Systems and methods for applying and sealing end closures to containers

Abstract

The present invention is directed to a system (100) and method for sealing a closure to a container, comprising a die assembly (300), a mandrel assembly (200), and a gas exhaust assembly (400). The mandrel assembly comprises an outer mandrel (210) and an inner mandrel (220). The outer mandrel is configured to translate vertically and hold the closure in place. The gas exhaust assembly, comprising at least one hollow channel (430) in the die and one or more channel openings (440) to the interior of the die, draws gas from the interior of the aligned container when the closure is held in place. The inner mandrel translates vertically to insert the closure into the container, and a sealing member (40) seals the closure in place.

Description

[Technical Field]

[0001] This application claims priority to U.S. Patent Application No. 63 / 071,069, filed August 27, 2020, which is incorporated herein by reference in its entirety.

[0002] FIELD OF THE INVENTION The present invention generally relates to systems and methods for forming and sealing containers having closures. [Background technology]

[0003] The present disclosure generally relates to containers and methods for sealing such containers. Paper-based or composite containers are often used for snack foods and similar products. Such containers often have a peelable / removable membrane sealed to the top rim of the container, a removable / replaceable overcap or end cap covering the membrane, and a metal closure seamed to the bottom rim of the container. Typically, the membrane is first sealed to the top rim. The container is then filled with product through the open bottom end of the container, and the metal closure is seamed to the bottom rim of the container.

[0004] The above-described process of using a metal bottom edge interferes with the recyclability of the container because seaming the metal closure to the bottom of the container makes it very difficult to separate the metal closure from the container itself after use. Without the paper-based body of the container being unable to separate 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 containers to increase the sustainability of the final product.

[0005] One solution to the need for recyclability is to produce containers with paper-based end closures rather than metal ends. However, existing equipment for seaming metal ends onto containers is built specifically for metal ends, and simply replacing a metal closure with a paper-based end closure is not compatible with current metal end seaming processes because paper-based end closures introduce unique challenges not present with metal ends (e.g., closure flexibility, separating the closure from a stack of closures, feeding the closure, folding the closure, joining non-metallic closures). Through ingenuity and considerable effort, the inventors have not only developed a system and method for applying paper-based end closures to containers, but have also developed a system and method that operates at high speeds (e.g., greater than 250 containers / minute). Summary of the Invention

[0006] In one embodiment, the present invention provides a sealing system for sealing a closure to a container, the system including a die assembly, a mandrel assembly, and a gas exhaust assembly. The die assembly can include a die having a positioning portion configured to hold a disk and a die opening adjacent the positioning portion, and at least one sealing member configured to provide heat to seal the disk to the container. The mandrel assembly can have a recessed position and an extended position and can include an outer mandrel having an extended portion sized to fit within an inner periphery of the positioning portion in its extended position adjacent a peripheral portion of the retained disk, an inner mandrel configured to translate through the extended portion of the outer mandrel and the inner periphery of the die opening to its extended position, and an ejector disposed within the inner periphery of the inner mandrel, the sealing member disposed opposite the mandrel assembly when the mandrel assembly is in its retracted position. The gas exhaust assembly may include at least one hollow channel disposed at least partially circumferentially within the die, at least one channel opening disposed within the die connecting the at least one channel to the interior of the die, the at least one channel opening being disposed between a positioning portion of the die and the sealing member, and means for drawing gas from the interior of the die, the at least one channel opening, and the at least one channel to the exterior of the die.

[0007] In certain methods of the present invention, the method may include positioning a disk in a positioning portion of the die, axially aligning a container with the positioning portion of the die, positioning the container so that a peripheral edge of the container is in contact with a lower surface of the die, translating an outer mandrel so that the outer mandrel restrains the disk in the positioning portion of the die, aspirating gas from the interior of the container, at least one channel opening, and at least one channel to the exterior of the die, translating the inner mandrel so that the inner mandrel presses the disk into the container and deforms the disk into the container end, and sealing the container end to the container.

[0008] In some embodiments, the system comprises a plurality of channel openings. In some embodiments, the system comprises at least one valve disposed within the die connecting at least one channel to an exterior of the die. In some embodiments, the system further comprises at least one tube connecting the at least one valve to a means for aspirating gas. In some embodiments, the means for aspirating gas comprises a side channel pump or a vacuum pump. In some embodiments, the system comprises a plurality of valves disposed within the die connecting at least one channel to an exterior of the die. In some embodiments, the channel opening is disposed between the retained disk and a container into which the retained disk will be sealed. In some embodiments, the vertically extending portion of the outer mandrel has a perimeter that is longer than the perimeter of the die opening. In some embodiments, the vertically extending portion of the outer mandrel restrains the disk against a positioning portion of the die.

[0009] In some embodiments of the method, when the outer mandrel restrains the disk against the positioning portion of the die, the interior of the container is sealed off from access to the atmosphere. In some embodiments of the method, the steps of applying suction and vertically translating the inner mandrel occur simultaneously or nearly simultaneously.

[0010] In one embodiment, the outer mandrel, inner mandrel, and ejector extend, translate, and retract parallel to one another. In one embodiment, the outer mandrel extends and retracts vertically, the inner mandrel translates and retracts vertically, and the ejector translates and retracts vertically.

[0011] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the description, serve to explain the principles of the invention.

[0012] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one skilled in the art, is set forth in this specification and reference is made to the accompanying drawings, in which: [Brief explanation of the drawings]

[0013] [Figure 1] 1 is a cross-sectional view of an exemplary sealing system according to one embodiment of the present invention. [Figure 2] 1 is a cross-sectional view of an exemplary sealing system according to one embodiment of the present invention. [Figure 3] 1 is a cross-sectional view of an exemplary sealing system according to one embodiment of the present invention. [Figure 4] 1 is a cross-sectional view of an exemplary sealing system according to one embodiment of the present invention. [Figure 5] 1 is a cross-sectional view of an exemplary sealing system according to one embodiment of the present invention. [Figure 6] 1 is a cross-sectional view of an exemplary sealing system according to one embodiment of the present invention. [Figure 7] 1 is a cross-sectional view of an exemplary sealing system according to one embodiment of the present invention. [Figure 8] 1 is a cross-sectional view of an exemplary sealing system according to one embodiment of the present invention. [Figure 9] 1 is a cross-sectional view of an exemplary sealing system according to one embodiment of the present invention. [Figure 10] 1 is a cross-sectional view of an exemplary sealing system according to one embodiment of the present invention. [Figure 11] 1 is a cross-sectional view of an exemplary sealing system according to one embodiment of the present invention. [Figure 12] 1 is a cross-sectional view of an exemplary sealing system according to one embodiment of the present invention. [Figure 13] 1 is a cross-sectional view of an exemplary sealing system according to one embodiment of the present invention. [Figure 14] FIG. 2 is a cross-sectional view of an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 15] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 16] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 17] 1 illustrates an exemplary sealing system according to one embodiment of the present invention. [Figure 18] 1 illustrates an exemplary sealing system according to one embodiment of the present invention. [Figure 19] 1 illustrates an exemplary sealing system according to one embodiment of the present invention. [Figure 20] 1 illustrates an exemplary sealing system according to one embodiment of the present invention. [Figure 21] 1 illustrates an exemplary sealing system according to one embodiment of the present invention. [Figure 22] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 23] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 24] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 25] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 26] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 27] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 28] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 29] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 30] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 31] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 32A]FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 32B] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 32C] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 32D] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 32E] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 32F] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 33] FIG. 2 illustrates an exemplary die and gas exhaust system according to one embodiment of the present invention. [Figure 34] FIG. 10 shows a graphical comparison of leak detection in a paper bottom closure of the present invention compared to a metal bottom closure. DETAILED DESCRIPTION OF THE INVENTION

[0014] Repeat use of reference characters in the present specification and drawings is intended to indicate same or analogous features or elements of the invention.

[0015] Reference will now be made in detail to the embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided as an explanation of the invention, not as a limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For example, features illustrated or described as part of one embodiment can be used on another embodiment to yield still a further embodiment. Therefore, it is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents.

[0016] In one embodiment, the present invention comprises a device and method for the production of high-barrier packaging for perishable products, such as hermetically closed containers for packaging moisture- and oxygen-sensitive solid food products. Once filled and closed, containers produced according to the devices and methods described herein can be capable of sustaining a variety of atmospheric conditions. More specifically, the hermetically closed containers can be suitable for maintaining the freshness of crisp food products, such as potato chips, processed potato snacks, nuts, and the like. As used herein, the term "hermetic" refers to the property of sustaining oxygen (O2) levels by a barrier, such as a seal, surface, or container.

[0017] In one embodiment, the systems and methods described herein can produce hermetically sealed containers having an all-paper, paper-based, or composite bottom that are formed / sealed (e.g., by a heated press tool) without introducing pinholes, pleats, cuts, or cracks in the barrier layer, the closed container, and / or the bottom (although the methods described herein should not be so limited and can be applicable to polymeric, metallic, or other types of bottoms known in the art).

[0018] In one embodiment, the systems and methods described herein can produce a hermetically sealed container having a paper-based composite bottom that can be inserted into the composite container and sealed in a recessed position without causing doming of the membrane seal (at the top end). In a typical insertion process that results in a recessed bottom, the increased pressure against the interior of the container caused by the insertion process itself causes the membrane closure to expand outward or "dome." That is, once inserted and sealed in place, the end closure forces air within the container into a smaller space to accommodate the recessed end closure. That increased pressure expands outward to the most flexible component, which is typically the membrane lid.

[0019] A domed membrane lid is not only aesthetically unattractive, but also creates certain manufacturing problems. For example, the domed membrane creates instability - the container cannot stand stably (upside down) on its membrane end when being transported to the downstream packaging process (i.e., from the sealing machine to the case cap). Furthermore, an overcap cannot be attached to the container when the membrane lid is domed, making the package unacceptable for sale.

[0020] As such, the systems and methods of the present invention provide a mechanism for applying a recessed paper-based bottom closure to a paper-based container without unacceptable levels of doming of the flexible film closure. More particularly, the present invention allows for gas evacuation simultaneously with or immediately prior to the sealing process occurring. In one embodiment, the methods and systems of the present invention allow for an adjustably defined volume of gas to be evacuated from the container. In some embodiments, this defined volume of gas directly correlates to the depth of the recessed end closure, avoiding overpressure situations within the container.

[0021] Furthermore, such hermetically sealed containers can be shipped worldwide, e.g., by sea, air, or rail, subject to fluctuating atmospheric conditions (e.g., caused by temperature fluctuations, humidity fluctuations, and altitude fluctuations) without unacceptable doming of the membrane lid. As understood in the art, such conditions may cause significant pressure differentials between the interior and exterior of the hermetically sealed container. Furthermore, atmospheric conditions may cycle between relatively high and relatively low values. The systems and methods for producing hermetically sealed containers described herein can provide containers that can be shipped and / or stored under widely different climatic conditions (i.e., temperature, humidity, and / or pressure) without unacceptable doming of the membrane lid. Furthermore, in the embodiments described herein, the hermetically closed containers can be formed from materials with sufficient strength, surface friction, and thermal stability for rapid manufacturing (i.e., high cycle output machine types and / or production lines).

[0022] As noted, hermetically sealed containers produced using the systems and methods described herein can include a paper-based composite bottom. Similarly, the container body can include a paper-based composite material, allowing the entire container to be recycled in a single stream (e.g., as opposed to a similar container with a metal bottom). The base and / or container body of the present invention can include any paper known in the art, such as, for example, cardboard, paperboard, cupboard stock, cup stock, litho paper, or even fiber-based and / or pulpable materials such as molded fibers. In some embodiments, the base and / or container body of the present invention can be 100% paper. In some embodiments, the container assembly can have a paper content by weight of about 90% or greater. In some embodiments, the container assembly can have a paper content by weight of about 95% or greater. These paper content percentages can advantageously qualify the container assembly as a single 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 enter the waste management stream to obtain raw materials from the residue for different uses. In other embodiments, the base and / or container body of the present invention can be a composite material.

[0023] "Sealing System" With reference to Figures 1 through 11, the containers described herein can be formed using the following closure system 100 and / or according to the following method. In one embodiment, the paper-based bottom can begin as a sheet or disc. Although the paper bottoms discussed herein are referred to as rounded or disc-shaped, the invention should not be so limited. The paper bottom can have any shape known in the art and can correlate to the shape of the container. For example, if the container has a square, rectangular, triangular, or irregular cross-section, the paper bottom can have the correlated shape (square, rectangular, triangular, or irregular).

[0024] For example, a composite sheet or paper-based disc 50 can be formed to fit a composite container body 60 by a mandrel assembly 200, a die assembly 300, and a container support assembly (not shown), working in conjunction. The mandrel assembly 200 can be utilized to press or press the paper-based disc 50 to form the paper-based disc 50 into a composite bottom 51 (shown in FIGS. 10-11 ).

[0025] The mandrel assembly 200 may include an outer mandrel 210 (sometimes referred to as a "downholder" due to its purpose of holding the disk 50 downward relative to the die assembly 300) and an inner mandrel 220 (sometimes referred to as a "sealing punch" due to its purpose of punch-drawing the disk 50 into the container 60 and sealing the disk 50 against the sidewall of the container 60). The outer mandrel 210 and the inner mandrel 220 may each move along the Y-axis independently of one another. The inner mandrel 220 may translate relative to the outer mandrel 210 to form the paper-based disk 50 into a bottom closure portion 51. Furthermore, the die assembly 300, in cooperation with the mandrel assembly 200, may shape the paper-based disk 50 into the bottom closure portion 51 and simultaneously, or nearly simultaneously, insert the closure portion 51 into the bottom end 62 of the composite body 60. The die assembly 300 may generally include 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 ring. 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 to align the container body 60 with the axis of the mandrel assembly 200 and the die assembly 300 and / or vertically along the axis of the mandrel assembly 200 and the die assembly 300.

[0026] In one embodiment, the mandrel assembly 200, die assembly 300, and 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 forced through the die opening 98 by the inner mandrel 220 and inserted into the bottom end 62 of the composite body 60 held by the tube support member.

[0027] Die assembly The die assembly 300 can be configured to receive and maintain the paper-based disc 50 prior to insertion of the disc 50 through the die opening 98 and into the container body 60. In some embodiments, the disc 50 is received from a separate disc feed assembly (not shown). In one embodiment, the die assembly 300 can be configured to mate with or otherwise align with the feed assembly. For example, the die 80 can include notches, ridges, or other alignment features 302 on its upper end (see FIG. 31 ) that allow the die 80 to mate with, align with, or receive corresponding mechanical elements of the feed assembly. This allows for proper placement of the disc 50 within the die 80.

[0028] More specifically, the die assembly 300 can include a die 80 (i.e., a die bushing ring) having a positioning portion 90 (i.e., a collet seat) configured to receive and align the paper-based disc 50 within the die 80 prior to forming the disc 50 into the recessed end 51. The positioning portion 90 can be disposed adjacent to a die opening 98 to align the paper-based disc 50 with the die opening 98.

[0029] The positioning portion 90 may include an angled surface 96 connecting a top surface 97 of the die 80 to a sidewall 94 of the positioning portion 90. The angled surface 96 may be angled downward toward a die opening 98 and the axis of the die assembly 300. In one embodiment, the angled surface 96 may allow the disk 50 to be guided into the positioning portion 90.

[0030] In one embodiment, the sidewall 94 of the positioning portion 90 may be vertical or substantially vertical. In one embodiment, the sidewall 94 of the positioning portion 90 may be longer than the thickness of the disk 50. In one embodiment, the outer diameter of the sidewall 94 of the positioning portion 90 may be substantially similar to the diameter of the disk 50. In another embodiment, the outer diameter of the sidewall 94 of the positioning portion 90 may be slightly larger than the diameter of the disk 50.

[0031] In one embodiment, the inclined surface 96 of the positioning portion 90 can have a larger perimeter nearest the top surface 97 of the die 80 and a smaller perimeter nearest the sidewall 94. In some embodiments, the perimeter of the outer edge of the inclined surface 96 of the positioning portion 90 can be larger than the paper-based disc 50. The inclined surface 96 can taper downward to allow gravity assistance for alignment of the paper-based disc 50 within the positioning portion 90. When seated, the paper-based disc 50 can be positioned adjacent to the disc support surface 92 and the sidewall 94 of the positioning portion 90. In one embodiment, the disc support surface 92 and the sidewall 94 of the positioning portion 90 connect at a 90-degree angle or a substantially 90-degree angle. In one embodiment, the disc support surface 92 can be horizontal or substantially horizontal. In one embodiment, the seated disc 50 is positioned such that its lower surface 54 (see FIG. 2 ) is adjacent to (i.e., sits on) the disc support surface 92. In one embodiment, the seated disk 50 is positioned so that its thickness is adjacent the side wall 94 of the positioning portion 90 .

[0032] In one embodiment, the inner periphery of the disc support surface 92 is smaller than the periphery of the disc 50. In one embodiment, the inner periphery of the disc support surface 92 is adjacent to the die opening 98. In one embodiment, the disc support surface 92 is disposed adjacent to the die opening inner surface 99. The die opening inner surface 99 may be vertical or substantially vertical in one embodiment. In one embodiment, the disc support surface 92 is disposed perpendicular or nearly perpendicular to the die opening inner surface 99.

[0033] In use, the disk 50 is inserted into the die assembly 300, positioned within the positioning portion 90, and seated on the disk support surface 92. In one embodiment, vacuum pressure can be applied to the paper-based disk 50 from below to align the paper-based disk 50 within the positioning portion 90 of the die 80.

[0034] Although the die opening 98 is shown as having a substantially circular cross-section, the die opening 98 can have a cross-section that is substantially circular, triangular, rectangular, square, pentagonal, hexagonal, or elliptical. In one embodiment, the die opening 98 can be configured to receive the inner mandrel 220, discussed below. In one embodiment, the die opening 98 can have a cross-section that is substantially similar to the cross-section of the inner mandrel 220.

[0035] "Gas Exhaust Assembly" In one embodiment, the system includes a gas exhaust assembly 400. In one embodiment, the gas exhaust assembly 400 is disposed at least partially within the die assembly 300. The gas exhaust assembly 400 can be designed to aspirate or vacuum a defined volume of gas from the interior vessel space prior to or simultaneously with the insertion of the disk 50 into the vessel 60.

[0036] The gas exhaust assembly 400 can include one or more valves 420 that are integral within the die assembly 300. In one embodiment, the valves 420 are disposed within the die 80. More specifically, there can be ports or bores 82 through the interior of the die 80 that connect the die exterior surface 89 to the internal channels 430. The valves 420 can be disposed within the ports or bores 82. The ports or bores 82 can connect the internal channels 430 to the upper surface of the die, the lower surface of the die, or a side / lateral surface of the die. That is, the valve(s) 420 can extend laterally within the die and / or can extend vertically upward or downward within the die. In one embodiment, the bores 82 can be configured generally horizontally within the die 80.

[0037] In one embodiment, bore 82 can be disposed in upper section 87 of die 80. In one embodiment, bore 82 and at least a portion of valve 420 can be disposed above channel 430. In one embodiment, valve 420 can have an opening facing downward within bore 82, toward channel 430. That is, there can be direct gas communication between valve 420 and channel 430. In one embodiment, air can be drawn from channel 430 by valve 420.

[0038] In one embodiment, the valve 420 can comprise any suction or vacuum valve known in the art. In one embodiment, the valve 420 can have an open position and a closed position. In the open position, the valve 420 can allow for the exchange of gas, and in the closed position, the valve 420 can not allow for the exchange of gas. In one embodiment, the valve 420 can comprise an elongated tube or pipe extending generally horizontally or vertically through 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 can be disposed adjacent to the internal channel 430. In some embodiments, a manifold connection 426 can connect the bore 82 and the channel 430. In certain embodiments, the through-hole 422 can be disposed immediately above at least a portion of the internal channel 430. In one embodiment, the through-hole 422 can connect to and communicate with the internal channel 430. The through-hole 422 can have any shape known in the art. In one exemplary embodiment, the through-holes 422 are circular, but may be oval, square, rectangular, or any other shape known in the art.

[0039] The internal channel 430, in one embodiment, can be hollow. The channel 430 can be shaped or configured as desired, but in one embodiment, can be square, rectangular, circular, or semicircular in cross section. The channel 430, in one embodiment, 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 sidewall 432. In one embodiment, the channel 430 can comprise two opposing sidewalls 432, 434 and a top wall 436. In one embodiment, the bottom wall of the channel 430 can constitute the top 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 has an open bottom end.

[0040] The channel 430 may have one or more channel openings 440 disposed between the channel 430 and the die opening inner surface 99. In one embodiment, 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 one embodiment, the channel openings 440 may connect the channel 430 to the interior of the die 80, thereby allowing gas 6 to be exchanged between the channel 430 and the interior of the die 80. That is, the channel openings 440 may provide gas communication between the channel 430 and the interior of the die 80. The channel openings 440 may be shaped as desired, but in one embodiment, may be square, rectangular, circular, oval, or semicircular in cross section. In certain embodiments, the channel openings 440 into the interior of the die 80 may be square or rectangular. The number, size, and arrangement of the channel openings 440 may vary based on the amount of gas that must be evacuated.

[0041] 22 and 23, the channel 430 may include a single channel opening 440. The channel opening 440 may extend circumferentially between the channel 430 and the die opening inner surface 99. In one embodiment, the channel opening 440 may extend partially or completely circumferentially around the die 80.

[0042] In other embodiments, the channel 430 can include multiple channel openings 440 (see FIGS. 14 and 25). For example, six channel openings 440 are shown in FIG. 25. The channel openings 440 can vary in size from one another. The channel openings 440 can be spaced equidistant from one another or can be distributed in any other manner known in the art. In one embodiment, the channel openings 440 can be disposed on only one side of the die assembly.

[0043] In one embodiment, the channel opening 440 can be disposed below the positioning portion 90 of the die 80. More specifically, the channel opening 440 can be disposed below the disk support surface 92 of the positioning portion 90. Thus, the channel opening 440 can be disposed below the disk 50 when the disk 50 is in place prior to insertion into the container 60 (see FIG. 33 ). In one embodiment, the channel opening 440 can be disposed within the die opening inner surface 99. In one embodiment, the channel 430 and the channel opening 440 can be disposed adjacent to the bottom surface 85 of the upper section 87 of the die 80.

[0044] In one embodiment, the channel 430 is completely circumferential within the die 80. In another embodiment, the channel 430 is partially circumferential within the die 80. In one embodiment, the channel 430 comprises a plurality of discontinuous channels within the die 80.

[0045] In one embodiment, the channel 430 can be sealed off from access to the atmosphere when the disk 50 is positioned within the positioning portion 90 of the die 80. In one embodiment, the vertically extending portion 212 of the outer mandrel 210 (discussed below) restrains the paper-based disk 50 (see FIG. 4) during bottom edge formation. In one embodiment, the pressure that the vertically extending portion 212 of the outer mandrel 210 applies to the paper-based disk 50 can seal the channel 430 from access to the atmosphere. At such point, the gas exhaust assembly 400 can aspirate or vacuum gas from the interior of the vessel, as described further herein.

[0046] In one embodiment, the valve 420 can be connected to a side channel pump, blower or fan, or vacuum pump (not shown) via piping or tubing 424 (see FIG. 31 ). Any side channel pump or vacuum pump or other suction device known in the art can be utilized. The valve 420 can be connected to the tubing via a coupling connection 410. The coupling connection 410 can be integral with the die 80. Alternatively, the coupling connection 410 can be threaded into the die 80. That is, there can be threads on at least a portion of the interior surface of the bore 82 that can align with and interconnect with threads on the exterior surface of the coupling connection 410.

[0047] The coupling connection 410 can have a distal end 412 configured to connect to a hose or tubing. The connection can be a snap fit, twist, or any other configuration known in the art. In one embodiment, the coupling connection 410 can include an elbow fitting, allowing the tubing to be mounted and suspended vertically, horizontally, or in any other position. In one embodiment, the coupling connection 410 can rotate about its axis to prevent tubing tangling.

[0048] In one embodiment, the exhaust assembly 400 includes multiple valves 420, coupling connections 410, and tubing. In a particular embodiment, the exhaust assembly 400 includes three valves 420 and three corresponding coupling connections 410 and tubing. In one embodiment, the number of valves 420 corresponds to the number of sealing member(s) 40 (discussed below). In this embodiment, if there are three sealing member(s) 40, there are three valves 420, each disposed within one of the sealing member(s) 40. In other embodiments, the number of valves 420 can be greater than the number of sealing member(s) 40. For example, the sealing member 40 can include a single, integral sealing member 40, but have two or three valves 420 disposed therein. In one embodiment, 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 can be disposed in each valve section 4 .

[0049] In one embodiment, the gas pumping mechanism operates within a reduced pressure vacuum chamber. In another embodiment, however, the gas pumping mechanism operates under standard atmospheric conditions without the use of a vacuum chamber.

[0050] "Mandrel Assembly" As noted above, the mandrel assembly 200 can include an inner mandrel 220 and an outer mandrel 210. The inner mandrel 220 and the outer mandrel 210 can be vertically translatable independently of one another. In one embodiment, the inner mandrel 220 and the outer mandrel 210 translate parallel to one another, which can be, but is not necessarily, vertical. For example, the system can provide an inner mandrel 220 and an outer mandrel 210 that translate horizontally or angularly.

[0051] In one embodiment, the inner mandrel 220 can move a first distance and the outer mandrel 210 can move a second distance, where the first and second distances are different from each other. Similarly, the inner mandrel 220 can move for a first time period and the outer mandrel 210 can move for a second time period, where the first and second times are different from each other. In one embodiment, the inner mandrel 220 and the outer mandrel 210 can move together during a first period of time. In one embodiment, the inner mandrel 220 can have a first extension length and the outer mandrel 210 can have a second extension length, where the first and second extension lengths are 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. Each of the outer mandrel 210, inner mandrel 220, and ejector 30 contacts the die assembly 300 simultaneously, in one embodiment.

[0052] The outer mandrel 210, in one embodiment, can be generally cylindrical. In this embodiment, the container can be cylindrical. However, if the container is not cylindrical (i.e., has a square, triangular, rectangular, irregular cross section, etc.), the outer mandrel 210 can have a shape and configuration that correlates with the shape and configuration of the container.

[0053] In another embodiment, the outer mandrel 210 can include a vertically (i.e., downwardly) extending portion 212 and a radially outwardly facing flange 214. The flange 214 can be absent in some embodiments (see FIG. 19 ). The vertically extending portion 212, in one embodiment, can be perforated and / or have a through hole 216 disposed therein. In one embodiment, the vertically extending portion 212 and the radially outwardly facing flange 214 can meet at a right angle or near a right angle.

[0054] In one embodiment, the vertically extending portion 212 of the outer mandrel 210 can be sized to fit within the inner periphery of the positioning portion 90. In one embodiment, the vertically extending portion 212 of the outer mandrel 210 has a perimeter that is greater than the perimeter of the die opening 98, such that the vertically extending portion 212 of the outer mandrel 210 cannot extend into the die opening. More specifically, the vertically extending portion 212 of the outer mandrel 210 can be sized and / or configured to be disposed adjacent the positioning portion sidewall 94 and the disk support surface 92 of the positioning portion 90 when fully extended. In one embodiment, the vertically extending portion 212 of the outer mandrel 210 can be extended after the disk 50 is seated within the positioning portion 90 and can be configured to secure the disk 50 in place (see FIG. 4 ).

[0055] As shown in Figure 12, the inner mandrel 220 can be generally cylindrical. As discussed above with respect to the outer mandrel, the inner mandrel 220 can be shaped and configured to correlate with the shape and configuration of the container. For example, if the container has a square cross-section, the inner mandrel 220 can have a square shape and configuration.

[0056] In one embodiment, the inner mandrel 220 can be sized to fit within the inner periphery of the vertically extending portion 212 of the outer mandrel 210. In one embodiment, the inner mandrel 220 can be configured to extend vertically below the vertically extending portion 212 of the outer mandrel 210. In this embodiment, once the disk 50 is seated within the positioning portion 90 and restrained by the fully extended vertically extending portion 212 of the outer mandrel 210, the inner mandrel 220 can continue to move vertically downward, extending beyond the base of the vertically extending portion 212 of the outer mandrel 210 and forcing / urging the disk 50 into the open end 62 of the container 60 (see FIG. 6 ).

[0057] The inner mandrel 220 can include a first mandrel surface 222 adjacent to a second mandrel surface 224, which together are configured to insert and shape the paper-based disc 50 (see FIG. 12 ). In one embodiment, the first mandrel surface 222 can be joined to the second mandrel surface 224 at an angle between approximately 92° and 94°. In one embodiment, the first mandrel surface 222 can be horizontal or substantially horizontal and, when fully extended, can be disposed adjacent to the top surface of the disc 50. In one embodiment, the second mandrel surface 224 can be vertical or substantially vertical and can be configured to abut the inner surface of the vertically extending portion 212 of the outer mandrel 210 as the inner mandrel 220 passes through the outer mandrel 210. That is, the circumference of the second mandrel surface 224 can be smaller than the inner circumference of the vertically extending portion 212 of the outer mandrel 210. In one embodiment, the second mandrel surface 224 is parallel to the inner surface of the vertically extending portion 212 of the outer mandrel 210 .

[0058] While the first mandrel surface 222 and the second mandrel surface 224 are shown in the figures as being substantially flat (horizontal and vertical), it is noted that the first mandrel surface 222 and the second mandrel surface 224 can be curved, contoured, or shaped. The inner mandrel 220 can 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 comprise any other contour. While the inner mandrel 220 is shown as having a substantially circular cross-section, it is noted that the inner mandrel 220 can have a cross-section that is substantially circular, triangular, rectangular, square, pentagonal, hexagonal, or elliptical.

[0059] As the inner mandrel 220 pushes the disk 50 into the container 60 (see FIGS. 5-6 ), the disk is forced out from between the outer mandrel 210 and the positioning portion 90 of the die assembly 300. The central portion 56 of the disk 50 can be forced downward through the die opening 98 and into the open end 62 of the container 60, so that the central portion 56 (first deformed surface 53) remains flat or substantially flat (i.e., horizontal). During insertion of the disk 50 into the container 60, in one embodiment, the peripheral portion 58 of the disk 50 can bend at a right angle or near a right angle, shown as the second deformed surface 55 in FIG. 11 . In this embodiment, the peripheral portion 58 of the disk 50 (becoming the second deformed surface 55) can be forced through the die opening 98 and adjacent to the second mandrel surface 224. The resulting second deformed surface 55 (formerly peripheral portion 58 ) of the disk 50 can be disposed vertically or nearly vertically adjacent the inner sidewall 66 of the container 60 at the open end 62 .

[0060] The disk 50 can be pressed into the container 60 any distance deemed practical in the art. In one embodiment, the disk 50 has a recessed composite bottom 51 (FIG. 11). In one embodiment, the peripheral edge 57 of the disk 50 is flush with the edge of the sidewall of the container 60. In another embodiment, the peripheral edge 57 of the disk 50 is disposed inwardly relative to the edge of the sidewall of the container 60. In one embodiment, the first deformed surface 53 and the second deformed surface 55 are joined at a right angle or near a right angle to the container body 60.

[0061] In one embodiment, the mandrel heater can be configured to heat the first mandrel surface 222 and / or the second mandrel surface 224 of the inner mandrel 220. In one embodiment, the mandrel heater can be disposed within the inner mandrel 220. The inner mandrel 220, in one embodiment, can further comprise an insulating portion formed from an insulating material configured to reduce heat transfer.

[0062] "Sealing member" The sealing member(s) 40 can be configured to provide heat and pressure for heat sealing. The sealing member(s) 40 can be positionable between a sealed position (FIGS. 1-6) and an open position (FIGS. 7-11). When in the sealed position, the sealing member(s) 40 are in contact with the outer surface 64 of the container 60, and when in the open position, the sealing member(s) 40 are not in contact with the container 60. In one embodiment, the sealing member(s) 40 comprise a segmented clamping bracket (see generally FIGS. 1-16).

[0063] In another embodiment, the sealing member 40 comprises a non-segmented clamping ring (see Figures 17-33). Figure 17 shows the system of the present invention with a non-segmented clamping ring, with the system in its initial state. In Figure 18, the system is moved to a position with the disc clamped in place. In Figure 19, the system is moved to a sealing position. Figure 20 shows removal of the sealing punch while the ejector holds the paper bottom in place. Finally, Figure 21 shows the ejector moving away from the container. Figures 17-23 further show connection to an exhaust line. In this embodiment, the sealing member can 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 a particular concern.

[0064] In one embodiment, e.g., a segmented clamping bracket embodiment, the sealing member(s) 40 can be rotatably coupled to the die assembly 300. The sealing member(s) 40 can be complementary shaped to one another so that when the sealing member(s) 40 are in the sealing position, the sealing member(s) 40 substantially surround the workpiece in a puzzle-like manner. In other embodiments, the sealing member 40 can comprise a single, integral member (i.e., a closed ring) that surrounds the container body 60 when the container is in place. When sealing the paper-based disc 50 to the composite body 60, the sealing member(s) 40 can compress the bottom end 62 of the composite body 60 along substantially the complete 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 substantially evenly compressed by the sealing member(s) 40. In one embodiment, there are three sealing members 40. In other embodiments, there is one sealing member 40 (i.e., a non-segmented clamping ring). However, it is noted that any number of sealing members 40 can be utilized. For example, the sealing system can include from about 1 to about 10 sealing members 40. Furthermore, the sealing member(s) 40 can each cover substantially equal sections of the composite body, or can cover substantially unequal sections.

[0065] The sealing member(s) 40 can be utilized to compress and heat the workpiece to perform the heat sealing operation. Each sealing member 40 can provide conductive heating to the container up to about 300°C. Additionally, the sealing member(s) 40 can apply pressure to the container up to about 30 MPa. The sealing member(s) 40 can be adjacent to one another.

[0066] As the sealing member(s) 40 contact the exterior surface 64 of the container body 60, the container body 60 and composite closure 51 can be compressed between the second mandrel surface 224 and the sealing member(s) 40. After compression and heat are applied for a sufficient dwell time, the sealing member(s) 40 can move away from the bottom end 62 of the container body 60 such that the sealing member(s) 40 are not in contact with the container body 60 after the dwell time has expired ( FIG. 10 ).

[0067] "Ejector" Once the sealing process is complete, in one embodiment, the mandrel assembly 200 is removed from the container body 60. In one embodiment, the outer mandrel 210 is translated outwardly 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 outwardly away from the die assembly 300 simultaneously.

[0068] In one embodiment, the ejector 30 is disposed within the inner mandrel 220 to aid in removal of the mandrel assembly 200 from the container 60. The ejector 30 may be spring-loaded in one embodiment. 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.

[0069] The ejector 30 can have a circumference at its lower end 32 that is shorter than the circumference of the inner mandrel 220. In this regard, the ejector 30 can be fitted to the inner circumference of the inner mandrel 220 in its retracted position (e.g., as shown in FIG. 12 ). In one embodiment, the base of the ejector 30 can comprise a cylindrical pyramid. In such an embodiment, the interior of the inner mandrel 220 can comprise a recess that is a cylindrical pyramid, thereby allowing the ejector 30 to be fitted to the inner mandrel 220. In one embodiment, the ejector 30 can be perforated and / or have a through hole disposed therein, as shown in FIGS. 20 and 28 .

[0070] In another embodiment, the base of the ejector 30 can include multiple disk contact sections that each contact the bottom closure 51 but are spaced apart from one another. For example, the ejector can include three or four prongs that are flattened at the contact surface with the closure 51 to avoid damage to the closure 51.

[0071] In one embodiment, the ejector has a bottom surface 34 designed to contact the bottom closure portion 51. In one embodiment, the ejector 30 can be solid across its bottom surface 34 from one side of the diameter to the other side of the diameter. In another embodiment, the ejector 30 can have a hollow interior portion, as shown in the figure. In this embodiment, the bottom contact surface 34 can be circular in cross section. In any embodiment, the bottom surface 34 of the ejector 30 can contact at least a portion of the first deformed surface 53 of the composite closure portion 51. In one embodiment, the first deformed surface 53 of the closure portion 51 can comprise a countersunk portion of the closure portion 51. In certain embodiments, the bottom surface 34 of the ejector 30 is circumferential and is positioned near the second deformed surface 55 of the composite closure portion 51 when in its extended position (e.g., as shown in FIG. 13 ).

[0072] In one embodiment, the bottom surface 34 of the ejector 30 can be flush with the first (lower) surface 222 of the inner mandrel 220 when the ejector 30 is in its recessed position (e.g., as shown in FIG. 12 ). In another embodiment, the ejector 30 can be slightly recessed within the inner mandrel 220 such that 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.

[0073] In one embodiment, the ejector 30 and the inner mandrel 220 (and / or the outer mandrel 210) can each translate vertically independently of one another. That is, the inner mandrel 220 can move a first distance and the ejector 30 can move a second distance, where the first and second distances are different from one another. Similarly, the inner mandrel 220 can move for a first time and the ejector 30 can move for a second time, where the first and second times are different from one another. In one embodiment, the inner mandrel 220 and the ejector 30 can move together for a first period of time. In one embodiment, the inner mandrel 220 can have a first extension length and the ejector 30 can have a second extension length, where the first and second extension lengths are different from one another.

[0074] In certain embodiments, the inner mandrel 220 (and / or outer mandrel 210) initially retracts vertically from the container 60 while the ejector 30 remains positioned adjacent to the composite closure 51 (shown in FIGS. 8 and 13 ) to maintain the position of the paper-based closure 51 within the container 60. In this embodiment, a space may be disposed between the outer periphery of the lower end 32 of the ejector 30 and the deformed portion 55 of the closure 51. This position ( FIGS. 8 and 13 ) may be referred to as the extended position of the ejector 30. In this embodiment, once the inner mandrel 220 has retracted beyond the peripheral edge of the container 60, in one embodiment, the ejector 30 then retracts vertically upward, back into the interior of the inner mandrel 220.

[0075] In another embodiment (see FIG. 28E ), after the sealing process is completed, 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 applying pressure to the closure portion 51. Alternatively, rather than applying pressure to the closure portion 51, the ejector 30 can translate downward with the container 60 and closure portion 51 in coordination with the movement of the container assembly. In this embodiment, the ejector 30 can then retract from contact with the closure portion 51 and retract into the mandrel assembly 200.

[0076] In one embodiment, ejector 30 comprises means for delivering a controlled blast of air directed at closure 51 simultaneously with or immediately prior to retraction of ejector 30 from closure 51. In one embodiment, delivery of pressurized air can include a showerhead mechanism disposed within ejector 30. In one embodiment, mandrel assembly 200 comprises an ejector coupling 201 and a mandrel or sealing head coupling 202 (see FIG. 19 ).

[0077] The ejector 30 of the present invention avoids the problems caused by the standard mandrel retraction process. That is, standard mandrel retraction involves dragging the mandrel away from the container (or vice versa), causing friction between the mandrel and the paper-based closure. Because the mandrel and the container are separate, any relative movement of the paper-based closure can cause folds, wrinkles, and / or air bubbles to form in the seal, reducing or destroying the container's airtightness. The ejector 30 of the present invention allows for stabilization of the paper-based closure's position within the container body during the mandrel removal process (i.e., during outfeed). The ejector 30 helps ensure an airtight seal between the closure 51 and the container 60 throughout the entire paper-bottom sealing process.

[0078] After retraction of both the inner mandrel 220 and the ejector 30, the container can optionally be removed from the die assembly 300 and mandrel assembly 200 in a vertically downward manner (FIG. 10). In one embodiment, the movement of the inner mandrel 220, ejector 30, and container can be synchronous. In one embodiment, the inner mandrel 220 and outer mandrel 210 can then be completely retracted vertically upward from the die assembly 300, optionally in a unitary manner (FIG. 11). In one embodiment, the mandrel assembly 200 and die assembly 300 are then positioned for another insertion, bottom closure formation, and sealing process.

[0079] "Container Support Assembly" The container support assembly can be configured to retrieve and / or maintain the metal body 60 and hold the metal body 60 in a desired location. The container support assembly can include a tube support member configured to receive the metal body 60. In one embodiment, the tube support member can lift the container 60 vertically upward against the die assembly 300 and mandrel assembly 200.

[0080] In one embodiment, the container 60 is inserted into the die assembly by lifting it upward and is secured in a vertical position within the die assembly by contacting the rim or edge of the container 60 with the lower surface of the die opening 98 (see FIGS. 2-3). The container 60 is in a secured position to prevent relative vertical movement of the container 60 while the inner mandrel 220 moves in and out of the container assembly.

[0081] "Closed part" As shown in FIG. 2 , in one embodiment, the paper-based disc 50 can have an upper surface 52 and a lower surface 54 that define a sheet thickness. In one embodiment, the paper-based disc 50 can include a layered structure, i.e., a fiber layer, an oxygen barrier layer, and a sealant layer. The paper-based disc 50 can include a central portion 56 and a peripheral portion 58. In one embodiment, the central portion 56 and the peripheral portion 58 can be substantially flat. For example, the paper-based disc 50 can be cut or formed into a circular disc. In another example, the paper-based disc 50 can be cut or formed into a dome-shaped disc (not shown) whereby the central portion 56 is offset from the peripheral portion 58 along the Y-axis.

[0082] After formation, the paper-based disc 50 becomes a bottom closure 51 (FIG. 11). The bottom closure 51 can have a first deformed surface 53 and a second deformed surface 55. In one embodiment, the first deformed surface 53 can be substantially horizontal. In one embodiment, the first deformed surface 53 includes a central portion 56 of the paper-based disc. In another embodiment, the second deformed surface 55 can be substantially vertical and / or can include a peripheral portion 58 of the paper-based disc. In one embodiment, the first deformed surface 53 can be adjacent to the interior cavity of the container 60, and the second deformed surface 55 can be adjacent to an interior surface 66 of the sidewall of the container 60.

[0083] "method" In use, the sealing system 100 receives the disk 50 and seats it within the positioning portion 90 of the die assembly 300, optionally using vacuum pressure to properly seat the disk. In one embodiment, the container 60 is then lifted toward the die assembly 300 by a lift plate until the peripheral edge of the container 60 contacts the lower surface of the die 80. In this embodiment, the container inner sidewall 66 may be flush with the die opening 98. The outer mandrel 210, in one embodiment, then translates vertically downward toward the disk 50 until it contacts the peripheral portion 58 of the disk 50, restraining the disk 50 in place. More specifically, the vertically extending portion 216 of the outer mandrel 210 may be configured to secure the disk 50 in place (see FIG. 4 ).

[0084] When the disk 50 is clamped in place by the outer mandrel 210 (i.e., the vertically extending portion 216 of the outer mandrel 210), the open end (bottom) of the container 60 is isolated from the ambient atmosphere. The force of the outer mandrel 210 against the disk 50 can create a sealed or near-sealed condition within the container 60 between the container 60 and the disk 50. The gas valve(s) can then be opened, if necessary, and air is vacuumed from the container interior through the channel openings 440 and the channels 430, thus creating an under-pressure condition within the container 60. More specifically, the side channel pump or vacuum pump can be designed to draw a defined volume of gas from the interior of the container. The defined volume of gas can be related to the size and volume of the container 60 and the depth to which the disk 50 is inserted into the container 60 to seal it thereto. More specifically, the defined volume of gas can be defined as the insertion depth of the paper bottom multiplied by the internal volume of the container. In any embodiment, the volume of gas evacuated should be less than the volume of gas that would cause the container 60 to collapse. In some embodiments, the rate at which gas is evacuated from the container can be adjusted. For example, some containers, such as those with larger internal volumes, may have a higher risk of collapse when using a high-speed gas evacuation process. 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 evacuation process. A process using a lower vacuum pressure may require a higher flow rate for the gas evacuation process. Those skilled in the art will understand these variations.

[0085] 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.

[0086] When the side channel pump or vacuum pump is started, air within the tubing, connector 410, and valve 420 can be sucked into the side channel pump or vacuum pump. Additionally, air within channel 430, channel opening 440, and the interior of the container can be sucked into the side channel pump or vacuum pump. Without releasing the pressure between outer mandrel 210 and disk 50, paper disk 50 is then immediately inserted (or punched) into container 60 by inner mandrel 220 so as to be recessed. The suction and insertion steps can occur simultaneously or nearly simultaneously. That is, air can be sucked from the interior of the container a fraction of a second before inserting disk 50 into container 60.

[0087] In one embodiment, insertion of the disk 50 into the container 60 is accomplished by the inner mandrel 220. In this embodiment, the inner mandrel 220 and ejector 30 can continue to translate vertically downward toward the disk 50. The inner mandrel 220 and ejector then contact the disk 50 and urge the disk 50 downward through the die opening 98 until the disk 50 is deformed to have a flat central portion and deformed sidewalls 55 adjacent the inner sidewall 66 of the container 60. In one embodiment, pressure can be applied to the disk by the first mandrel surface 222 and / or the second mandrel surface 224 of the inner mandrel 220 (e.g., by actuating the inner mandrel 220 along the Y-axis).

[0088] The deformed composite closure 51 can then be hermetically sealed to the container body 60. In one embodiment, this occurs without releasing the pressure of the inner mandrel and die that maintains the under-pressure condition within the container. Compression and heat can be applied to the deformed composite closure 51 and / or the container body 60, causing their respective sealant layers to form a hermetic seal. In one embodiment, 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 against the exterior surface 64 of the container 60 and / or the deformed sidewall of the closure 51.

[0089] An airtight seal according to the present disclosure can be formed by sealing member 40 at a temperature greater than about 90°C, such as, for example, from about 120°C to about 280°C, or from about 140°C to about 260°C. A suitable airtight seal can be formed by maintaining sealing member(s) 40 in contact with bottom end 62 of composite body 60 for any dwell time sufficient to heat the sealant layer to a suitable temperature to form an airtight seal, such as, for example, less than about 5 seconds, from about 0.8 seconds to about 5 seconds, or from about 1 second to about 4 seconds. Bottom closure 51 and bottom end 62 of composite body 60 can be compressed between sealing member 40 and inner mandrel 220 at any pressure less than about 30 MPa, such as a pressure of from about 1 MPa to about 22 MPa.

[0090] After compression and / or heat have been applied for a sufficient dwell time, the sealing member 40 can move away from the bottom end 62 of the container 60, such that the sealing member 40 is not in contact with the composite body 60 after the dwell time has expired ( FIG. 7 ). The inner mandrel 220 can then be retracted from the closure 51 while the ejector 30 remains in place. Once the inner mandrel 220 has at least cleared the peripheral edge of the container 60, the ejector 30 then retracts, optionally with a blast of pressurized air to aid in a smooth retraction process. The ejector 30 then retracts fully within the inner mandrel 220. The container 60 then moves away from the die assembly 300 and mandrel assembly 200 before, during, or after the mandrel assembly 200 is fully retracted from the die assembly 300.

[0091] In one embodiment, the systems and methods described herein can produce hermetically sealed containers with a paper-based composite bottom that can be inserted into the composite container and sealed in a recessed position without causing the membrane seal (i.e., the membrane seal at the top edge) to dome due to excessive pressure within the container. Because the top seal membrane is not domed, there are no instability issues. The container can stand stably (upside down) on its membrane end as it is transported to the downstream packaging process (i.e., from the sealing machine to the case cap). Furthermore, an overcap can be easily attached to the container because the membrane lid is not domed.

[0092] Furthermore, the hermetically sealed containers of the present invention can be shipped worldwide, for example, by sea, air, or rail, subject to varying atmospheric conditions (caused, for example, by temperature fluctuations, humidity fluctuations, and altitude fluctuations) without unacceptable doming of the membrane lid.

[0093] In certain embodiments, multiple composite containers can be formed by systems and devices suitable for processing multiple paper-based discs, bottom closures, and composite containers in a synchronized manner. For example, a manufacturing system can include multiple mandrel assemblies, multiple die assemblies, multiple gas exhaust assemblies, and multiple tube support assemblies operating in a cooperative manner. In particular, a turret device having multiple subassemblies, each subassembly including a mandrel assembly, a die assembly, a gas exhaust assembly, and a tube assembly, can simultaneously or synchronously accept and process discs. Depending on the complexity of the turret device, hundreds of individual composite containers can be produced per cycle in a synchronized manner. Thus, any of the processes described herein can be performed simultaneously. For example, when each subassembly operates in a synchronized manner, each of the following can be performed simultaneously: a first paper-based disk can be positioned over the die opening; a second paper-based disk can be constrained between the mandrel assembly and the die assembly; a third paper-based disk can be formed into a first bottom closure by insertion into the first metal body, and the third bottom closure can be hermetically sealed to the second metal body. Alternatively, any of the operations described herein can be performed simultaneously, such as by a device having multiple subassemblies.

[0094] In one embodiment, the systems and methods of the present invention allow the closure system to operate at high speeds (e.g., greater than 300 containers / minute). In another embodiment, the systems and methods of the present invention allow the closure system to operate at speeds of at least 400 containers / minute. In yet another embodiment, the systems and methods of the present invention allow the closure system to operate at speeds of at least 500 containers / minute.

[0095] It should be appreciated that the present disclosure provides an airtight closure container for packaging moisture-sensitive and / or oxygen-sensitive solid food products, such as, for example, crisp hydrocarbon-based food products, salted food products, crisp food products, potato chips, processed potato snacks, nuts, and the like. Such an airtight closure container can provide an airtight closure under widely different climatic conditions, including high and low temperatures, high and low humidity, and high and low pressure. Furthermore, the airtight closure container can be manufactured according to the methods described herein by processes including conduction heating techniques that have relatively low environmental pollution. The airtight closure container described herein has low weight, high structural stability, and can be suitable for recycling. [Example]

[0096] In the following examples, the paper bottom containers of the present invention (composite container, paper bottom, membrane cover, and overcap) were tested for various properties. The paper bottoms of the tested containers were made of flexible board (i.e., cup stock) (195 g / m²) as the paper layer. 2 (0.3 mm thick), a tie layer, aluminum foil (8 μm) as a barrier layer, and an ionomer layer (32 g / m) as a sealant layer. 2 ) was included. In some containers, a PET layer was included to protect the aluminum barrier layer. In other embodiments, an aluminum barrier layer was not included. All versions passed testing, as shown below.

[0097] [Example 1] In the high-altitude test, a container of the present invention was placed in a sealed chamber, and the pressure in the chamber was increased to at least 11 in. Hg over a period of approximately 10 minutes. If the container could withstand 10 in. Hg (simulating atmospheric pressure as the container travels over the Rocky Mountains) for at least 10 minutes, the container passed the test. If it could not, the container was listed as "missed." As used herein, "Rocker Bottoms Observed" refers to membrane and / or paper bottom doming during vacuum chamber confinement due to overpressure conditions that are normal under such conditions. After removal from the container, the doming returned to neutral. Dome formation can be considered as the membrane or paper bottom moving outward from the interior of the container so that it extends beyond the relevant cut edge of the container. Failures include leaks, peeling membranes or paper bottoms, sustained distortion after pressure is released, seam rupture or delamination, membrane or paper bottom rupture, and / or other failures that will prevent the container from meeting airtightness standards. If the membrane or paper bottom domes inward into the can upon pressure release, this can indicate a leak failure. Test results are discussed below.

[0098] [Table 1a]

[0099] Testing has shown a 99.4% success rate for the paper bottom described herein, which is acceptable.

[0100] [Table 1b]

[0101] Testing has shown an acceptable success rate of 98% for the standard laminate and 100% for the lightweight paper bottom described herein.

[0102] [Example 2] In this example, a container of the present invention was subjected to a helium leak test. Helium can be used as a tracer gas to detect leaks because it only constitutes about 5 ppm in the atmosphere, so background levels are very low. Helium also has a relatively low mass, making it mobile and completely inert / non-reactive. 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 gas from within the container could be drawn and passed through a mass spectrometer to read any increase in helium level within the container above the background reading. In this example, the helium leak limit was 2.3 x 10 -4 mbar * The average speed was 100 s / sec. A success rate of 99.8% was observed. This result is acceptable.

[0103] [Table 2]

[0104] [Example 3] In this example, a container of the present invention was subjected to a container integrity test. The container was placed in a vacuum chamber under 200 mbar pressure, and vacuum collapse was measured over a 20-second period. The method uses pressure change measurements to indirectly measure the flow from the container into a constant volume chamber. A mass extraction variant measures the flow required to maintain the vacuum at a constant level (ASTM F2338 and ASTM F3287). If the container has a leak, it will reduce the expected vacuum inside the vacuum chamber. Vacuum loss or collapse was measured over 1 second. The pass / fail threshold was set at 42 Pa / s. A 98.6% success rate was observed. This result is acceptable.

[0105] [Table 3]

[0106] [Example 4] In this implementation, a container of the present invention was subjected to a container periodic test interval ("PTI") test. The container was placed in a vacuum chamber under 700 mbar pressure and vacuum collapse was measured over a 20 second period. Vacuum loss or collapse was measured for 1 second. The pass / fail threshold was set at 20 Pa / s. A 96% success rate was observed. This result is acceptable.

[0107] [Table 4]

[0108] [Example 5] In this example, the inventors analyzed the simulated shelf life of containers of the present invention. Containers with a 0.0% residual oxygen level were filled, sealed, and stored. The containers were then tested for residual oxygen levels after 6 and 9 months. The pass / fail threshold was set at 2.0% residual oxygen or less over these periods (a threshold of 4.0% to 4.5% can be considered acceptable after approximately 18 months). A 92% success rate was observed. This result is acceptable.

[0109] [Table 5]

[0110] [Example 6] In this example, we used the vacuum collapse method described herein to compare leakage of containers with a paper-bottom closure of the present invention to containers with a metal-bottom closure. 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" comprises a metal-bottom container. As can be seen, the paper-bottom container has an overall smaller pressure drop during vacuum collapse than the container with a metal bottom end. Figure 34 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. 1. A sealing system for sealing a closure to a container, comprising:

1. A die assembly comprising: a die having a positioning portion configured to hold a disk and a die opening adjacent to the positioning portion; at least one sealing member configured to provide heat to seal the disk to the container; a die assembly comprising: A mandrel assembly having a recessed portion and an extended portion, an outer mandrel having an extension portion adjacent a peripheral portion of the retained disk that is sized to fit within an inner periphery of the positioning portion in the extended position; an inner mandrel configured to translate through an inner periphery of the extended portion of the outer mandrel and through the die opening to the extended position; and an ejector disposed within the inner periphery of the inner mandrel; Equipped with the sealing member is disposed opposite the mandrel assembly when the mandrel assembly is in its retracted position; a mandrel assembly; 1. A gas exhaust assembly comprising: at least one hollow channel disposed at least partially circumferentially within said die; at least one channel opening disposed within the die and connecting the at least one hollow channel to an interior of the die, the at least one channel opening being disposed between the positioning portion of the die and the sealing member; and means for drawing gas from the interior of the die, the at least one channel opening, and the at least one hollow channel to an exterior of the die; a gas exhaust assembly comprising: A system comprising:

2. The system of claim 1 comprising a plurality of channel openings.

3. The system of claim 1 , further comprising at least one valve disposed within the die connecting the at least one hollow channel to the exterior of the die.

4. 4. The system of claim 3, further comprising at least one tube connecting said at least one valve to said means for drawing gas.

5. The system of claim 1 , wherein the means for drawing gas comprises a side channel pump.

6. The system of claim 1 , further comprising a plurality of valves disposed within the die connecting the at least one hollow channel to the exterior of the die.

7. The system of claim 1 , wherein the channel opening is disposed between the retained disk and the container into which the retained disk is sealed.

8. The system of claim 1 , wherein the extending portion of the outer mandrel has a perimeter that is greater than a perimeter of the die opening.

9. The system of claim 1 , wherein the extending portion of the outer mandrel restrains the disk against the positioning portion of the die.

10. The system of claim 1 , wherein the at least one channel opening is disposed perpendicularly between the positioning portion of the die and the sealing member.

11. The system of claim 1 , wherein the outer mandrel, the inner mandrel, and the ejector extend, translate, and retract in parallel with one another.

12. the outer mandrel extends vertically; the inner mandrel translates vertically; The system of claim 1 , wherein the ejector translates vertically.

13. The system of claim 1 , wherein the closure is paper-based.

14. 1. A method for sealing a closure to a container, comprising: Providing a die assembly, a die having a positioning portion configured to hold a disk and a die opening adjacent to the positioning portion; at least one sealing member configured to provide heat to seal the disk to the container; providing a die assembly comprising: providing a mandrel assembly having a recessed portion and an extended portion, said mandrel assembly comprising: an outer mandrel having an extension portion adjacent a peripheral portion of the retained disk, the extension portion being sized to fit within an inner periphery of the positioning portion in the extended position; an inner mandrel configured to translate through an inner periphery of the extended portion of the outer mandrel and through the die opening to the extended position; and an ejector disposed within the inner periphery of the inner mandrel; Equipped with the sealing member is disposed opposite the mandrel assembly when the mandrel assembly is in its retracted position; providing a mandrel assembly; providing a gas exhaust assembly, at least one hollow channel disposed at least partially circumferentially within said die; at least one channel opening disposed within the die and connecting the at least one hollow channel to an interior of the die, the at least one channel opening being disposed between the positioning portion of the die and the sealing member; and means for drawing gas from the interior of the die, the at least one channel opening, and the at least one hollow channel to an exterior of the die; providing a gas exhaust assembly comprising: positioning the disk in the positioning portion of the die; axially aligning the container with the positioning portion of the die; positioning the container so that a peripheral edge of the container is in contact with a lower surface of the die; translating the outer mandrel so that the outer mandrel restrains the disk against the positioning portion of the die; drawing gas from the interior of the vessel, the at least one channel opening, and the at least one channel to an exterior of the die; translating the inner mandrel so that the inner mandrel presses the disk into the container and deforms the disk into the container end; sealing the container end to the container; A method comprising:

15. 15. The method of claim 14, wherein the interior of the container is sealed off from access to the atmosphere when the outer mandrel restrains the disk in the positioning portion of the die.

16. The method of claim 14 , wherein the steps of aspirating gas and translating the inner mandrel occur simultaneously.

17. The method of claim 14 , wherein the steps of aspirating gas and translating the inner mandrel occur simultaneously.

18. The method of claim 14 comprising a plurality of channel openings.

19. The method of claim 14 , further comprising at least one valve disposed within the die connecting the at least one hollow channel to the exterior of the die.

20. 20. The method of claim 19, further comprising at least one tube connecting said at least one valve to said means for drawing gas.

21. The method of claim 14 , wherein the means for drawing gas comprises a side channel pump.

22. The method of claim 14 , further comprising a plurality of valves disposed within the die connecting the at least one hollow channel to the exterior of the die.

23. The method of claim 14 , wherein the channel opening is disposed between the retained disk and the container into which the retained disk is sealed.

24. The method of claim 14 , wherein the extending portion of the outer mandrel has a perimeter that is greater than a perimeter of the die opening.

25. The method of claim 14 , wherein the outer mandrel, the inner mandrel, and the ejector extend, translate, and retract in parallel with one another.

26. the outer mandrel extends vertically; the inner mandrel translates vertically; The method of claim 14 , wherein the ejector translates vertically.

27. The method of claim 14 , wherein the sealing member is disposed perpendicularly opposite the mandrel assembly when the mandrel assembly is in the retracted position of the mandrel assembly.

28. The method of claim 14 , wherein the at least one channel opening is disposed perpendicularly between the positioning portion of the die and the sealing member.

29. The method of claim 14, wherein the closure is paper-based.

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