Methods and devices for knurl formation for closures

Abstract

A device and system disclosed is disclosed herein for forming knurls. The device may include a knurl applicator chuck for thermoformed polyester resin closures. The chuck can include a top adapter configured to interface with a capping machine; a bottom portion having a through hole extending therethrough to capture and retain a polyester resin closure; and a plurality of jaws received between the top adapter plate and the bottom plate, the plurality of jaws each including a plurality of radially inward facing teeth, the teeth being configured to create knurls on an outer surface of the closure when the chuck is rotated in a first direction, during a capping process, and release the closure when the chuck is rotated in a second direction.

Description

Attorney Docket No.227254-702601 Date of Filing: February 21, 2025 METHODS AND DEVICES FOR KNURL FORMATION FOR CLOSURES CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No.63 / 556,071, filed February 21, 2024, U.S. Provisional Application No. 63 / 559,809, filed February 29, 2024, and U.S. Provisional Application No.63 / 642,610, filed May 3, 2024, the disclosures of which are incorporated herein by reference in their entirety. TECHNICAL FIELD

[0002] The present disclosure relates to container closures, for example methods and devices for forming a knurl on the closure. BACKGROUND

[0003] Pharmaceutical, beverage, and many other containers are conventionally prepared from polyethylene terephthalate (“PET”), while closures of the containers are conventionally prepared from high-density polyethylene (“HDPE”) or polypropylene (“PP”) through injection molding. Injection molding of the closures may limit the thinness of the parts of the closures due to flow rate restrictions and ability to eject the closures from the mold. Additionally, the incompatibility of HDPE and PP with the PET recycle stream requires that the closures be sorted away from the associated containers by post-consumer recycling processing facilities. Therefore, there is a need in the art for closures formed from materials that are more readily recyclable and are formed with a plurality of knurls for easier handling and feel to the closure.

[0004] High Density Polyethylene (HDPE) is the current polymer of choice for the bottle capping industry. However, HDPE is not optimal for recycling, as it can only be recycled up to 10 times before its quality is compromised resulting in the material being discarded as waste. HDPE resins used for caps have a narrow melt flow index. There are also particular specifications for caps used in different applications such as Hot Fill, Water, or CSD bottles. Even one recycling attempt can lead to manufacturing defects that impact cap performance and manufacturing efficiency. Moreover, within the environment of food safety, there are stringent requirements for HDPE used in cap seals, which means that caps are downcycled after use. The use of PET solves this problem as it can be mechanically recycled an unlimited number of times with no quality degradation, which was not always possible. The improvement of rPET recycling over the last decade has significantly reduced issues related to black specks and degradation. More importantly, PET is compatible with the SSP process, which allows the molecular weight to be brought backAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 up with each mechanical recycling loop. Additionally, there is an extra step to separate HDPE and PET through sink float system with current bottle recycling methods.

[0005] The traditional method of producing HDPE caps with knurls involves either injection or compression molding. Injection molding involves injecting molten plastic into a mold cavity, while compression molding uses heat and pressure to force a charge of plastic into a mold. Both methods result in a cap with the desired shape and texture, including the necessary knurls. For thermoformed PET caps, the process focuses on precise features on the inside of the cap.

[0006] While thermoforming offers several advantages over traditional methods, there are still challenges associated with producing PET caps with knurls on the outside. Forming the knurls on the outside of the cap requires careful interaction with the existing forming process or a method to make the knurls after forming. This can be difficult due to the confined space of the mold. Additionally, if the knurls are formed while the PET is still hot and soft, cutting may not be required, but this must be done quickly before the material cools and hardens. There is also a risk of deformation during the formation of the knurls, which can affect the quality and functionality of the cap.

[0007] The instant disclosure provides for devices and methods which can be used to form knurls on the exterior of the cap made from PET. SUMMARY

[0008] In an embodiment, a knurl applicator chuck for thermoformed polyester resin closures is disclosed. The chuck includes a top adapter configured to interface with a capping machine; a bottom portion having a through hole extending therethrough to capture and retain a polyester resin closure; and a plurality of jaws received between the top adapter plate and the bottom plate, the plurality of jaws each including a plurality of radially inward facing teeth, the teeth being configured to create knurls on an outer surface of the closure when the chuck is rotated in a first direction, during a capping process, and release the closure when the chuck is rotated in a second direction.

[0009] In some embodiments, the polyester resin can include polyethylene terephthalate ("PET"). The plurality of jaws can be four jaws. Each of the jaws can include 18 teeth. The jaws can be maintained within the chuck by pivot pins. An O-ring can surrounds the plurality of jaws to create a pre-tension. The chuck can additionally include a jaw retaining disc disposed between the jaws and the top adapter. The pivot pins can be received within holes in the jaw retaining disc. The jaws and jaw retaining disc can form a floating assembly within the chuck.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0010] In some embodiments, the jaw retaining disc can includes a downward extending cylinder facing the jaws, and radially inward of the jaws, configured to limit inward motion of the jaws and limit the resulting force applied to the closure. The chuck can additionally include a housing ring having a plurality of radially inward extending cam surfaces disposed between the top adapter and the bottom portion. The plurality of radially inward extending cam surfaces are configured to push the plurality of jaws radially inward as the housing ring is rotated relative to the closure. The chuck can include a plurality of bolts retaining the top adapter, housing ring, and bottom portion together such that the jaws are retained therein.

[0011] In some embodiments, the bottom portion can further include a funneled entry at a bottom of the through hole configured to direct the closure into the chuck. The chuck can be configured to create knurls in an outer surface of the closure having a depth of at least 0.2 mm deep. The chuck can be configured to create knurls in the outer surface of the closure at room temperature.

[0012] In an embodiment, a method of forming knurls in thermoformed polyester resin closures is provided, the methods includes connecting a top adapter of a chuck with a capping machine; inserting the closure into a bottom portion having a through hole extending therethrough to capture and retain the closure; rotating the chuck in a first direction such that a plurality of jaws create knurls on an outer surface of the closure when the chuck is rotated in the first direction; and releasing the closure from the chuck when the chuck is rotated in a second direction, opposite to the first direction.

[0013] In some embodiments, the rotating step can be performed while applying the closure to a container. The polyester resin can include polyethylene terephthalate ("PET"). The knurls can be formed in an outer surface of the closure have a depth of at least 0.2 mm.

[0014] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. DRAWINGS

[0015] In order that the present disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings. The components in the figures are not necessarily to scale. Moreover, in the figures, like-referenced numerals designate corresponding parts through the different views.

[0016] FIG.1 illustrates a side view with a partial diametrical cross-section of an example of a closure mounted to an example of a finish of a container;Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0017] FIG.2 illustrates a diametrical cross-sectional view of another example of a closure including an external seal for sealing to another example of a finish of a container;

[0018] FIG.3 illustrates a perspective view of yet another example of a closure;

[0019] FIG. 4A illustrates a perspective view of yet another example of a closure that is formed but not fully processed about a finish of a container;

[0020] FIG.4B illustrates a perspective view of the example of a closure of FIG.4A that has been fully processed about a finish of a container;

[0021] FIG. 5 illustrates a diametrical cross-sectional view of yet another example of a closure including a plurality of internal knurls about a circumference of an inner surface of a tamper evidence feature;

[0022] FIG. 6 illustrates a partial diametrical cross-sectional view of the example of a closure of FIG.5 processed on yet another example of a finish of a container;

[0023] FIG.7 illustrates a perspective view of yet another example of a closure including a tamper evidence feature including a folded band folded outward around an outer wall;

[0024] FIG. 8 illustrates a side view of yet another example of a closure including a plurality of threads;

[0025] FIG. 9A illustrates a side view of yet another example of a closure including one thread and a plurality of knurls distributed circumferentially;

[0026] FIG.9B illustrates a side view of yet another example of a closure including three separate threads and a plurality of knurls distributed circumferentially;

[0027] FIG.9C illustrates a perspective view of the closure illustrated in FIG.9A;

[0028] FIG.9D illustrates a perspective view of the closure illustrated in FIG.9B;

[0029] FIG. 10 illustrates a side view of yet another example of a closure including a plurality of threads;

[0030] FIG. 11A illustrates a perspective view of yet another example of a closure including two separate thermoformed layers that are subsequently combined;

[0031] FIG.11B illustrates a perspective diametrical cross-sectional view of the example of the closure illustrated in FIG.11A;

[0032] FIG.11C illustrates a diametrical cross-sectional view of the example of the closure of FIGs.11A and 11B;

[0033] FIG.12A illustrates a perspective view of yet another example of a closure and an example of a seal;

[0034] FIG. 12B illustrates a perspective view of a closure-seal combination of the example of the closure and the example of the seal illustrated in FIG.12A;Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0035] FIG.12C illustrates a perspective view of an example of a closure-seal combination on yet another example of a finish;

[0036] FIG. 13 illustrates a perspective diametrical cross-sectional view of yet another example of a closure on yet another example of a finish, a circumference of a top wall of the closure that is ultrasonically or thermally bonded to a top surface of the finish;

[0037] FIG. 14 illustrates a perspective of yet another example of a closure including a branding feature on a top wall;

[0038] FIG.15 illustrates a plot of average thread depth and pressure retention of twenty- five sample closures;

[0039] FIG. 16 illustrates a plot of the ability of twenty-five sample closures to retain pressure when applied to a finish of a container;

[0040] FIG.17A illustrates a partial cross-sectional view of an upper portion of an example of an injection-molded closure;

[0041] FIG. 17B illustrates a partial cross-sectional view of the example of the closure illustrated in FIG.17A mounted to yet another example of a finish; and

[0042] FIG. 18 illustrates a plot of the closing torque versus seal as a function of thread formation.

[0043] FIG. 19 illustrates perspective view of another example of a closure including a plurality of knurls about a circumference of an exterior.

[0044] FIG.20 illustrates a side view of the closure of Figure 19 including the plurality of knurls on the exterior surface of the closure.

[0045] FIG.21 illustrates a prior art flex chuck.

[0046] FIG. 22A illustrates an exploded view of a knurl forming chuck according to an embodiment of the present disclosure.

[0047] FIGS.22B and 22C illustrate a chuck holding a cap according to an embodiment of the present disclosure.

[0048] FIGS. 23A and 23B illustrate alternative top adapter plates according to embodiments of the present disclosure.

[0049] FIG. 24 illustrates a chuck housing according to an embodiment of the present disclosure.

[0050] FIG. 25 illustrates a chuck spacer according to an embodiment of the present disclosure.

[0051] FIGS.26A and 26B illustrate alternative bottom plates according to embodiments of the present disclosure.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0052] FIGS. 27A and 27B illustrate alternative jaws according to embodiments of the present disclosure.

[0053] FIGS. 28A and 28B illustrate alternative jaw retaining disc according to embodiments of the present disclosure.

[0054] FIG.29 illustrates an O-ring according to an embodiment of the present disclosure.

[0055] FIG.30 is a partial view of jaws interfacing with a cap.

[0056] FIGS. 31A, 31B, and 31C illustrate various interference fit applicators according to embodiments of the present disclosure.

[0057] FIG.32 is a chart illustrating cap application and removal torque.

[0058] FIG. 33 illustrates a perspective view of an exemplary embodiment of a thermoformed PET container closure including a plurality of knurls about a circumference of an exterior, according to the present disclosure.

[0059] FIG. 34 illustrates a side view of an exemplary embodiment of a thermoformed PET container closure including a plurality of knurls about a circumference of an exterior in accordance with the present disclosure.

[0060] FIG.35 illustrates a top view of an exemplary embodiment of a thermoformed PET container closure including a plurality of knurls about a circumference of an exterior, according to the present disclosure.

[0061] FIG.36 illustrates an exemplary embodiment of a thermoforming process whereby knurls can be formed on a thermoformed PET container closure, in accordance with the present disclosure.

[0062] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0063] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0064] In an example, the present disclosure provides closures formed from a polymer that may be recycled in the same recycling stream as the containers closed by the closures. Examples of suitable polymers from which the closures described herein may be formed may include polyester resins, including bio-modified polyesters, such as co-polymers of PET and polyethylene furandicarboxylate (“PEF”), which may include from 0 to 100 mole percent of each of PET and PET (for example, 100 mole percent or less of PET, with the remainder, if any, being PEF), andAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 co-polymers modified by isophthalic acid (“IPA”) or other additives or co-monomers. In certain examples, closures may be made of a polyester resin that includes PEF of up to 90 mole percent (0.90 mole fraction) of the polyester resin. In other examples, the PEF may be derived from a reaction of furandicarboxylate (“FDCA”) with ethylene glycol, polyethylene glycol (“PEG”) and / or diethylene glycol (“DEG”). In still other examples, closures may be made from a polyester resin having a total comonomer content of the reaction product of FDCA with ethylene glycol, PEG, and / or DEG of up to 50 mole percent (0.5 mole fraction) of the polyester resin. The polyester resin may be prepared by a process including melt blending PEF with PET, or by a process that includes reacting ethylene glycol with FDCA. In still other examples, closures may be made by injection molding or compression molding a polyester resin including a total comonomer content of the reaction product of FDCA with ethylene glycol, PEG, and / or DEG of up to 90 mole percent (0.90 mole fraction) of the polyester resin), or up to 50 mole percent (0.50 mole fraction) of the polyester resin, or from 5 to 25 mole percent (from 0.05 to 0.25 mole fraction) of the polyester resin, or from 12 to 15 mole percent (0.12 to 0.15 mole fraction) of the polyester resin. In still other examples, closures may be made by thermoforming a polyester resin having a total comonomer content of the reaction product of FDCA with ethylene glycol, PEG, and / or DEG of up to 50 mole percent (0.50 mole percent) of the polyester resin, or from 0.5 to 20 mole percent (from 0.05 to 0.20 mole fraction) of the polyester resin, or from 1 to 8 mole percent (from 0.01 to 0.08 mole fraction) of the polyester resin. In still other examples, a container may be made of a polyester or polyester resin described herein. A closure comprising a polyester or polyester resin described herein may be heat shrunk to a finish or thermally or ultrasonically bonded to a finish of a container comprising a polyester or polyester resin described herein.

[0065] In another example, a closure may include a plurality of layers of polyester resins. In certain examples, an inner layer of a plurality of layers may be more compliant than an outer layer of the plurality of layers to more readily deform to the finish, and provide a better seal. Additionally, or alternatively, an outer layer may provide more aesthetic appeal than an inner layer, which may be more functional than an outer layer. Examples of techniques for preparing a closure including a plurality of layers of polyester resins may include thermoforming, compression molding, and injection molding.

[0066] As described herein, examples of closures made from polyester resin, such as PET and / or PEF, may have a number of advantages over closures made from conventional materials, such as HDPE and / or PP. For example, the polyester resin closures described herein may help to avoid contaminating a recycle stream and may be made from a high fraction of recycled polyester resin, such as recycled PET (“rPET”). The rPET supply may be cleaner and more readilyAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 accessible than HDPE supplies. In certain examples, the polyester resins may be supplemented with bio-based PET (“bio-PET”) or virgin-PET. Additionally, or alternatively, another advantage of the polyester resin closures described herein may be that the polyester resin closures may increase the oxygen and carbon dioxide barrier compared to HDPE and PP, thereby increasing the resulting shelf-life of beverages due to the improvement in barrier. In certain examples, an oxygen barrier of closures including PET may be at least 10 times greater than an oxygen barrier of closures made from HDPE. In other examples, the oxygen barrier of closures may even further increase if the closures also include FDCA. Additionally, or alternatively, another advantage of the polyester resin closures described herein may be that the polyester resin closures will not float, and may reduced the tendency of closures to contaminate the environment.

[0067] Additionally, or alternatively, another advantage of the polyester resin closures described herein may be that the polyester resin closures may provide for lighter container finishes, which may reduce the cost of materials and the amount of material wasted. Additionally, or alternatively, another advantage of the polyester resin closures described herein may be that because the coefficient of thermal expansion of a polyester resin closure described may closely match the coefficient of thermal expansion of a PET finish of a container, the ability to successfully seal a lighter finish may improve. Additionally, or alternatively, another advantage of the polyester resin closures described herein may be that during a deformation caused by an external force, such as during storage or transportation, a closure and a finish may deform similarly due to the material of the closure and the finish being similar, resulting in the sealing between the closure and finish remaining intact.

[0068] Additionally, or alternatively, another advantage of the polyester resin closures described herein may be that because the polyester resin closures are made from a material similar to, or the same as, the container, such as, for example, PET, the closures may be thermally or ultrasonically welded to the finish of the container. In some examples, a polyester resin closure described herein may be welded to a PET finish at one or more locations. In certain examples, a closure may be welded to a top rim of a finish to provide an additional seal between the closure and the finish. In other examples, one or more spot welds may be included so as to provide evidence of lack of tampering. The ability to weld a closure to a PET container may also offer a unique way to meet the tethering requirements of the European Union and considered for the United States. In still other examples, a polyester resin closure described herein may include a tamper-evident (“TE”) band, a spiral tether, or another feature such as a hinge that is spot welded at one or more terminal points to the container, providing a tether with controlled strength.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0069] In an example, the closures described herein may require from 10 N to 20 N of force for removal.

[0070] In an example, polyester resin closures described herein may be made via a thermoforming process. Thermoformed closures may be designed to balance wall thickness and tuning for an interference fit with container finishes within the elastic limit of PET or any of the other polymers described herein, such as by, for example, including a plug seal or an external seal. Because of the relatively higher stiffness of polyester resins, such as PET, compared to HDPE and PP (for example, on the order of two times higher), the seal designs for conventional HDPE and PP closures may be ineffective for thermoformed polyester resin disclosures described herein, because the seal designs for conventional HDPE and PP closures rely upon a relatively high level of elastic deformation that is generally not achievable with thermoformed polyester resin closures described herein. Accordingly, in certain examples, the seal configurations of thermoformed polyester resin closures may be tailored to provide sufficient sealing with less material strain.

[0071] In an example, closures described herein may be made by vacuum forming. In certain examples, closures described herein may be made via pressure-assisted vacuum forming at pressures up to 4 bar, preferably up to 24 bar, and more preferably up to 40 bar. In other examples, a thermoformed polyester resin closure with a plug seal may include a relatively wide sealing surface that may be designed to bridge defects (for example, scratches) that may be present in the finish of a container. By contrast, plug seals of conventional HDPE and PP closures take advantage of the relative softness of the HDPE and PP material and are designed with relatively high levels of elastic deformation that result in relatively smaller areas of sealing contact with the finish. In still other examples, a polyester resin closure described herein, such as a thermoformed polyester resin disclosure, may include a sealing surface of a plug seal with a width of 0.7 millimeters that may be configured for a finish with an inner diameter of 26 millimeters, and a width of 1.5 millimeters that may be configured for a finish with an inner diameter of 48 millimeters.

[0072] In an example, a plug seal of a closure described herein may be configured for providing an interference fit with a finish, such that a sealing surface of the closure may provide sufficient pressure against a mating surface of the finish and provide sufficient sealing, including for containing pressurized contents, such as carbonated liquids. An amount of interference may refer to a difference between a radius of a sealing surface of a closure and a corresponding sealing surface of a finish. The amount of interference may vary depending on a diameter of a finish and a wall thickness of a closure. In certain examples, an amount of interference may range from 0.02 millimeters to 0.2 millimeters for material thicknesses in a range of from 0.2 millimeters to 0.5Attorney Docket No.227254-702601 Date of Filing: February 21, 2025 millimeters. In other examples, an amount of interference for a closure thermoformed from a sheet of PET having a thickness of 0.5 millimeters may be 0.05 millimeters. An amount of interference may be adjusted, for example by changing a behavior of the polyester resin such as by including FDCA and / or DEG, such that a softer polymer may result in a larger interference fit and / or a larger thickness. The values for interference disclosed herein are nominal interference values provided as examples, and variations from the disclosed values may occur due to manufacturing variability.

[0073] In an example, a polyester resin closure described herein may be thermoformed from a sheet of polyester resin described herein having a thickness of from 0.20 millimeters to 2.00 millimeters. In certain examples, a sheet of polyester resin may have a thickness of from 0.20 millimeters to 1.95 millimeters, or to 1.90 millimeters, or to 1.85 millimeters, or to 1.80 millimeters, or to 1.75 millimeters, or to 1.70 millimeters, or to 1.65 millimeters, or to 1.60 millimeters, or to 1.55 millimeters, or to 1.50 millimeters, or to 1.45 millimeters, or to 1.40 millimeters, or to 1.35 millimeters, or to 1.30 millimeters, or to 1.25 millimeters, or to 1.20 millimeters, or to 1.15 millimeters, or to 1.10 millimeters, or to 1.05 millimeters, or to 1.00 millimeters, or to 0.95 millimeters, or to 0.90 millimeters, or to 0.85 millimeters, or to 0.80 millimeters, or to 0.75 millimeters, or to 0.70 millimeters, or to 0.65 millimeters, or to 0.60 millimeters, or to 0.55 millimeters, or to 0.50 millimeters, or to 0.45 millimeters, or to 0.40 millimeters, or to 0.35 millimeters, or to 0.30 millimeters, or 0.25 millimeters; or from 0.25 millimeters, or from 0.30 millimeters, or from 0.35 millimeters, or from 0.40 millimeters, or from 0.45 millimeters, or from 0.50 millimeters, or from 0.55 millimeters, or from 0.60 millimeters, or from 0.65 millimeters, or from 0.70 millimeters, or from 0.75 millimeters, or from 0.80 millimeters, or from 0.85 millimeters, or from 0.90 millimeters, or from 0.95 millimeters, or from 1.00 millimeters, or from 1.05 millimeters, or from 1.10 millimeters, or from 1.15 millimeters, or from 1.20 millimeters, or from 1.25 millimeters, or from 1.30 millimeters, or from 1.35 millimeters, or from 1.40 millimeters, or from 1.45 millimeters, or from 1.50 millimeters, or from 1.55 millimeters, or from 1.60 millimeters, or from 1.65 millimeters, or from 1.70 millimeters, or from 1.75 millimeters, or from 1.80 millimeters, or from 1.85 millimeters, or from 1.90 millimeters, or from 1.95 millimeters to 2.00 millimeters; or any range that may be formed from any two of the foregoing numbers, including any subranges therebetween. Preferably, a sheet of polyester resin may have a thickness of from 0.50 millimeters to 0.90 millimeters, including any of 0.50 millimeters, 0.55 millimeters, 0.60 millimeters, 0.65 millimeters, 0.70 millimeters, 0.75 millimeters, 0.80 millimeters, 0.85 millimeters, or 0.90 millimeters, including any ranges or subranges therebetween. In other examples, a desirable or preferable thickness of a sheet of aAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 polyester resin described herein used to prepare a polyester resin closure described herein may be a determinable function of a diameter of a polyester resin closure.

[0074] In an example, so as to enable a plug seal of a closure described herein to deform when engaging a finish, a thermoformed polyester resin closure may be configured with sufficient radial clearance between an outer surface of the finish and an outer wall of the closure, which encloses the outer surface of the finish. Without a radial clearance, a plug seal of a closure may not be able to fully insert within a finish, or stress on a closure may be high enough to cause failure.

[0075] In an example, a thermoformed polyester resin closure described herein may be configured with an external seal that seals with an outer surface of a mouth of a finish. The external seal may be achieved with an interference fit with the finish. An amount of interference may depend on the application. Examples of interferences and wall thicknesses disclosed above for the plug seal may be used for the external seal. In certain examples, a sealing of the external seal may be enhanced by taking advantage of an ability of a polyester resin to heat shrink by heat shrinking a closure after capping.

[0076] To achieve a suitable interference of a seal, such as a plug seal and / or an external seal, with the finish, and in certain examples, a suitable clearance between an outer wall of a closure and a finish, the dimensions of the interference and the clearance may be well controlled during manufacture by thermoforming a closure using a male mold that matches a shape of a desired interference with the finish while accounting for shrinkage. The features of the closure that may provide the interference and clearance with the finish may be in contact with the mold.

[0077] Because thermoformed polyester resins are relatively stiff, a sealing surface of a polyester resin closure may have a relatively low surface roughness. In certain examples, a low surface roughness may be achieved by polishing regions of a thermoforming mold that form the sealing surfaces. In other examples, portions of a thermoforming mold that do not form the sealing surfaces of the closure are not polished, or are not polished to the same degree as portions that do form the sealing surface so as to avoid a closure sticking to the mold and being difficult to release. Examples of a roughness of sealing surface(s) of a closure may include about 0.2 microns (an Ra value of 0.2 or an N4 finish).

[0078] In various examples, a seal, a thread-engagement, and / or a TE band of a polyester resin disclosure described herein may be configured to provide an opening torque in a range of from 0.45 N-m to 1.24 N-m, and preferably 1.02 N-m. In various examples, a closure may be configured to provide a pressure retention of less than or equal to 2 bar, and preferably less than or equal to 10 bar.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0079] In an example, a polyester resin used in thermoformed closures described herein may include some amount of FDCA and / or DEG, which may provide numerous advantages. For example, FDCA and DEG may interfere with crystal formation, so resulting material may have a longer processing window in which to form features on the closure. Additionally, including FDCA and / or DEG may make material of a closure sufficiently different from material of a finish such that the closure does not fuse to the container during storage. Additionally, including FDCA and / or DEG may lower a modulus of material of a closure, which may allow for higher material strains, and higher material strains may be useful for increasing a seal between a closure and a finish.

[0080] In an example, a closure may be made by injection molding or compression molding a polymer resin. In certain examples, the polyester resin may include some amount of FDCA and / or DEG. The FDCA and / or DEG content may sufficiently reduce the modulus of the material such that a closure may easily eject from various cavities of a mold. For example, a modulus of the amorphous phase of the material may be in the range of 1 to 3 GPa. An increased FDCA content may increase the processing window such that ejection of a closure is easier, because the polyester resin may remain soft for a longer period of time. The amount of FDCA and / or DEG in a polyester resin that is submitted to injection molding or compression molding may be relatively higher than an amount of FDCA and / or DEG in a thermoformed closure because of a need for greater compliance in injection molding or compression molding. In certain examples, an ability of a material to flow during injection molding or compression molding may be increased by limiting an intrinsic viscosity of the material. Examples of methods of limiting an intrinsic viscosity of the material may include limiting the duration of solid-state polymerization of the polyester resin after synthesizing the polyester resin. In certain examples, an intrinsic viscosity may be in a range of from 0.4 dL / g to 0.7 dL / g. Similar to thermoformed closures, by including FDCA and / or DEG in a polyester resin closure described herein, the closure material may be made sufficiently different from a finish material such that the closure may not fuse to the container during storage. Further, by including FDCA and / or DEG in a polyester resin closure described herein, the modulus of the closure material may be lowered, which may allow for higher material strains, and which may increase the seal between the closure and the finish.

[0081] In an example, a movable core component may be used in injection molding or compression molding in order to reduce the need of warm threads so as to strip stiff PET, which is conventionally performed with injection molded HDPE. In certain examples, an FDCA-, PEG- , and / or DEG-modified polyester resin may be used in combination with a movable core.

[0082] In certain examples, closures may be colored using dye or dyeing processes that are compatible with recycling. For example, a dye used to color a closure may be compatible withAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 recycling. In other examples, a dye or an ink may be removable via washing. In still other examples, a nanocoating may be deposited on a surface of a closure.

[0083] Closures may be configured to fit custom or industry standard finishes. Examples of industry standard thread finishes may include 26 / 22, 29 / 25, 29 / 21, 28PCO1881, 30 / 25, 38 / 33, and 48 mm.

[0084] Closures Made of Copolymers of PET and PEF (“PETF”)

[0085] In an example, a closure may be made of a PET-based copolymer that may be particularly suited for injection molding and / or thermoforming. The PET-based copolymer incorporates a co-monomer to control crystallization and reduce melt processing temperatures. In certain examples, the present disclosure provides a copolymer of PET and PET (also referred to as a FDCA-modified PET copolymer, or “PETF”). In other examples, the FDCA may be incorporated at a range of amounts such as to enhance the polymer reaction rates during both melt and solid state polymerization, and such as to allow polymer performance that may match traditional PET controlled by adding an amount of IPA. In still other examples, FDCA may be substituted for or added to PET in addition to IPA so as to make PETF. In still other examples, FDCA may be added in a low fraction, and the PETF copolymer product may be made following the same process as to make PET.

[0086] In an example, the present disclosure provides a FDCA-modified PET copolymer that incorporates FDCA at an amount that may allow appropriate retardation of crystal formation in PET during closure forming. In certain examples, the PETF may include less than 10 mole % FDCA, or less than 9 mole % FDCA, or less than 8 mole % FDCA, or less than 7 mole % FDCA, or less than 6 mole % FDCA, or less than 5 mole % FDCA, or less than 4 mole % FDCA, or less than 3 mole % FDCA, or less than 2 mole %, or less than 1 mole % FDCA, or an amount in a range formed from any two of the foregoing numbers, including all ranges and subranges therebetween. In other examples, the PETF may include as low as 0.5 mole % FDCA, and retard crystal formation sufficiently. In still other examples, the PETF may include from 0.5 mole % to 5 mole % FDCA, of from 0.5 mole % to 4 mole % FDCA, or from 0.5 mole % to 3 mole % FDCA, or from 0.5 mole % to 2 mole % FDCA, or from 1 mole % to 5 mole % FDCA, or from 1 mole % to 4 mole % FDCA, or from 1 mole % to 3 mole % FDCA, or from 1 mole % to 2 mole % FDCA; or about 1.1 mole % FDCA, or about 1.2 mole % FDCA, or about 1.3 mole % FDCA, or about 1.4 mole % FDCA, or about 1.5 mol % FDCA, or about 1.7 mol % FDCA, or about 1.8 mol % FDCA, or about 1.9 mol % FDCA, or about 2 mol % FDCA, or an amount in a range formed from any two of the foregoing numbers, including all ranges and subranges therebetween.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0087] In an example, the copolymers provided herein may include repeating units (L), (M), and (N), or any salts thereof:

[0088] Repeating unit (L) may be a polyethylene furanoate (“PEF”) repeating unit based on furandicarboxylic acid (FDCA). In an example, repeating unit (L) may be present in an amount of from 0.5 mol % to 90.0 mol %, or to 85.0 mol %, or to 80.0 mol %, or to 75.0 mol %, or to 70.0 mol %, or to 65.0 mol %, or to 60.0 mol %, or to 55.0 mol %, or to 50.0 mol %, or to 45.0 mol %, or to 40.0 mol %, or to 35.0 mol %, or to 30.0 mol %, or to 25.0 mol %, or to 20.0 mol %, or to 15.0 mol %, or to 10.0 mol %, or to 9.5 mol %, or to 9.0 mol %, or to 8.5 mol %, or to 8.0 mol %, or to 7.5 mol %, or to 7.0 mol %, or to 6.5 mol %, or to 6.0 mol % of the copolymer; or from 6.5 mol %, or from 7.0 mol %, or from 7.5 mol %, or from 8.0 mol %, or from 8.5 mol %, or from 9.0 mol %, or from 9.5 mol %, or from 10.0 mol %, or from 15.0 mol %, or from 20.0 mol %, or from 25.0 mol %, or from 30.0 mol %, or from 35.0 mol %, or from 40.0 mol %, or from 45.0 mol %, or from 50.0 mol %, or from 55.0 mol %, or from 60.0 mol %, or from 65.0 mol %, or from 70.0 mol %, or from 75.0 mol %, or from 80.0 mol %, or from 85.0 mol % to 90.0 mol % of the copolymer; or any range made from any two of the foregoing numbers, including any subranges therebetween. In certain examples, repeating unit (L) may be present in an amount of from 0.5 mol % to 6.0 mol % of the copolymer, including all subranges therebetween. In other examples, repeating unit (L) may be present in an amount of up to 90.0 mol % of the copolymer. As the mole percent of FDCA is increased, the rate and degree of crystallization of PET may decrease.

[0089] Repeating unit (M) is may be based on terephthalic acid (“PTA” or “TPA”). In an example, repeating unit (M) may be present in an amount of from 10.0 mol % to 99.5 mol %, or to 99.0 mol %, or to 98.5 mol %, or to 98.0 mol %, or to 97.5 mol %, or to 97.0 mol %, or to 96.5 mol %, or to 96.0 mol %, or to 95.5 mol %, or to 95.0 mol %, or to 94.5 mol %, or to 94.0 mol %, or to 93.5 mol %, or to 93.0 mol %, or to 92.5 mol %, or to 92.0 mol %, or to 91.5 mol %, or toAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 91.0 mol %, or to 90.5 mol %, or to 90.0 mol %, or to 85.0 mol %, or to 80.0 mol %, or to 75.0 mol %, or to 70.0 mol %, or to 65.0 mol %, or to 60.0 mol %, or to 55.0 mol %, or to 50.0 mol %, or to 45.0 mol %, or to 40.0 mol %, or to 35.0 mol %, or to 30.0 mol %, or to 25.0 mol %, or to 20.0 mol %, or to 15.0 mol %, or to 10.0 mol %; or from 10.0 mol %, or from 15.0 mol %, or from 20.0 mol %, or from 25.0 mol %, or from 30.0 mol %, or from 35.0 mol %, or from 40.0 mol %, or from 45.0 mol %, or from 50.0 mol %, or from 55.0 mol %, or from 60.0 mol %, or from 65.0 mol %, or from 70.0 mol %, or from 75.0 mol %, or from 80.0 mol %, or from 85.0 mol %, or from 90.0 mol %, or from 90.5 mol %, or from 91.0 mol %, or from 91.5 mol %, or from 92.0 mol %, or from 92.5 mol %, or from 93.0 mol %, or from 93.5 mol %, or from 94.0 mol %, or from 94.5 mol %, or from 95.0 mol %, or from 95.5 mol %, or from 96.0 mol %, or from 96.5 mol %, or from 97.0 mol %, or from 97.5 mol %, or from 98.0 mol %, or from 98.5 mol % to 90.0 mol %; or any range made from any two of the foregoing numbers, including any subranges therebetween. In certain examples, repeating unit (M) may be present in an amount of from 94 mol % to 99.5 mol %, including all subranges therebetween. In other examples, repeating unit (M) may be present in at least 10.0 mol % of the copolymer.

[0090] Repeating unit (N) is based on IPA, and may be optional. In certain examples, repeating unit (N) may be present in an amount of from 0 mol % to 4 mol %, including all subranges therebetween.

[0091] In an example, the FDCA-modified PET copolymers described herein may act as a polymerization / melt-processing aid and may lead to several processing advantages, including, for example: improving the melt-phase polymerization times and / or process temperatures; allowing lower melt phase processing temperatures, which may reduce thermal degradation by-products and may improve b* (yellow) color of the copolymer; as FDCA concentration increases, decreasing process temperatures and protecting the polymer from thermal degradation by-products that may be associated with FDCA polymers produced at typical, unmodified PET process temperatures; reducing the melt temperatures of the copolymer to allow lower processing temperatures in closure forming; reducing the melt temperatures without reducing the melt viscosity in closure forming; producing polymers with high intrinsic viscosity (“IV”) at polymerization times and temperatures associated with unmodified PET; and / or producing high IV polymers with high IV at solid-state polymerization times and temperatures associated with unmodified PET.

[0092] In an example, crystal nucleation in PETF including FDCA in amounts of <2 mol % may be accelerated by nano-particles that have the ability to nucleate crystals in PET. In anotherAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 example, the rate nucleation of PETF including FDCA in amounts of >2 mol %, and even over 5 mol%, may be increased by using crystallization additives such as graphene.

[0093] In an example, a PEF component may have less entanglement density than PET.

[0094] In an example, the PETF provided herein may have low PEF yellowing due to low FDCA fractions used.

[0095] In an example, pellet blending for PETF concentration may be another route to PET with a low mole percent of FDCA.

[0096] In an example, PETF for use in the polyester resin closures described herein may be made by esterification of ethylene glycol (“EG”) and PTA in the presence of FDCA and optionally IPA. In certain examples, FDCA may be present in a range of from 0.05 mol % to 6 mol %, or from 1.5 mol % to 2 mol %, including all ranges and subranges therebetween. In other examples of PETF, in which IPA is also incorporated, IPA may be present in a range of from 0.01 mol % to 2 mol %, including all subranges therebetween.

[0097] PTA-Based Melt Polymer Process

[0098] In an example, the initial reaction of the PTA-based polymer process may react PTA with EG under a pressure of 40-50 psig at 250-270°C. Water may be evolved and separated using a distillation column. The reaction may be carried out under pressure because of the low solubility of PTA in EG at the boiling point of EG of 197°C. After most of the theoretical amount of water has been collected, the pressure may be reduced to atmospheric as the remaining water is evolved. The resulting bis(2-hydroxyethyl) terephthalate (“BHET”) may be heated in the presence of a suitable catalyst (such as antimony triglycolate), and EG is extracted in a kind of ester- interchange as two molecules of BHET form a dimer. If the released EG is removed from the system by distillation, further reactions may be possible. In certain examples, a dimer may react with another BHET molecule to form a trimer; two molecules of dimer may form a tetramer. By such stepwise growth process, a high-molecular-weight polymer may be produced.

[0099] In certain examples, suitable catalysts used for PET polymerization may include Sb- and Ti-based catalysts. In other examples, phosphoric acid and phosphates may be added to perform one or more of several roles, including, for example to serve as a catalyst or to minimize thermal oxidation. In still other examples, impurities in PTA may be less than 1 ppm of one or more of Fe, Co, Mo, Ni, Ti, Cr, Ca, Al, MG, Na, and K. Impurities of greater quantity may be present in PTA, and the impurities may act as chain terminators or cause discoloration.

[0100] For melt-phase polymerization, high temperatures, such as from 265 to 300°C, may be required, and the pressure above the melt polymer must be reduced to approximately 1 torr so as to facilitate the high molecular weights required for polymer performance. In production plants,Attorney Docket No.227254-702601 Date of Filing: February 21, 2025 multi-stage steam or glycol ejectors may be used to achieve the low pressure of approximately 1 torr.

[0101] PTA-Based Solid-State Polymerization (“SSP”)

[0102] Polyesters may be polymerized in the solid state as well as in the melt phase. In an example, to achieve solid-state polymerization, the polymer chip produced in the melt polymer process may be heated to high temperatures, such as from 200 to 210°C, under vacuum or in a stream of inert gas, such as nitrogen. The SSP process may allow high molecular weights to be achieved without the problems associated with processing hot, extremely viscous melts. Further, because the reaction temperature of the SSP process is lower than melt polymerization, thermal degradation of the polymer may be minimal.

[0103] During melt polymerization, degradation reactions may lead to the formation of acetaldehyde (“AA”) and carboxyl end groups. The SSP process acts as a “cleaning” process that may remove the melt phase degradation products and may reduce AA levels in polymer chips to 1 ppm or lower. Reduction of AA levels may be important for polymers used to make food-grade bottles destined to contain sodas and water, because even trace amounts of AA may produce off- flavors.

[0104] The main reaction in SSP is polyesterification, a result of the dehydration reaction between carboxyl and hydroxyl end groups on the polymer chains. The results of the polyesterification process gives SSP the ability to increase the viscosity and reduce the carboxyl end group (“CEG”) level in the polymer, both of which may be desirable properties in downstream applications. Furthermore, SSP also removes the cyclic oligomers formed in the melt phase polymers that may cause deposition problems in downstream polymer applications.

[0105] The rate of SSP may be governed by the diffusion of water and glycol out of the polymer chip and / or the rate of removal of AA. The reaction rate may be highly dependent upon a size of a polymer chip and there may be a molecular weight gradient from a surface to a center of a polymer chip.

[0106] In an example, toners may be used to adjust a color of the resulting PETF.

[0107] In an example, PETF for closures may be produced by melt mixing or blending pellets including FDCA in higher concentrations with PET that does not include FDCA. In certain examples, 10 mol % PET including an FDCA content of 10% blended with 90 mol % PET without FDCA yields PET including 1% FDCA.

[0108] Thermoformed PET Closure with Plug Seal

[0109] Referring to FIG.1, a side view with partial diametrical cross section of an example of a thermoformed polyester resin closure 100 mounted to an example of a finish 200 of a containerAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 typically used for storing liquid contents, such as still or carbonated drinks, is illustrated. Closure 100 may be made of any of the polyester resins described herein. Closure 100 includes internal threads 102 formed into outer cylindrical wall 104 of closure 100 for engaging with external threads 206 of finish 200. The threads 206 may be continuous threads or may be interrupted threads. Other examples may be configured for snap-on engagement with finish 200. Outer cylindrical wall 104 extends downwardly from annular wall 112.

[0110] Closure 100 includes plug seal 108 for sealing against inner surface 204 of finish 200. Plug seal 108 includes cylindrical wall 110 that extends downwardly from annular wall 112 of closure 100. Annular wall 112 may be configured to seat against top surface 210 of rim 208 of finish 200. Outwardly facing radical surface 114 of inner cylindrical wall 110 of plug seal 108 may be dimensioned for an interference fit with the corresponding inwardly facing surface 204 of rim 208 of finish 200 for sealing. In certain examples, an interference fit may be 0.05 millimeters for a wall thickness of 0.5 millimeters. As closure 100 is threaded onto finish 200, plug seal 108 is forced into the mouth of finish 200 into a compressed state in which outwardly facing radial surface 114 of plug seal 108 pushes against inwardly facing surface 204 of finish 200, forming a seal, the mouth being the open volume between diametrically opposing inwardly facing surfaces 204 of rim 208 of finish 200. Inner cylindrical wall 110 extends downwardly from annular wall 112 to lower wall 120. The degree of interference fit and dimensions of plug seal 108 and finish 200 determine the sealing force and, thus, these parameters may be adjusted to adjust the degree of sealing force for a given application. The interference fit between plug seal 108 and finish 200 may serve as a locking feature for locking closure 100 to finish 200. Plug seal 108 may include chamfer 122 for guiding plug seal 108 past lip 212 of the mouth of finish 200 as closure 200 is capped onto the container.

[0111] Plug seal 108 may be configured to have a relatively wide sealing interface with finish 200, the sealing interface being the contact area between outwardly facing radial surface 114 and inwardly facing surface 204 of finish 200, the sealing interface being designed to bridge defects (for example, scratches) that may be present in finish 200. An example width for the contact area between outwardly facing radial surface 114 and inwardly facing surface of the finish for finish 200 with an inner diameter of 26 millimeters may be 0.7 millimeters, and for finish 200 with an inner diameter of 48 millimeters may be 1.5 millimeters.

[0112] To enable closure 200 to elastically deform in the region of plug seal 108, closure 200 may be designed for a clearance between outer skirt 126 of outer cylindrical wall 104 of closure 100 and corresponding outer surface 214 of rim 208 of finish 200. The amount of clearance may be at least as much as the amount of interference of plug seal 108 with finish 200. ForAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 example, the amount of clearance may be 0.05 millimeters or more for an interference of 0.05 millimeters.

[0113] An interference fit 250 may be provided for threads 102 to ensure that closure 100 is tightly fitted to finish 200. An exemplary interference fit is 0.05 millimeters. Interference fit 324 of threads 102 may also serve as locking feature for locking closure 100 to finish 200. The interference may increase with reduction of the modulus of the material of closure 100.

[0114] Closure 100 includes tamper evidence feature 116, which in FIG.1 is illustrated in the form of folded band 106 that engages with a tamper evidence ledge 202 of finish 200. As closure 100 is threaded onto finish 200, folded band 106 rides over ledge 202, and once folded band 106 has cleared ledge 202, fits into place beneath ledge 202, as illustrated in FIG.1. Tamper evidence feature 116 may include a plurality of spaced-apart bridges 128 that connect folded band 106 to main body 124 of closure 100. In the event that closure 100 is unthreaded from finish 200, folded band 106 will be retained in position by ledge 202. The upward force from unthreading of closure 100 will eventually cause sufficient stress on bridges 128 that they will break, providing evidence that closure 100 has been tampered with.

[0115] Optionally, one or more of bridges 128 may be dimensioned such that its or their breaking stress is greater than the breaking stress of remaining bridges 128 such that the one or more bridges 128 will remain intact to provide a tether to keep closure 100 attached to the bottle upon removal.

[0116] In certain examples of closure 100, a pull tab may be included in place of folded band 106 as tamper evidence feature 116. The pull tab may be configured such that the pull tab must be at least partially removed in order to disengage closure 100 from finish 200.

[0117] Closure 100 may be thermoformed with a sheet of PET (or any of the materials described herein) with a thickness of 0.22 millimeters to 1.0 millimeters, preferably about 0.5 millimeters.

[0118] In other examples, the interface between annular wall 112 and top surface 210 of rim 208 of finish 200 may serve as a secondary seal. In still other examples, the secondary seal may be formed and / or enhanced by welding the two surfaces together, such as ultrasonically or via direct application of heat.

[0119] In still other examples, the portion of closure 100 with the greatest diameter is cylindrical in shape without any significant outwardly projecting interruptions in the general cylindrical shape. For example, as illustrated in FIG.1, lower outer wall 120 of outer cylindrical wall 104 of main body 124, which is at the greatest diameter of closure 100, may be vertical, whichAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 may enable the use of conventional capping equipment, which is typically designed to grip onto cylindrical shapes.

[0120] Lower wall 130 extends across a bottom of inner cylindrical wall 110. In certain examples, lower wall 130 may have a concave upward shape as illustrated in the example in FIG. 1 that, when pressure is applied (upward against lower wall 130 from pressurized contents of the container that closure 100 closes, becoming convex downward. A change in shape may result in the pressure applied to lower wall 130 increasing the pressure on the sealing interface between plug seal 108 and finish 200. In other examples, lower wall 130 may include one or more ridges, such as cylindrical ridges, or other features to control a shape that lower wall 130 may form when under pressure.

[0121] Thermoformed polyester resin closures may be configured with an external seal instead of or in addition to a plug seal. External seals may be easier to thermoform than plug seals, and may provide sufficient sealing for at least some beverages. Optionally, a heat shrinking step may be used to solidify the external seal of the closure.

[0122] Referring to FIG. 2, a diametrical cross-sectional view of another example of a thermoformed resin closure 300 that includes external seal 380 for sealing to finish 350 of a container is illustrated. Closure 300 may be made of any of the polyester resins described herein. External seal 380 may be provided by an interference fit between an inner surface 302 of the top end of closure 300 and outer surface 354 of mouth 352 of finish 350. An exemplary interference fit may be 0.05 milliliters.

[0123] Similar to closure 100 illustrated in FIG. 1, closure 300 may be configured for threaded engagement with finish 350 or may be configured for a snap-on pressure fit engagement with finish 350. Closure 300 may also include a tamper evidence feature such as folded band 304 like folded band 106 in closure 100.

[0124] Referring to FIG.3, a perspective view of yet another example of a closure 400 is illustrated. Outer wall 402 of closure 400 includes a plurality of threaded portions 404 equally distributed around outer wall 402. In between each of the plurality of threaded portions is each of a plurality of knurled portions 406, the plurality of knurled portions 406 equally distributed around outer wall 402. The knurls (or “ridges”) of the plurality of knurled portions 406 may be axial, and extend at least part of the way between annular wall 408 and lower outer wall 410, for example the upper half of the closure 400. As illustrated in FIG. 3, the threaded portions 404 are “interrupted” by the portion of the closure 400 which has the knurls formed thereon. In an embodiment, knurls can be formed in the upper portion of the lower mold component and be retracted before rotational demolding.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0125] Referring to FIG.4A, a perspective view of yet another example of a closure 450, which is formed but not fully processed about a finish of a container, is illustrated. Lower wall 452 includes tamper evidence feature 456 and folded band 454 that has not been processed to fold behind tamper evidence feature 456 and under a ledge of a finish (not shown). FIG.4B illustrates a perspective view of yet another example of a closure 460 that has been fully processed with folded band 454 processed to fold behind tamper evidence feature 456 and under a ledge of a finish (not shown).

[0126] Referring to FIG.5, a diametrical cross-sectional view of yet another example of a closure 500 including a plurality of internal knurls 504 about the circumference of an inner surface of tamper evidence feature 502. Plurality of internal knurls 504 may result in unconventional handling by contacting a surface of folded band 506 when closure 500 is processed on a finish of a container.

[0127] Referring to FIG. 6, a partial diametrical cross-sectional view of the example of closure 500 illustrated in FIG. 5 processed on a finish 600 of a container is illustrated. As illustrated in FIG.6, a surface of folded band 506 is in contact with plurality of internal knurls 504 of tamper evidence feature 502.

[0128] Referring to FIG.7, a perspective view of yet another example of a closure 700 is illustrated. Closure 700 includes a tamper evidence feature including a folded band 702 that is folded outward around outer wall 706 of closure 700. Folded band 702 includes a plurality of slits 704 that are evenly distributed circumferentially about folded band 702.

[0129] Referring to FIG. 8, a side view of yet another example of a closure 800 is illustrated. Closure 800 includes a plurality of threads 802 evenly distributed about a side wall of closure 800, each distinct thread of the plurality of threads 802 including one of a corresponding plurality of thread starts 804.

[0130] Referring to FIG. 9A, a side view of yet another example of a closure 900 is illustrated. FIG.9C illustrates closure 900 in a perspective view. Closure 900 includes one thread 902, with one thread start 904 at the beginning of thread 902. Tamper evidence feature 906 includes a plurality of knurls distributed circumferentially about closure 900. FIG.9B illustrates a side view of yet another example of a closure 950, and FIG. 9D illustrates closure 950 in a perspective view. Closure 950 includes a plurality of threads 952, such as, for example, three threads distributed evenly about the side wall of closure 950. Each of the plurality of threads 952 includes one of a corresponding plurality of thread starts 954. In certain examples, an example of closure 900 may be compatible with industry standard container finish PCO 1881. In other examples, an example of closure 950 may be compatible with industry standard container finishAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 26 / 22 mm. FIGs. 9A, 9B, 9C, and 9D illustrate that closures 900, 950 may be prepared from polyester resins described herein for a variety of finish formats with a range of numbers of thread starts and in a range of sizes.

[0131] Referring to FIG. 10, a side view of yet another example of a closure 1000 is illustrated. Closure 1000 includes a plurality of threads 1002, each of which includes one of a corresponding plurality of thread starts 1004. In certain examples, plurality of threads 1002 may include three, four, five, six, seven, eight, nine, ten, eleven, twelve, or more distinct threads, corresponding, respectively, to a plurality of thread starts 1004, which may include three, four, five, six, seven, eight, nine, ten, eleven, twelve, or more distinct thread starts in a number that equals the number of threads. Plurality of threads 1002 may allow snap-on application of closure 1000 to a finish of a container, and twist-off removal of closure 1000 from the finish.

[0132] Referring to FIG.11A, a perspective view of yet another example of a closure 1100 is illustrated. Closure 1100 includes two separate thermoformed layers that are subsequently combined: outer layer 1104, which includes a plurality of knurls 1102 distributed circumferentially about an outer surface of an outer layer outer cylindrical wall of outer layer 1104, and inner layer 1106, which includes thread 1108 on an inner surface of the inner layer outer cylindrical wall. Outer layer 1104 includes first shaped downward depression 1120 in an outer layer lower wall, and inner layer 1106 includes a second shaped downward depression 1118 in an inner layer lower wall, as the perspective diametrical cross-sectional view of FIG.11B illustrates. As illustrated in the diametrical cross-sectional view in FIG.11C, a lower surface 1114 of first shaped downward depression 1120 may confront and lock axially against an upper surface 1116 of second shaped downward depression 1118. Outer layer 1104 includes outer layer folded band 1110 disposed radially outward along a bottom circumference of the outer layer outer cylindrical wall which may confront and lock within a groove of inner layer folded band 1112. Outer layer 1104 and inner layer 1106 may lock rotationally and axially when combined, but may be thermoformed separately so that plurality of knurls 1102 and inner thread 1108 may both be defined by direct contact with a surface of a mold. In an embodiment, the two layers may be molded simultaneously, then cut out with a joint, e.g., a folded joint, and assembled in a subsequent step.

[0133] Referring to FIG.12A, a perspective view of yet another example of a closure 1200 is illustrated. Closure 1200 may be used with a finish of a container including a wide mouth. Closure 1200 includes thread 1204 and top wall 1202. Closure 1200 may be configured to close over a seal 1210. Seal 1210 may be attached to top surface 1232 of a finish 1230 of a container about circumference 1212 of seal 1210. Seal 1210 may be a foil seal. Seal 1210 may be configured as a tamper evidence feature that indicates whether a container has been opened by breakingAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 contact between circumference 1212 and top surface 1232. Seal 1210 may include a brand logo on a face of seal 1210 facing top wall 1202 of closure 1200. FIG.12B illustrates the closure-seal combination 1220 of closure 1200 with seal 1210 when seal 1210 is within closure 1200 and visible through top wall 1202. FIG.12C illustrates a perspective view of closure-seal combination 1220 on finish 1230. Thread 1204 of closure contacts thread 1234 of finish 1230, such that closure 1200 covers seal 1210. Under closure 1200, circumference 1212 of seal 1210 is attached to top surface 1232.

[0134] Referring to FIG.13, a perspective diametrical cross-sectional view of yet another example of a closure 1300 on a finish 1350 of a container is illustrated. Finish 1350 may have a wide diameter, corresponding to a container with a wide mouth. Top wall 1302 of closure 1300 includes circumference 1304 that is ultrasonically or thermally bonded to top surface 1352 of finish 1350.

[0135] Referring to FIG.14, a perspective view of yet another example of a closure 1400 is illustrated. Closure 1400 includes branding feature 1402 in a top wall of closure 1400, which may be selectively colored. The geometry of closure 1400 may enhance the surface stiffness of closure 1400.

[0136] Referring to Figure 19, a perspective view of yet another example of a closure 2000 is illustrated. Closure 2000 including a plurality of external knurls 2002 about the circumference of an exterior surface 2004 of the closure 2000. The plurality of external knurls 2002 may be found on the tamper evidence feature 2006 and on the threaded portion 2008 of the exterior surface 2004 of the closure 2000. The plurality of knurls may also be present and disposed on the top portion of the tamper evidence feature 2006 of the closure 2000.

[0137] Additionally, the closure 2000 includes a plurality of threads 2010, such as, for example, three threads distributed evenly about the side wall of closure 2012. Each of the plurality of threads 2010 includes one of a corresponding plurality of thread starts 2014. In certain examples, an example of closure 2000 may be compatible with industry standard container finish PCO 1881. In other examples, an example of closure 2000 may be compatible with industry standard container finish 26 / 22 mm.

[0138] Referring to Figure 20, a side view of yet another example of a closure 2000 is illustrated. FIG. 19 illustrates closure 2000 in a perspective view. Closure 2000 includes one thread 2020, with one thread start 2022 at the beginning of thread 2020. A tamper evidence feature 2006 includes a plurality of knurls distributed circumferentially about closure 2000. Further, the closure 2000 may include one thread 2020 with a thread start 2022 whereby the thread 2020 has a plurality of knurls disposed thereon.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0139] The present disclosure additionally provides methods of making closures described herein.

[0140] In an example, a method of making a closure described herein may include thermoforming a sheet of polyester resin into the closure. In certain examples, the thermoforming may include applying the sheet of polyester resin to a male mold.

[0141] In another example, a method of making a closure described herein may include injection molding or compression molding a polyester resin into the closure.

[0142] The present disclosure additionally provides methods of sterilizing closures and containers described herein.

[0143] In an example, a method of sterilizing a closure and a container described herein may include applying the closure to the container, and exposing the closure and the container to a source of electromagnetic radiation of a wavelength of from 200 to 300 nanometers. In certain examples, the exposing may be for a duration from 1 minute, or from 2 minutes, or from 5 minutes, or from 10 minutes, or from 15 minutes, or from 20 minutes, or from 25 minutes to 30 minutes or more; or from 2 minutes to 5 minutes, or to 10 minutes, or to 15 minutes, or to 20 minutes, or to 25 minutes, or to 30 minutes or more; or any range made from any two of the foregoing numbers, including any subranges therebetween. In other examples, the source of electromagnetic radiation may be of a wavelength of 253 nanometers to 254 nanometers. In still other examples, the source of electromagnetic radiation may be of a wavelength of from 255 nanometers to 280 nanometers. In still other examples, the source of electromagnetic radiation may be of a wavelength of about 230 nanometers. Examples of sources of electromagnetic radiation may include a low-pressure mercury lamp, ultraviolet light-emitting diodes, and a pulsed-xenon lamp.

[0144] The instant disclosure can provide for methods and devices for creating knurls on the cap itself, after it has been manufactured. In an embodiment, the instant disclosure provides for a chuck that can apply knurling to the cap during the capping process. For example, additionally or alternatively, initially, this disclosure can be separated into two main objectives; 1) design an applicator chuck for closures formed from, e.g., PET, and 2) to develop a manner in which knurling can be applied to the closure, or cap, formed from PET, for example. The instant applicator chuck may be needed in the case of PET caps due to the smooth exterior of the cap which is a result of the forming process. The smooth exterior of the cap can present unique challenges with interaction and therefore transference of torque from the capping machine to the cap. A typical applicator chuck, designed for standard 1881 closures, can only apply torque to the cap at approximately 0.8 in*lbs., which falls short of the NSF PCO 1881 testing standard. These torque standards for application and removal of caps are critical for the design. The chuck surfaceAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 can be modified to a higher grip material, but this can lead to increased wear and reduce the lifetime of the chuck.

[0145] The second objective, adding knurling to the exterior of the cap, can assist in the user removal process of the cap. Currently, knurling on caps can provide a dual purpose of assisting in the application of the cap by having the chuck integrate into this knurling pattern to transfer the torque applied by the capping machine. This knurling can also serve the purpose of being an ergonomic aid to the removal process. A range of preferences can go into the selection of the number and depth of knurls, but using current HDPE closures can provide a starting point.

[0146] Currently, bottling facilities often run custom chucks such as a Standard Flex Chuck which can be seen in FIG.21A. This chuck 12 uses ball bearings 14 as an assist feature to initially conform the jaws 16 to the cap shape. This can help when the cap applicator 12 is in the process of picking up the cap 10 and prevents crushing or misloading the cap 10. The jaws 14 can knurled faces which match the depth and spacing of the knurls which appear on the cap. These jaws 14 are partially retained into the chuck by and receive the force needed to ‘clamp’ around the cap via two rubberized bands which are seated on the posterior side of the jaw. These two interactions, the knurling on the jaw and the force provided by the bands, are the combination needed to currently apply a cap. The smooth exterior of PET caps today reduce the function of this chuck and other chuck designs due to material properties of the PET.

[0147] Typical knurl depths are on the order of 0.4 to 0.2 mm. Caps without knurls are common in the market. Examples are often found in medical packaging applications, such as vitamins. As is known in the industry, the typical chuck used for these applications includes a higher friction material to assist application. Usually that is a rubber-like material that helps grip the cap. One reason this is avoided in many beverage applications is these types of chucks wear faster than their metal counterparts. In addition, the knurls themselves help with grip of wet surfaces by hand. Many beverages are kept cold and therefore exhibit condensation before opening where knurls are particularly beneficial.

[0148] Therefore, the instant disclosure can provide for unique solutions to the existing technologies to allow for application of knurling on a cap formed from PET. The instant disclosure can provide for a sprag chuck applicator which can employ the use of a sprag chuck and can employ the use of a clutch feature to create knurls during thermoforming or to grip pre-formed caps at room temperature. The instant sprag chuck can be assembled using a number of subassemblies including a set of jaws retained within a chuck housing to retain the cap and form knurls on the cap in both heated and room temperature conditions.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0149] In an embodiment, as shown in FIG.22A, a sprag chuck 3000 is disclosed that can mimic the mechanical function of a sprag clutch in that jaws can apply a radial inward force when the chuck is rotated in one direction and no radially inward force when the chuck is rotated in the opposite direction. In some embodiments, the sprag chuck 3000 can be formed from a resilient metal material. For example, the sprag chuck 3000 can be formed from 304 Stainless Steel. 304 Stainless Steel, or similar materials as they are readily available, consistently used in food grade applications, durable, non-reactive, & easy to keep clean. In an embodiment, the assembly 3000 can include an outer housing which encompasses, and retains, the jaws. In some embodiments, the outer housing can include at least a top adapter 3010, an optional housing spacer 3020, a housing ring 3030, and a bottom portion, or plate, 3040 – which are retained together with a plurality of bolts 3050. In some embodiments, one or more, or in some cases four jaws 3060, can be retained within the housing, as illustrated in FIG.22A. For example, the jaws 3060 can retain a closure 10 within the chuck 3000, as shown in FIGS.22B and 22C. The depth that the closure 10 is received within the chuck 3000 can impact line performance. The jaws 3060 can be received within the assembly to be pivotable about pivot pins 3080, each of which are at the same radial distance from the central axis A of the assembly, shown as pivot axis P. The location of the pivot pins 3080 can be fixed by means of a jaw retaining disc 3070 such that the pivot pins 3080 are at the same radial distance can allow for consistent and even application of the knurls onto the exterior of the cap. In an embodiment, the pivot axis P of the jaws 3060 can be moved to improve the evenness of the knurl impression. In some embodiments, the biting angle of the jaw 3060 can be adjusted so that the impressed position is the ideal one. For example, an offset by a slight angle making one end of the jaw bite in deeper than the other end can accomplish a desired biting angle. In some embodiments, each of the jaws 3060 can have substantially the same geometry, within acceptable manufacturing tolerances.

[0150] In an embodiment, each jaw 3060 can be shaped such that the backside 3062 can interact with the rotating outer housing. This mechanical interface can function akin to a cam and cam follower to translate the torque applied by the capping machine to the jaw then to the cap, creating a relation between the torque applied and the compressive force provided by the jaws. The jaw 3060 can include a through hole 3065 to receive the respective pivot pin 3080. On an opposite face 3064 of the jaw 3060, as shown in FIG.27A, the jaw can include teeth 3066 which can be shaped similarly to a pipe wrench where they will ‘bite’ easier into the exterior surface of the cap in one direction than the other, which also helps to jumpstart this sprag interaction. Alternatively, other shaped teeth can be used within the scope of this disclosure. FIG. 27B illustrates an alternative geometry of the jaw 3060, modifications of the geometry can affect theAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 forces applied to the cap during use of the chuck 3000. The instant sprag clutch can provide the torque required to surpass the yield strength of PET which can be minimal compared to the torque provided by the capping machine. This indicates that indentations, or knurls, can be ‘cut’ into the exterior of the cap from the interaction of the jaws with the cap, during the capping process. These indentations can then be used by the end consumer which would aid in the removal process.

[0151] Looking to FIG.23A, the instant chuck 3000 can include a top adapter plate 3010, for example, to be the interface between the capping machine and the capping chuck. The top adapter plate 3010 can include a plurality of through holes 3012 around a rim for bolts 3050 which can retain the chuck assembly 3000 together. At the top surface of the top adapter plate 3010, a substantially centered through hole 3014 can be formed to provide an interface between the capping machine (not shown) and the chuck 3000. In an embodiment, the through hole 3014 can be a socket receiver, or have a substantially square shape, or other shapes suitable to transfer torque. Alternatively, as shown in FIG.23B, the top adapter plate 3010 can have a threaded surface 3016, to be threaded onto a capping machine. Relative to the orientation of the assembly shown in FIG. 22, below the top adapter plate 3010, a chuck housing spacer 3020 can optionally be included. Advantageously, the chuck housing spacer 3020 can be a future proofing portion of the assembly that can allow the chuck 3000 to be tuned to different heights of internal jaw assemblies 3060. In an embodiment, as shown in FIG.25, the spacer 3020 can be sized to allow room for a jaw retaining disc 3070 to fit within it and can provide for retaining the jaw retaining disc centered relative to the assembly. Additional functionality of the jaw retaining disk is discussed below. In an embodiment, the chuck 3000 can include an outer housing 3030 which can form the body of the chuck, as seen in FIGS. 22 and 24. The outer housing 3030 can include one or more cam surfaces 3032 which extend radially inward from an inner surface 3034 of the outer housing. In some embodiments, the housing spacer 3020 can additionally include cam surfaces, aligned with the cam surfaces 3032 of the outer housing 3030. The cam surfaces 3032 can interface with the jaws and can transfer force from the outer housing onto the jaws 3060 while the chuck 3000 rotates. For example, because the jaws 3060 are retained within the outer housing 3030 about a respective pivot pin 3080, as the cam surface 3032 rotates relative to the fixed location of the pivot pins 3080 and the teeth 3066 on the jaws “grip” the cap, the cam surfaces can push the jaws radially inward such that the teeth on the jaws are pushed, or forced, into the PET cap.

[0152] In an embodiment, at a bottom of the assembly, a bottom plate 3040 can be affixed to the assembly, as illustrated in FIG.26A. The bottom plate can include a “funnel” shape 3042 to facilitate ease of entry of a cap into the assembly. In some embodiments, other funnel type shapes can be used to facilitate guiding the cap into the chuck 3000, as shown in FIG.26B. TheAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 bottom plate 3040 can additionally maintain the jaws within the assembly. Through each of the top plate 3010, chuck housing spacer 3020, housing 3030, and the bottom plate 3040, at least two through holes can extend in alignment with the through holes in the respective parts of the assembly. Once the parts are assembled, at least one bolt 3050 can be threaded through the series of through holes to retain the assembly together. In one embodiment the bolts 3050 can be M5 bolts and the through holes can be 5 mm in diameter. However, other sized bolts and through holes can be used. Further, any known mechanical or chemical retention mechanisms can be used to maintain the assembly together, e.g., welding. Moreover, while four through holes and bolts 3050 are shown, two or more sets of bolts and through holes can be used to maintain the assembly together.

[0153] The resulting chuck assembly 3000 advantageously allows for the jaws 3060 to “bite” or “dig” into the PET cap to form the knurls when rotated in a first direction and the jaws release from the cap when rotated in the opposite direction to allow the cap to be released from the sprag chuck.

[0154] Turning back to the jaw subassembly, in some embodiments there can be four jaws 3060, as shown in FIG.22. Each of the jaws 3060 can include a plurality of teeth 3066 which can be pressed into the cap to form the knurl. In an embodiment, each jaw 3060 can include 10-30 teeth 3066. For example, each jaw 3060 can include 18 individual teeth 3066 having a triangular cross-section. In a case where there are four jaws 3060, then there can be 72 teeth to create 72 individual impressions to form the knurl, as shown in FIG.30. In an embodiment, about the outer surface 3062 of the jaw a slot 3068 can be formed that is perpendicular to the through hole 3065. During assembly, an O-ring 3090, or other elastic rings as shown in FIG. 29, can be disposed within the slot of each of the jaws such that the O-ring can bias the jaw radially inward, as graphically illustrated in FIG.22. The O-ring 3090 can keep a small amount of compression to the four jaws 3060 so they can apply a small force to pick up the cap prior to application of the knurling. The O-ring 3090 can be a high-temperature soft silicone O-ring which can withstand temperatures up to 400°F and can be sized to the SAE standard AS568.

[0155] The jaw retaining disc 3070 can sit above the jaws and can retain the placement of the jaws 3060 using the pivot pins 3080. In an embodiment, the jaw retaining disc 3070, pivot pins 3080, the jaws 3060, and the O-ring 3090, can form a floating assembly being held within the housing. In some embodiments, as shown in FIG.28A, the jaw retaining disc 3070 can include a downward extending inner cylinder 3072 which can limit the motion of the jaws 3060 inward to allow for proper insertion of the cap. Alternatively, as shown in FIG.28B, the inner cylinder 3072 may not be included.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0156] In use, the instant chuck 3000 can be used during a capping process which includes placing the closure 20 onto a bottle, or other container. Alternatively, the instant chuck 3000 can be used as a standalone process from the capping process.

[0157] In an embodiment, the amount of compression that the sprag chuck 3000 may need to apply to the cap during application and removal can be calculated as follows. Combining the known yield strength of PET, the number of teeth & area of tooth interaction of a sprag chuck according to the instant disclosure, one can determined how much torque is required for the teeth to bite into the cap and form knurls. In an embodiment, for example, 1.9 (in*lbs.) of torque may be required, as shown.

[0158] Calculations:

[0159] ^^^^^^^^^^^^ ^^^^ ^^^^^^ ^^^^^^^^ℎ  =  72

[0160] ^^^^^^^^^^ℎ ^^^^ ^^^^^^^^ℎ ^^^^^^^^^^^^^^^^^^^^^^  =  3.8 (^^^^)  =  0.0038 (^^)

[0161] ^^^^^^^^ℎ ^^^^^^ ^^^^^^^^ℎ  =  0.2 (^^^^)  =  0.0002 (^^)

[0162] ^^^^^^ ^^^^^^^^^^^^  =  15 (^^^^)  =  0.015 (^^)

[0163]

[0164] ^^்^^௧^ ூ^௧^^^^௧^^^  =  (^^்^^௧^ ூ^௧^^^^௧^^^)(^^^^^^^^ℎ ^^^^^^ ^^^^^^^^ℎ) =(0.0038^^)(0.0002^^) = 0.00000076 (^^ଶ)

[0165] Where ^^்^^௧^ ூ^௧^^^^௧^^^is the area of each tooth interfacing with the cap.

[0166] ^^௧^௧^^ ^^௧^^^^௧^^^ = (^^௧^^௧^ ^^௧^^^^௧^^^)(^^^^^^^^^^^^ ^^^^ ^^^^^^^^ℎ) = 0.00000076 ⋅72 = 3.39^^ − 07(^^ଶ)

[0167] Where ^^௧^௧^^ ^^௧^^^^௧^^^is the total area of the teeth being applied to the cap.

[0168] ^^^^^^^^^^ ^^^^^^^^^^^^^^ℎ^ா் = 42 (^^^^^^)

[0169] ^^^^^^^^^^  =  (^^^^^^^^^^ ^^^^^^^^^^^^^^ℎ^ா்)(^^௧^௧^௧ ^^௧^^^^௧^^^) = (42000000)(3.39^^ −07) = 14.25 (^^^^)

[0170] ^^^^^^^^^^^^  =  (^^^^^^ ^^^^^^^^^^^^)(^^^^^^^^^^) = 0.015 ⋅ 14.25 = 0.21 (^^ ⋅ ^^)

[0171]

[0172] Convert to in*lbs.:

[0173] 0.21 ^^ ⋅ ^^  →  1.9 (^^^^ ⋅ ^^^^^^)

[0174] The cap performance measures the general consistency of application and removal torques. In an embodiment, the cap performance can be shown in Table 1. Table 1 Cap PerformanceAttorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0175] In an alternative embodiment, the knurls can be applied to a cap using an interference fit applicator, for example as shown in FIG.31A. An interference fit applicator 3100, as disclosed, provides for the ability to generate a dual function. Initially, this interference fit between the interference fit applicator 3100 and the cap can create a compressive force. The interior surface 3110 of the applicator can, in an embodiment, be formed as teeth 3120 that can be aligned in parallel with an insertion axis of the device. In an embodiment, at the tips of the teeth 3120, the force can be concentrated to overcome the yield strength of the PET. Through this interaction, the teeth 3120 can ‘dig’ into the exterior of the cap to allow the applicator to pick the cap up and allow the cap to be placed on a filled bottle. In some embodiments, the teeth 3120 can be formed as a single piece with the applicator 3100. In an alternative embodiment, the interference fit applicator 3100 can additionally include an knurling insert 3130, as shown in FIG.31B, or can include a knurling insert 3130 and an insert 3140 for forming the tamper evidence band, as shown in FIG. 31C. The capping machine can rotate the chuck, applying it onto the bottle about pre- formed threads on the bottle and the interior of the cap, then lift off, using the weight of the bottle to aid in the removal of the applicator from the cap. This application process can result in a fully applied cap which would also have knurls ‘cut’ into the exterior of the cap, the knurls can be 0.1 – 0.4 mm deep, for example 0.2 mm deep. The knurls, now formed on the cap, can assist in the ergonomic removal of the cap from the bottle by a consumer. FIG.32 illustrates the applicationAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 and removal forces for caps formed with the instant sprag clutch chuck 3000 and the application and removal forces for caps formed with the instant interference chuck applicator 3100.

[0176] In an alternative embodiment, a heated die can be used to form the knurls. The heated die can use heat lamps to add heat energy to the die. The heated die can be applied to the cap; shortly after the forming process, but prior to the removal of the mold from the cap. The heated die can imprint the knurls to the exterior of the freshly formed cap. The key difference between this solution and a heated die is the use of heat and the tamper evident (TE) interaction band. The applicator, in contrast, is meant to be used at room temperature, which would prevent any dimensional differences of the cap due to this heat. EXAMPLES

[0177] The present disclosure may be better understood in connection with the following Examples. In addition, the non-limiting examples are an illustration. The person skilled in the art will appreciate that it may be necessary to vary the procedures for any given example of the present disclosure, e.g., vary the order or steps and / or the chemical reagents used. EXAMPLE 1

[0178] Thermoforming of PET Closures

[0179] Herein is described the development of a replacement of injection molded HDPE / PP-based PCO 1881 plastic bottle caps with a PET closure thermoformed from sheets of PET. Among the challenges during development were to develop a mold and a process to solve issues related to the plug seal, Tamper Evident (“TE”) feature.

[0180] The use of a benchtop style JT-018 Dental Thermoformer (“JT-018”) was explored. A primary objective was to create the geometry for and produce a prototype mold, for modeling PET closures. A goal was to create a thermoformed plug seal that met or exceeded industry standards for a closure, while also developing a TE band.

[0181] Use of the JT-018 allowed for the production of various iterations of a single closure that may be tested for functionality against industry standards for product seal, closure and opening torque, and tamper evident closures. Considerations in the production of the prototype also included mass production capabilities, and the closure process used by the bottling industries and equipment manufacturers.

[0182] Off-the-shelf equipment was modified to provide better process control. For example, controls were added to the heating element on the JT-018.

[0183] Specialized tools were developed for testing and process enhancement. For example, a pressure testing skid allowed for the pressure testing of finished molds. A cap punchAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 allowed for the efficient cut of finished closures. A pressure bell allowed for increasing the external pressure on the thermoformer to gain higher detail.

[0184] A design for the mold for thermoforming the closure was developed in order to allow for demolding of dissimilar geometry without entrapment. A CAD program, Solid Works, was utilized to develop a mold that could be three-dimensionally printed and communicated to stakeholders. Three-dimensional printing of initial prototype molds allowed for the trial of several concepts, economically, with rapid turn-around of mold revisions. Rough surfaces that would translate to the finished thermoformed closure, and cause issues with seal integrity, were polished out using a multi-step polishing process starting at 800 Grit and ending at an 80,000 Grit jewelry polishing compound. The final thermoformed product was cut-out utilizing a cutting die and tested for performance against industry standards.

[0185] Engineering considerations included temperature control, an aluminum mold, an external pressure apparatus, and seal testing.

[0186] A. Temperature Control: PET is a crystalline plastic that has unique properties while being heated. PET enters its glass transition range, becoming malleable and clear, from 67- 80°C (153-76°F). With time, PET crystallizes, becoming white in color and brittle, between 80- 260°C (176-500°F). PET melts at 260°C (500°F). Thus, PET is versatile in usage but may have limitations. The molding machine has a maximum temperature of 457°C (855°F) and may heat the plastic too fast. Therefore, a variable resistor was inserted onto the molding machine to manage the temperature control to have more accurate temperatures and to be able to control molding of the PET easier.

[0187] B. Aluminum Mold: High Thermal Conductivity, or quick heat transfer, causes heat from PET during molding to be whisked away very quickly for fast cooling of the PET closure and fast cooling of the mold.

[0188] C. External Pressure Apparatus: Vacuum within the machine was needed to draw hot plastic into the crevices of the mold. Maximum vacuum that can be achieved is 1 bar (14 psi). Due to working in the glass range of the PET, more pressure was required to form sharp angles found on the mold. An external pressure apparatus may allow for a range of external pressures, wherein diminishing returns in the formation of the plastic around the mold were encountered after reaching 4.1 bar (60 psi). With the addition of the 4.1 bar (60 psi) external pressure along with the 1 bar (14 psi) internally, the plastic may form easily around the mold. Higher external pressures may further improve the definition of part features.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0189] D. Testing for a Seal: Testing for a leak in the seal requires a way to generate pressure within the caps. A pressure testing apparatus was created to create the pressure on the cap and, then using water, look for air bubbles leaking from the caps.

[0190] The testing performed on the closures included torque testing, weights and measures (for example, based on thread depth, and cap weight), and seal testing. Testing was performed to determine the crystallization point of the material. Excess heat create a rapid crystallization transition phase that was difficult to control. A resistive control to the JT-018 was added to control the heat for repeated trials.

[0191] Table 2 provides crystallization data (Cycle Time for Forming PET Plastic). The temperature of the heater was at the heater’s maximum temperature for all trials, which was approximately 468.3° C (875° F). The level from heater was mid-way between the mold and the heater. TABLE 2

[0192] Preliminary testing was performed on the finished mold, with marginal results. Limitations in the vacuum-forming process failed to produce fully developed threats. As a result, torques in excess of 0.5 Nm were not achieved, and the cap failed to hold a measurable pressure. A device was added to induce exterior pressure and trials were repeated with improved control.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0193] A device was constructed to allow for the application of external pressure during the forming process. Vacuum processing was limited to 1 atm (1.01 bar) of differential pressure under perfect seal conditions. The modified system allowed for the application of up to an additional 10 bar of differential pressure to force greater forming detail. Trials showed 4 bar to be sufficient. Table 3 summarizes the testing data. TABLE 3Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0194] A correlation was observed between closing torque and seal pressures, as illustrated in FIG.18. As closing torque increases or decreases the ability to hold a seal has a proportional relationship.

[0195] Improvements to thread detail were realized in the seal when external pressure was applied during the thermoforming process. A correlation can be seen between increased seal pressure and produced thread torque.

[0196] Finished thermoformed caps were reviewed under a polarized film to reveal lines of stress and material deformation from the thermoforming process.

[0197] Other films were analyzed to validate the thermoforming process. These materials failed to develop a torque or ability to hold pressure, but the analysis showed nearly fully developed thread detail. Thus, modifications to increase pressure on thermoforming machine could lead to an increased performance with the thicker and stiffer PET material. EXAMPLE 2

[0198] Injection Molded PET Closure

[0199] In an example, closures may be injection-molded polyester resins, such as polyester resins having an FDCA and / or DEG content that sufficiently increases a compliance of the polyester resin material relative to PET to enable the material to be injection-molded. In certain examples, a closure is of a standard injection-molded configuration (in other words, a closure has a similar shape to injection-molded HDPE and PP closures), such as illustrated in FIGs.17A and 17B. FIG.17A illustrates a partial cross-sectional view of an upper portion of an injection-molded polyester resin closure 1500. FIG.17B illustrates a partial cross-sectional view of closure 1500 mounted to finish 1502. Closure 1500 includes a conventional injection-molded plug seal 1504. The FDCA- and / or DEG-modified polyester resin may have sufficiently low modulus that plug seal 1504 may be able to achieve relatively high elastic deformation as is evident in comparing the deflection of plug seal 1504 in FIG.17B relative to FIG.17A.

[0200] In certain examples, an injection-molded closure is configured similarly to a standard injection-molded HDPE or PP closure but with lower wall thicknesses to reduce the relative stiffness of the closure. In addition to wall thickness, an interference fit may be reduced as discussed for the range used for thermoformed PET closures in order to accommodate the relatively higher stiffness of PET or co-monomer-modified polyester. EXAMPLE 3

[0201] Copolymer for Closures Produced Via Synthesis of 2% FDCA in PETAttorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0202] In an example, a copolymer suitable for closures was produced via polymerization of 2% FDCA in PET and SSP. The process of synthesizing the copolymer PET with 2% FDCA from PTA (or TPA) and EG was divided into two stages. The transesterification stage went on until the temperature of the top of the distillation was below 90°C, and the mixture was clear. Esterification was followed by polycondensation. During the course of synthesis, the reaction was monitored based on the amount of water produced and collected in a buffer tank. About 369 milliliters of water was recovered. The material was extracted from the reactor when the intrinsic viscosity reached approximately 0.55 dL / g based on torque calibration. Tables 4 and 5 below provide the reaction conditions in the esterification reactor and polycondensation reactor, respectively. TABLE 4 EsterificationTABLE 5 PolycondensationAttorney Docket No.227254-702601 Date of Filing: February 21, 2025EXAMPLE 4

[0203] Impact of FDCA Fraction on Crystallization

[0204] An impact of the amount of FDCA present in a copolymer on crystallization in a polyester resin copolymer suitable for closures was demonstrated. Specifically, as the FDCA fraction was increased, the rate and degree of crystallization in PET was observed to decrease.

[0205] Table 6 provides DSC results that demonstrate (1) an increase in Tg with FDCA fraction, (2) an increase in Tm, and (3) a reduction in % crystallinity. TABLE 6 DSC Results

[0206] Varying the amount of FDCA also changed other physical and chemical properties of the resulting copolymer, including, for example, the modulus of elasticity, and gas diffusion (barrier) properties. Both % crystallinity of the copolymer and the mobility of the furan dicarboxylate component of the copolymer impact the modulus of elasticity and gas diffusion properties, such that the same % crystallinity in PET without FDCA had lower diffusion or mechanical properties than PET with FDCA. EXAMPLE 5

[0207] Thread Depth and Pressure Retention

[0208] Using a standard laboratory-sized torque tester, a preform was placed in clamps and zeroed. Applying consistent torque in a clockwise manner, a closure was applied until snug, or until roughly 580 degrees. A positive value will be an Application Torque. Once a closure is applied, the closure was removed by applying force in a counterclockwise direction. A negativeAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 value will be a Removal Torque. Applying consistent torque in a clockwise manner, a closure was applied past snug or 580 degrees until failure. A positive value will be a Strip Torque. A closure will be deformed after a Strip Torque test. After several tests are performed a preform is exchanged with a new unused preform as a neck finish may be damaged after repeated tests, which may skew data. Torque may also be tested with a blown bottle filled with water.

[0209] A pressure retention test uses a standard battery bike / ball air pump to generate air pressure used to blow off a closure. The pump is connected to an additional pressure gauge to provide two readings on the pressure being applied. Pressurized air is routed into an 1881 neck. An 1881 closure was placed on a neck finish and secured with standard application procedures. The 1881 neck finish may be exchanged for other neck finishes and further 1881 necks. Air pressure rises until the 1881 closure reaches failure. Failure may be a slow leak with a steady decrease in air pressure inside a neck finish, or dramatic failure, which involves rapid loss of pressure. TABLE 7Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0210] FIG.15 illustrates a plot of average thread depth and pressure retention of twenty- five sample closures, and the relationship between average thread depth and pressure retention of the closures. FIG. 16 illustrates a plot of the ability of twenty-five sample closures to retain pressure when applied to a finish of a container.

[0211] FIGS.33, 34, and 35 illustrate an exemplary embodiment of a thermoformed PET container closure 4100 that is particularly well suited for including knurls formed by way of the thermoforming processes described herein. In general, the closure 4100 may be a monolithic portion of thermoplastic material and produced by thermoforming. The thermoplastic material may comprise a polystyrene such as SAN or ABS, or a polyolefin such as PP or PE, or a polycarbonate or, in particular, a polyester such as PET, PBT or PEF. Further, in some embodiments, the closure 4100 can be made from a single thermoplastic material or can be made from a plurality of thermoplastic materials. In one embodiment, the material of the closure 4100 can comprise PET, and the container, which is to be closed with the closure 4100, is also made of PET. Further details regarding techniques for forming the closure 4100 may be found in PCT Application, entitled “Polyester Resin Closures For Containers,” filed on April 20, 2023, and having application serial number PCT / US23 / 66008, the entirety of said application being incorporated herein by reference.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0212] As shown in FIGS.33-35, the closure 4100 can have a cover wall 4104 and a side wall 4108. The side wall 4108 can be integrally connected to the cover wall 4104 and oriented transversely to the cover wall 4104. The side wall 4108 can be circumferentially closed. The closure 4100 can have an interior (not illustrated) configured to receive a finish portion of the container to be closed with the closure 4100. The interior can be partially bounded by the cover wall 4104 and the side wall 4108. The closure 4100 can include an opening 4112 opposite to the cover wall 4104, through which “access” to the interior is possible.

[0213] As shown in FIG.34, the closure 4100 can have a vertical axis 4116. The side wall 4108 can extend along this vertical axis 4116. The vertical axis 4116 can be transverse and in particular perpendicular to the cover wall 4104. The opening 4112 can also be oriented transversely and in particular perpendicular to the vertical axis 4116. In some embodiments, the vertical axis 4116 may include an axis of rotational symmetry of the closure 4100. In some embodiments, wherein the closure 4100 serves as a closure cap for a bottle, the closure 4100 can be at least approximately cylindrical with the side wall 4108 disposed symmetrically around the vertical axis 4116.

[0214] The closure 4100 can include an annular wall 4120 and a cylindrical wall 4124 that extends downwardly from the annular wall 4120 and surrounds the cover wall 4104. Interior surfaces of the annular wall 4120 and the cylindrical wall 4124 comprise a plug seal (not shown) for scaling against an inner surface of a finish portion of the container to be closed with the closure 4100. An interior surface of the annular wall 4120 may be configured to scale against a top surface of a rim of the finish, while an outwardly facing radial surface of the cylindrical wall 4124 may be dimensioned for an interference fit with a corresponding inwardly facing surface of rim of finish for scaling. As the closure 4100 is threaded onto the finish, the plug seal is forced into a mouth of the finish and into a compressed state in which the outwardly facing radial surface of the cylindrical wall 4124 pushes against the inwardly facing surface of finish, thereby forming a seal.

[0215] The closure 4100 can include one or more internal threads 4128 formed into the side wall 4108 for engaging with external threads of the finish portion of the container to be closed with the closure 4100. The threads 4128 can be continuous threads or may be interrupted threads. In the illustrated embodiment, the closure 4100 can include one thread 4128, with one thread start 4132 at the beginning of the thread 4128. In some embodiments, however, the closure 4100 may include a plurality of threads 4128, such as, for example, three threads distributed uniformly around the side wall 4108 of closure 4100. As such, each of the plurality of threads 2128 includes one of a corresponding plurality of thread starts 4132.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0216] With continuing reference to FIGS. 33-35, the closure 4100 may be viewed as broadly comprising a threaded portion 4136 and a tamper evidence feature 4140. As the closure 4100 can be threaded onto a finish portion of a container, the tamper evidence feature 4140 can ride over a ledge of the finish portion, clears the ledge, and fits into place beneath ledge. The tamper evidence feature 4140 may include a plurality of spaced-apart bridges (not shown) that connect the tamper evidence feature 4140 to the threaded portion 4136 of the closure 4100. In the event that the closure 4100 is unthreaded from the finish portion, tamper evidence feature 4140 can be retained in position by the ledge of the finish portion. The upward force from unthreading of the closure 4100 can eventually cause sufficient stress on the bridges that they will break, providing evidence that the closure 4100 has been tampered with.

[0217] As shown in FIGS.34, the closure 4100 can include a plurality of external knurls 4144 distributed around the circumference of the threaded portion 4136. As discussed with respect to the above embodiments, the external knurls 4144 can serve to improve the grip of the threaded portion 4136 of the closure 4100. Further, the closure 4100 can include a plurality of knurls 4148 distributed around the circumference of the tamper evidence feature 4140. It should be appreciated that it is possible to form knurls at a plurality of diameters.

[0218] FIG. 36 illustrates an exemplary embodiment of an alternative thermoforming process 4160 whereby knurls can be formed on a thermoformed PET container closure, such as the closure 4100 shown in FIGS. 34. The process 4160 can begin at step 4164, wherein a thermoplastic material is heated to a temperature that allows the material to become more flexible and easier to shape. In some embodiments, the temperature ranges between about 120°C and about 150°C. In an embodiment, the temperature is around 140°C. The selected temperature preferably is above the glass transition temperature of PET (approximately 70°C) but below a temperature of about 160°C at which PET starts to crystallize.

[0219] In step 4168, the heated PET material can be placed into a thermoforming mold. The mold can be designed with precision to create the desired features on the inside of the closure, including the threads and other internal components. The mold can be designed to accommodate the formation of knurls, such as the knurls 4144, 4148 shown in FIGS.34, on the outside of the closure 2100. In step 4172, a pressure ranging between about 4 bar to about 10 bar can be applied to the PET material using the thermoforming mold. Experimental observations have demonstrated that this pressure is sufficient to shape the PET material into the desired closure design but not so high as to cause damage to the PET material.

[0220] In step 4176, while the PET material is still hot and pliable (e.g., at a temperature of approximately 120°C), knurls, such as the knurls 4144, 4148 shown in FIGS.34, can be pressedAttorney Docket No.227254-702601 Date of Filing: February 21, 2025 or “coined” onto the surface of the closure using a fixed ring. In some embodiments, the fixed ring is configured to fit over the closure and mold and to be easily pulled from the mold once the knurls have been formed. While the PET material is cooling and hardening, the fixed ring can be quickly pulled off the closure in step 4180. This can optimize the cycle time while the knurls are fully formed. Details regarding the fixed ring are discussed in greater detail in U.S. Provisional Application, entitled “Knurl Formation For PET Closure,” filed on February 29, 2024, and having application serial number 63 / 559,809, the entirety of said application being incorporated herein by reference.

[0221] In step 4184, the size and shape of the knurls can be adjusted as needed using different tools or dies. In some embodiments, the pressure applied during this step can be adjusted patterns. More important than the precise pressure reading is precise displacement of the PET material. Knurls of constant depth such as 0.3 mm work well for capping applications, but many different knurl depths are possible as are many different wall thickness options. Typical wall thicknesses are around 1 mm, but even less than 0.5 mm or more than 2 mm are possible are contemplated. It is further contemplated that the thermoforming process 4160 enables forming knurls on the outside of thermoformed PET caps without compromising the integrity of the closure, within the confines of the mold, and ensuring that the formation of the knurls is quick enough to prevent the PET material from cooling and hardening before the process is complete.

[0222] Compared with existing technology, the beneficial effects of the thermoforming process 4160 provided herein are as follows:

[0223] 1. Efficient Production: The thermoforming process disclosed herein provides a method to effectively form knurls on the outside of thermoformed PET closures, which is more efficient than conventional methods like injection or compression molding. As such, the thermoforming process provided herein significantly speeds up the production process and increases overall productivity.

[0224] 2. Quality Control: By forming the knurls while the PET is still hot and soft, the thermoforming process of the present disclosure eliminates a need for cutting, which can potentially damage the closure. Thus, the present thermoforming process ensures the integrity of the closure and maintains its quality.

[0225] 3. Versatility: The thermoforming process disclosed hereinabove can be adapted to different types of molds and machines, making the thermoforming process herein relatively more versatile and suitable for large-scale production.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0226] 4. Enhanced User Experience: The knurls formed on the outside of the closure can improve the user’s experience when removing the closure from a bottle. Thus, the thermoforming process presented herein leads to increased customer satisfaction and loyalty.

[0227] 5. Cost-Effective: While thermoforming may require specialized equipment and processes, it can be more cost-effective in the long run compared to injection or compression molding. This is because thermoforming can produce a larger number of caps per cycle, reducing the overall cost of production. And thermoforming does not require wells or dwell space between thin portions of the closure to allow polymer to flow.

[0228] It is contemplated, therefore, that the thermoforming process of the present disclosure provides a practical and efficient solution to the technical problem of forming knurls on the outside of thermoformed PET closures or thermoformed caps from any polymer, offering significant improvements over existing approaches in terms of efficiency, quality control, versatility, enhanced user experience, and cost-effectiveness.

[0229] Moreover, selecting PET is logical for this process in order to make mono-material recyclable containers. PHA or PLA, however, are also practical options to enable the manufacture of bio-degradable closures. Even HDPE or PP can be adapted to the process and allow the use of a wider spectrum of melt flow indices, which would be important for the use of recycled resins.

[0230] The technology of providing knurls on a thermoformed PET closure has significant application prospects in the packaging industry, particularly in the production of food and beverage containers. As consumers increasingly demand sustainable and eco-friendly packaging solutions, the use of PET for container production is on the rise. Thermoforming PET closures, with their potential for precision and efficiency, can significantly contribute to this trend. Moreover, the ability to add knurls to the outside of the closure enhances both the machine application of closures and user interaction upon removal, which are key considerations in the design of packaging products. This thermoforming process disclosed herein can therefore be particularly beneficial in industries where efficient packaging processes and enhanced user experience are paramount, such as the fast-moving consumer goods (FMCG) sector. In terms of market demand, the global packaging industry is expected to grow significantly in the coming years, driven by factors such as increasing e-commerce activity and rising disposable incomes in emerging markets. This growth is likely to drive demand for innovative packaging solutions, including thermoformed PET closures with integrated knurls. Furthermore, as more and more companies seek to reduce their environmental impact, the adoption of sustainable packaging materials like PET is likely to increase, further boosting the demand for the thermoforming process provided hereinabove.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0231] The uses of the terms “a” and “an” and “the” and similar referents in the context of describing the present disclosure (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of the term “plurality of” is defined by the Applicant in the broadest sense, superseding any other implied definitions or limitations hereinbefore or hereinafter unless expressly asserted by Applicant to the contrary, to mean a quantity of more than one. All methods described herein may be performed in any suitable order unless otherwise indicated herein by context.

[0232] As will be understood by one skilled in the art, for any and all purposes, all ranges recited herein also encompass any and all possible sub-ranges and combinations of sub-ranges thereof, as well as the individual values making up the range, particularly integer values. It is therefore understood that each unit between two particular units is also disclosed. For example, if “10 to 15” is disclosed, then 11, 12, 13, and 14 are also disclosed, individually, and as part of a range. A recited range (for example, weight percentages or carbon groups) includes each specific value, integer, decimal, or identity within the range. Any listed range may be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, or tenths. As will also be understood by one skilled in the art, all language such as “up to,” “at least,” “greater than,” “less than,” “more than,” “or more,” and the like, include the number recited and such terms refer to ranges that can be subsequently broken down into sub- ranges. In the same manner, all ratios recited herein also include all sub-ratios falling within the broader ratio. Accordingly, specific values recited for radicals, substituents, and ranges are for illustration only; they do not exclude other defined values or other values within defined ranges for radicals and substituents. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0233] One skilled in the art will also readily recognize that where members are grouped together in a common manner, such as in a Markush group, the invention encompasses not only the entire group listed as a whole, but each member of the group individually and all possible subgroups of the main group. Additionally, for all purposes, the invention encompasses not only the main group, but also the main group absent one or more of the group members. The invention therefore envisages the explicit exclusion of any one or more of members of a recited group. Accordingly, provisos may apply to any of the disclosed categories or examples whereby any one or more of the recited elements, species, or examples may be excluded from such categories or examples, for example, for use in an explicit negative limitation.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025

[0234] As used herein, the terms “comprise(s),” “include(s),” “having,” “has,” “can,” “contain(s),” and variants thereof, are intended to be open-ended transitional phrases, terms, or words that do not preclude the possibility of additional acts or structures. The present description also contemplates other examples “comprising,” “consisting of,” and “consisting essentially of,” the examples or elements presented herein, whether explicitly set forth or not.

[0235] In describing elements of the present disclosure, the terms “1st,” “2nd,” “first,” “second,” “A,” “B,” “(a),” “(b),” and the like may be used herein. These terms are only used to distinguish one element from another element, but do not limit the corresponding elements irrespective of the nature or order of the corresponding elements.

[0236] Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meanings as those generally understood by those skilled in the art to which the present disclosure pertains. Such terms as those defined in a generally used dictionary are to be interpreted as having meanings equal to the contextual meanings in the relevant field of art.

[0237] As used herein, the term “about,” when used in the context of a numerical value or range set forth means a variation of ±15%, ±14%, ±10%, or ±5%, among others, would satisfy the definition of “about,” unless more narrowly defined in particular instances.

[0238] Although the present disclosure has been described with reference to examples and the accompanying drawings, the present disclosure is not limited thereto, but may be variously modified and altered by those skilled in the art to which the present disclosure pertains without departing from the spirit and scope of the present disclosure.

[0239] In addition to the features mentioned in each of the independent aspects enumerated above, some examples may show, alone or in combination, the optional features mentioned in the dependent aspects and / or as disclosed in the description above and shown in the figures.

Claims

Attorney Docket No.227254-702601 Date of Filing: February 21, 2025 CLAIMS What is claimed is:

1. A knurl applicator chuck for thermoformed polyester resin closures, the chuck comprising: a top adapter configured to interface with a capping machine; a bottom portion having a through hole extending therethrough to capture and retain a polyester resin closure; and a plurality of jaws received between the top adapter plate and the bottom plate, the plurality of jaws each including a plurality of radially inward facing teeth, the teeth being configured to create knurls on an outer surface of the closure when the chuck is rotated in a first direction, during a capping process, and release the closure when the chuck is rotated in a second direction.

2. The chuck of claim 1, wherein the polyester resin comprises polyethylene terephthalate (“PET”).

3. The chuck of claim 1, wherein the plurality of jaws includes four jaws.

4. The chuck of claim 3, wherein each of the jaws includes 18 teeth.

5. The chuck of claim 1, wherein the jaws are maintained within the chuck by pivot pins.

6. The chuck of claim 5, wherein an O-ring surrounds the plurality of jaws to create a pre-tension.

7. The chuck of claim 5, further comprising a jaw retaining disc disposed between the jaws and the top adapter plate.

8. The chuck of claim 7, wherein the pivot pins are received within holes in the jaw retaining disc.

9. The chuck of claim 8, wherein the jaws and jaw retaining disc form a floating assembly within the chuck.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025 10. The chuck of claim 7, wherein the jaw retaining disc includes a downward extending cylinder facing the jaws, and radially inward of the jaws, configured to limit inward motion of the jaws and limit the resulting force applied to the closure.

11. The chuck of claim 1, further including a housing ring having a plurality of radially inward extending cam surfaces disposed between the top adapter and the bottom portion.

12. The chuck of claim 11, wherein the plurality of radially inward extending cam surfaces are configured to push the plurality of jaws radially inward as the housing ring is rotated relative to the closure.

13. The chuck of claim 11, further including a plurality of bolts retaining the top adapter, housing ring, and bottom portion together such that the jaws are retained therein.

14. The chuck of claim 1, wherein the bottom portion further includes a funneled entry at a bottom of the through hole configured to direct the closure into the chuck.

15. The chuck of claim 1, wherein the chuck is configured to create knurls in an outer surface of the closure having a depth of at least 0.2 mm deep.

16. The chuck of claim 15, wherein the chuck is configured to create knurls in the outer surface of the closure at room temperature.

17. A method of forming knurls in thermoformed polyester resin closures, the methods comprising: connecting a top adapter of a chuck with a capping machine; inserting the closure into a bottom portion having a through hole extending therethrough to capture and retain the closure; rotating the chuck in a first direction such that a plurality of jaws create knurls on an outer surface of the closure when the chuck is rotated in the first direction; and releasing the closure from the chuck when the chuck is rotated in a second direction, opposite to the first direction.

18. The method of claim 17, wherein the rotating step is performed while applying the closure to a container.Attorney Docket No.227254-702601 Date of Filing: February 21, 2025 19. The method of claim 17, wherein the polyester resin comprises polyethylene terephthalate (“PET”).

20. The method of claim 17, wherein the knurls in an outer surface of the closure have a depth of at least 0.2 mm.

Images