] After molding, the paper-based disc 50 becomes a bottom closure 51 (for example, as shown in Figure 11). The bottom closure 51 may have a first deformed surface 53 and a second deformed surface 55. In some embodiments, the first deformed surface 53 may be substantially horizontal. In some embodiments, the first deformed surface 53 comprises the central portion 56 of the paper-based disc. In another embodiment, the second deformed surface 55 may be substantially vertical and / or comprises the peripheral portion 58 of the paper-based disc. In some embodiments, the inward-facing side of the first deformed surface 53 (for example, the lower surface 54 of the paper-based disc 50) may be adjacent to the interior of the container body 60, and the inward-facing side of the second deformed surface 55 (for example, the lower surface 54 of the paper-based disc 50) may be adjacent to the inner surface 66 of the side wall 63 of the container body 60. As will be discussed in more detail herein, in some embodiments, the ionomer layer 50i of the paper-based disc 50 within the second deformed surface 55 can be thermally melted to form a seal with the inner surface 66 of the side wall 63 of the container body 60.

[0143] "method" During use, the sealing system 100 receives the disk 50 and optionally uses vacuum pressure to seat the disk 50 within the positioning portion 90 of the die assembly 300 to properly seat the disk. In some embodiments, the container body 60 is then lifted toward the die assembly 300 by a lifting plate until the peripheral edge 205 of the container body 60 contacts the lower surface of the die 80. In such embodiments, the inner surface 66 of the container body 60 may be coplanar with the die opening 98. In some embodiments, the outer mandrel 210 then translates downward perpendicularly toward the disk 50 until the outer mandrel 210 contacts the peripheral portion 58 of the disk 50, restraining the disk 50 in place. More specifically, a vertically extending portion 212 of the outer mandrel 210 may be configured to fix the disk 50 in place (for example, as shown in Figure 4).

[0144] When the disc 50 is tightened in place by the outer mandrel 210 (e.g., the vertically extending portion 212 of the outer mandrel 210), the open end (bottom) of the container body 60 is isolated from the ambient atmosphere. The force of the outer mandrel 210 on the disc 50 can create a sealed or nearly sealed condition within the container 60 between the container 60 and the disc 50. The gas valve(s) are then opened if necessary, and air is vacuumed out from inside the container through the channel openings 440 and channel 430, thus creating an underpressure condition inside the container. More specifically, a side channel pump may be designed to draw a specified volume of gas from inside the container. The specified volume of gas may be related to the size and volume of the container 60, as well as the depth to which the disc 50 is inserted into the container body 60 to seal it to the container body 60. More specifically, the specified volume of gas may 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 volume of gas to be exhausted should be less than the volume of gas that would cause the container 60 to collapse. In some embodiments, the rate at which the gas is exhausted from the container can be adjusted. For example, some containers, such as those with larger internal volumes, may be at a higher risk of collapse if a high-speed gas exhaust process is used. In some cases, the vacuum level can be adjusted. For example, a process using a higher vacuum pressure may require a lower flow rate for the gas exhaust process. A process using a lower vacuum pressure may require a higher flow rate for the gas exhaust process. Those skilled in the art will understand these variations.

[0145] In some embodiments, the gas exhaust process can occur over a period of about 60 msec or less. In other embodiments, the gas exhaust process can occur over a period of about 40 msec to about 50 msec. In some embodiments, the gas exhaust process can occur over a period of about 200 msec or less.

[0146] When the side channel pump is started, air in the tube, connector 410, and valve 420 can be drawn into the side channel pump. Furthermore, air in the channel 430, channel opening 440, and inside the container can be drawn into the side channel pump. Without releasing the pressure between the outer mandrel 210 and the disc 50, the paper disc 50 is then immediately inserted (or driven) into the container body 60 by the inner mandrel 220. The suction and insertion steps can occur simultaneously or almost simultaneously. That is, air can be drawn from inside the container for just a moment before the disc 50 is inserted into the container body 60.

[0147] In some embodiments, insertion of the disc 50 into the container body 60 is achieved by an inner mandrel 220. In such embodiments, the inner mandrel 220 and ejector 30 can continue to translate downward perpendicularly toward the disc 50. The inner mandrel 220 and ejector 30 may then contact the disc 50 and bias the disc 50 downward through the die opening 98 until the disc 50 is deformed to have a flat central portion and deformed side walls 55 adjacent to the inner surface 66 of the container body 60. In one embodiment, pressure can be applied to the disc by a first mandrel surface 222 and / or a second mandrel surface 224 of the inner mandrel 220 (for example, by acting the inner mandrel 220 along the Y-axis).

[0148] The deformed composite closure 51 can then be hermetically sealed to the container body 60. In some embodiments, this occurs without releasing the pressure of the inner mandrel and die, which maintains subpressure conditions inside the container. Compression and heating can be applied to the deformed composite closure 51 and / or the container body 60, thereby causing the respective sealant layers of both to form an hermetically sealed seal. In some embodiments, the heat is provided by at least the sealing member 40. Similarly, the sealing member 40 and the second mandrel surface 224 of the inner mandrel 220 can provide opposing pressure to at least one of the outer surface 64 of the container body 60 and the deformed sidewall 55 of the bottom closure 51.

[0149] The airtight seals according to this disclosure can be formed by the sealing member 40 at a temperature higher than approximately 90°C, such as 120°C to approximately 280°C, or approximately 140°C to approximately 260°C. A suitable airtight seal can be formed by maintaining the sealing member 40 in contact with the bottom end 62 of the composite body 60 for any residence time sufficient to heat the sealant layer to a temperature suitable for forming an airtight seal, such as a value shorter than approximately 5 seconds, approximately 0.8 seconds to approximately 5 seconds, or approximately 1 second to approximately 4 seconds. 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 mandrel 220 at any pressure less than approximately 30 MPa, such as a pressure of approximately 1 MPa to approximately 22 MPa.

[0150] After compression and / or heat have been applied for a sufficient residence time, the sealing member 40 can separate from the bottom end 62 of the container body 60, thereby so that the sealing member 40 is not in contact with the composite body 60 after the residence time has ended (for example, as shown in Figure 10). The inner mandrel 220 can then retract from the closure 51 while the ejector 30 remains in place. Once the inner mandrel 220 has cleared at least the peripheral edge of the container body 60, the ejector 30 then retracts, optionally accompanied by a blast of pressurized air to aid in a smooth retraction process. The ejector 30 then retracts completely into the inner mandrel 220. The container body 60 then separates from the die assembly 300 and the mandrel assembly 200, in the meantime or after the mandrel assembly 200 has completely retracted from the die assembly 300.

[0151] In some embodiments, the systems and methods described herein can produce hermetically sealed container assemblies having a paper-based composite bottom closure, which is inserted into the composite container body and sealed in a recessed position without causing dome formation of the membrane seal (e.g., the membrane seal at the upper end) due to excessive pressure inside the container. Since the upper seal membrane is not domed, instability problems do not exist. The container assembly can stand stably (upside down) on its membrane end when being transported to the downstream packaging process (e.g., from a sealing machine to a case packer). Furthermore, since the upper closure (e.g., the peelable membrane) is not domed, an overcap can be easily attached to the upper end of the container assembly, covering the upper closure.

[0152] Furthermore, the hermetically sealed container assemblies of this disclosure can be transported worldwide by sea, air, or rail, for example, without the unacceptable dome formation of a membrane lid, and are subject to fluctuating atmospheric conditions (caused, for example, by temperature fluctuations, humidity fluctuations, and altitude fluctuations).

[0153] In certain embodiments, multiple composite container assemblies can be formed by a system or device suitable for synchronously processing multiple paper-based discs, bottom closures, and composite container bodies. For example, a manufacturing system may include multiple mandrel assemblies, multiple die assemblies, multiple gas exhaust assemblies, and multiple tube support assemblies operating cooperatively. In particular, a turret-mounted device having multiple subassemblies, each subassembly comprising a mandrel assembly, a die assembly, a gas exhaust assembly, and a tube assembly, can receive and process discs simultaneously or synchronously. Depending on the complexity of the turret-mounted device, hundreds of separate composite container assemblies can be manufactured cooperatively per cycle. Therefore, any of the processes described herein can be performed simultaneously. For example, when each subassembly operates synchronously, each of the following can be performed simultaneously: the first paper-based disk can be positioned above the die opening; the second paper-based disk can be constrained between the mandrel assembly and the die assembly; the third paper-based disk can be formed into the first bottom closure by insertion into the first composite body, and the third bottom closure can be hermetically sealed to the second composite body. Alternatively, any of the operations described herein can be performed simultaneously, for example, by having a device with multiple subassemblies.

[0154] In some embodiments, the systems and methods of the present disclosure enable the sealing system to operate at a fast rate (e.g., faster than 300 container assemblies / minute). In some embodiments, the systems and methods of the present disclosure enable the sealing system to operate at a rate of at least 400 container assemblies / minute. In some embodiments, the systems and methods of the present disclosure enable the sealing system to operate at a rate of at least 500 container assemblies / minute.

[0155] It should be understood that this disclosure provides hermetically sealed container assemblies for packaging moisture-sensitive and / or oxygen-sensitive solid food products, such as crisp hydrocarbon-based food products, salted food products, crisp food products, potato chips, processed potato snacks, nuts, and the like. Such hermetically sealed container assemblies can provide airtight seals under vastly different climatic conditions, including high and low temperatures, high and low humidity, and high and low pressure. Furthermore, hermetically sealed container assemblies can be manufactured according to the methods described herein by processes including heat transfer heating techniques or conduction heating techniques, which have relatively low environmental pollution. The hermetically sealed container assemblies described herein are low in weight, have high structural stability, and can be suitable for recycling.

[0156] In some embodiments, the systems and methods described herein can produce hermetically sealed container assemblies having a paper-based composite bottom closure, which is inserted into the open bottom end of a composite container body and sealed in a recessed position without causing dome formation of an upper closure (e.g., a peelable membrane) that seals the upper end. In a typical insertion process in which the paper-based disc is deformed into a recessed bottom closure, the increase in pressure inside the container (by the insertion process itself) causes the upper closure to expand outward or “dome.” In other words, when the bottom closure is inserted into the open bottom end of the container body and sealed in place, it pushes the air inside the container into a smaller space to accommodate the recessed bottom closure. This increased pressure spreads outward to the most flexible component, which is typically the upper closure (e.g., a membrane lid).

[0157] Domed membrane lids are not only aesthetically unappealing, but can also cause certain manufacturing problems. For example, domed membranes can cause instability. In some cases, container assemblies with dome formation problems cannot stand stably (upside down) on their membrane edges while being transported to downstream packaging processes (e.g., from sealing machines to case packers). Furthermore, if the top membrane is domed, the overcap cannot be attached to the container assembly, rendering the package unacceptable for sale.

[0158] 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 paper-based bottom closure without introducing an unacceptable level of dome formation in the flexible closure (e.g., a peelable film). More specifically, the systems and methods of the disclosure can enable gas evacuation simultaneously with or immediately before the sealing process takes place. In some embodiments, the methods and systems enable the evacuation of a controllably defined volume of gas from inside the container. In some embodiments, this defined volume of gas directly correlates to a desired depth of the recessed bottom closure, thereby avoiding excessive pressure conditions inside the container. [Examples]

[0159] In the following embodiments, the paper-bottomed containers of the present invention (composite containers, paper bottoms, membrane covers, and overcaps) were tested for various properties. The paper bottoms of the tested containers consisted of flexible board (i.e., cup stock) as the paper layer (195 g / m²). 2 (0.3 mm thick), tie layer, aluminum foil (8 μm) as a barrier layer, and ionomer layer (32 g / m²) as a sealant layer. 2 ) was included. In some containers, a PET layer was included to protect the aluminum barrier layer. In other embodiments, the aluminum barrier layer was not included. All versions passed testing as shown below.

[0160] [Example 1] In high-altitude tests, the vessel of the present invention was placed in a sealed chamber, and the pressure inside the chamber was raised to at least 11 inHg for a period of about 10 minutes. If the vessel could withstand 10 inHg (simulating atmospheric pressure when the vessel is traveling over the Rocky Mountains) for at least 10 minutes, the vessel passed the test. If it could not withstand, the vessel was listed as “missed”. As used herein, “Rocker Bottoms Observed” means the domed membrane and / or paper bottoms formed by overpressure conditions, which are normal under such conditions, while the vessel is confined in a vacuum chamber. After removal from the vessel, the dome formation returned to neutral. Dome formation can be considered as the movement of the membrane or paper bottoms from the inside out of the vessel so that they extend beyond the relevant cut of the vessel. Failures or malfunctions include leakage, delamination of the membrane or paper base, strain retained after pressure is released, seam rupture or delamination, rupture of the membrane or paper base, and / or other failures that prevent the container from meeting airtightness standards. If the membrane or paper base forms a dome inward into the can upon pressure release, this may indicate a leakage failure. Test results are described below.

[0161] [Table 1a]

[0162] The tests showed a success rate of 99.4% for the paper base described herein, which is acceptable.

[0163] [Table 1b]

[0164] The tests showed a 98% success rate for standard laminates and a 100% success rate for the lightweight paper bases described herein, which are acceptable success rates.

[0165] [Example 2] In this embodiment, the container of the present invention underwent a helium leak test. Helium can be used as a tracer gas to detect leaks because its background level is very low, as it constitutes only about 5 ppm in the atmosphere. Helium is also mobile and completely inert / non-reactive, as it has a relatively low mass. The sealed container of the present invention 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 so that a sample of the gas from inside the container could be taken out and passed through a mass spectrometer to read an increase in the helium level inside the container that exceeds the background reading. In this embodiment, the helium leak limit was 2.3 × 10⁻⁶ -4 mbar * The result was l / s. A success rate of 99.8% was observed. This result is acceptable.

[0166] [Table 2]

[0167] [Example 3] In this embodiment, the vessel of the present invention underwent a vessel integrity test. The vessel was placed in a vacuum chamber under a pressure of 200 mbar, and vacuum collapse was measured over a period of 20 seconds. The method uses pressure change measurement to indirectly measure the flow from the vessel into a constant volume chamber. A mass extraction deformation type measures the flow required to maintain a constant level of vacuum (ASTM F2338 and ASTM F 3287). If the vessel has a leak, it will reduce the expected vacuum inside the vacuum chamber. Vacuum drop or collapse was measured over 1 second. The success / failure threshold was set at 42 Pa / s. A success rate of 98.6% was observed. This result is acceptable.

[0168] [Table 3]

[0169] [Example 4] In this implementation, the vessel of the present invention underwent a Periodic Test Interval (PTI) test. The vessel was placed in a vacuum chamber under a pressure of 700 mbar, and vacuum collapse was measured over a 20-second period. Vacuum drop or collapse was measured per second. The success / failure threshold was set at 20 Pa / s. A success rate of 96% was observed. This result is acceptable.

[0170] [Table 4]

[0171] [Example 5] In this embodiment, the inventors analyzed the simulated storage life of the container of the present invention. Containers with a residual oxygen level of 0.0% were filled, sealed, and stored. The containers were then tested for residual oxygen levels after 6 months and 9 months. The success / failure threshold was set to 2.0% residual oxygen or less over these periods (a threshold of 4.0% to 4.5% could be considered acceptable after approximately 18 months). A success rate of 92% was observed. This result is acceptable.

[0172] [Table 5]

[0173] [Example 6] In this embodiment, the inventors compared the leakage of a container with a paper bottom closure of the present invention to that of a container with a metal bottom closure using the vacuum decay method described herein. The pressure drop was measured in Pa / s for the cans. The "blue" and "green" cans are paper bottom containers, while the "Reference with metal end" is a metal bottom container. As can be seen, the paper bottom containers have a generally smaller pressure drop during vacuum decay compared to the containers with metal bottom ends. Figure 37 shows a graph of the results. Overall, the paper bottom of the present invention outperformed the metal bottom in terms of consistency in avoiding leakage.

Claims

1. A paper-based container assembly comprising: A container body, at least one sidewall defining a container interior; an upper rim defining an upper edge of the at least one sidewall; and a bottom peripheral edge defining a bottom end of said at least one side wall; A container body comprising: a top closure attached to the top rim; a bottom closure recessed inwardly from the bottom end to form a seal with an interior surface of the container body; Equipped with at least one of the container body and the bottom closure comprises a plurality of layers including one or more barrier layers and one or more paper-based layers; The paper-based container assembly is ３ / m ２ and an oxygen permeability of approximately 0.5 g / m per day ２ 1. A paper-based container assembly having a water vapor transmission rate of:

2. The oxygen transmission rate of the paper-based container assembly is about 0.05 cm per day ３ / m ２ 2. The paper-based container assembly of claim 1, wherein:

3. The water vapor transmission rate of the paper-based container assembly is about 0.05 g / m per day ２ 2. The paper-based container assembly of claim 1, wherein:

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

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

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

7. 6. 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 metallized polyethylene terephthalate (MPE).

8. 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 aluminum.

9. 6. 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 metallized polybutylene terephthalate (MPBT).

10. 6. 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 aluminum oxide (AlOx)-coated polyethylene terephthalate (PET).

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

12. 2. The paper-based container assembly of claim 1, wherein the bottom closure is recessed inward from the bottom end of the container body by a recess distance in the range of about 0.2 to 2 cm.

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

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

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

16. A paper-based container assembly comprising: A cylindrical container body, at least one sidewall comprising one or more paper base layers attached to one or more barrier layers, and one or more ionomer layers attached to said one or more barrier layers, said one or more ionomer layers defining a container interior; an upper rim defining an upper edge of the at least one sidewall; and a bottom peripheral edge defining a bottom end of said side wall; A container body comprising: a top closure sealed to the top rim, one or more paper-based layers attached to one or more barrier layers; and one or more peelable sealant layers attached to said one or more barrier layers; an upper closure portion comprising: a bottom closure recessed inwardly from the bottom end to form a seal with an interior surface of the container body; one or more cupstock paperboard layers attached to one or more barrier layers; and one or more ionomer layers attached to said one or more barrier layers; a bottom closure comprising: Equipped with the one or more paper-based layers of the container body, the top closure, and the bottom closure comprise at least about 95% by weight of the paper-based container assembly; The paper-based container assembly is expected to grow at a rate of approximately 0.5 cm per day. ３ / m ２ and an oxygen permeability of approximately 0.5 g / m per day ２ 1. A paper-based container assembly having a water vapor transmission rate of:

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

18. 17. The paper-based container assembly of claim 16, wherein at least one barrier layer of the side wall, 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. 17. The paper-based container assembly of claim 16, wherein at least one barrier layer of the side wall, at least one barrier layer of the top closure, and at least one barrier layer of the bottom closure each comprise aluminum oxide (AlOx)-coated polyethylene terephthalate (PET).

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

21. A paper-based container assembly comprising: A cylindrical container body, At least one sidewall, one or more paper-based layers attached to one or more barrier layers selected from the group consisting of metallized polyethylene terephthalate (MPET), metallized polybutylene terephthalate (MPBT), aluminum oxide (AlOx)-coated polyethylene terephthalate (PET), and aluminum; and one or more ionomer layers attached to the one or more barrier layers, the one or more ionomer layers defining an interior of the container; at least one side wall comprising an upper rim defining an upper end of the at least one sidewall; and a bottom peripheral edge defining a bottom end of said side wall; A container body comprising: a top closure sealed to the top rim, one or more paper-based layers attached to one or more barrier layers selected from the group consisting of metallized polyethylene terephthalate (MPET), metallized polybutylene terephthalate (MPBT), aluminum oxide (AlOx)-coated polyethylene terephthalate (PET), and aluminum; and a top closure comprising one or more peelable sealant layers attached to the one or more barrier layers; a bottom closure recessed inwardly from the bottom end to form a seal with an interior surface of the container body; one or more cupstock paperboard layers adhered to one or more barrier layers selected from the group consisting of metallized polyethylene terephthalate (MPET), metallized polybutylene terephthalate (MPBT), aluminum oxide (AlOx) coated polyethylene terephthalate (PET), and aluminum; and one or more ionomer layers attached to said one or more barrier layers; a bottom closure comprising: Equipped with the one or more paper-based layers of the container body, the top closure, and the bottom closure comprise at least about 95% by weight of the paper-based container assembly; The paper-based container assembly is expected to grow at a rate of approximately 0.5 cm per day. ３ / m ２ and an oxygen permeability of approximately 0.5 g / m per day ２ 1. A paper-based container assembly having a water vapor transmission rate of:

22. Approximately 0.05 cm per day ３ / m ２ and an oxygen transmission rate of approximately 0.05 g / m per day ２ 22. The paper-based container assembly according to claim 21, having a water vapor transmission rate of:

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