Paper-based multilayer closures and methods and systems of making such closures

Abstract

A closure, process and system for making therefor are provided herein. The thermoforming process may include (a) assembling a multilayer structure that comprises at least one paper layer coupled to at least one thermoplastic layer; (b) curing the multilayer structure; (c) thermoforming the multilayer structure into a closure by placing the multilayer structure into or onto a mold; and (d) removing the closure from the mold. A closure may include a multilayered structure that comprises at least one paper layer coupled to at least one thermoplastic layer, the closure comprising an interior surface that is configured to receive a finish portion of a container. A system may include (a) a multilayer structure comprising at least one paper layer coupled to at least one thermoplastic layer; (b) a thermoforming machine; (c) a mold; and (d) an automated rotation system.

Description

Attorney Docket No. 227254-747601PAPER-BASED MULTILAYER CLOSURES AND METHODS AND SYSTEMS OF MAKING SUCH CLOSURESCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 694,051, filed September 12, 2024, the disclosure of which is incorporated herein by reference in its entirety.FIELD

[0002] Embodiments of the present disclosure generally relate to container closures. More specifically, embodiments of the disclosure relate to multilayered paper-based closures, and processes and systems for forming threads on said closures.BACKGROUND

[0003] There is a need for closures that maintain structural reliability and durability, but with a reduced environmental impact and cost for overall production.SUMMARY

[0004] A thermoforming process and molds for use thereof are provided for forming threads on an interior of thermoformed PET container closures.

[0005] Provided herein is a closure that includes: (a) a multilayered structure that includes at least one paper layer coupled to at least one thermoplastic layer, and (b) an interior surface configured to receive a finish portion of a container. In some embodiments, the at least one thermoplastic layer includes a thermoplastic coating. In some embodiments, the at least one paper layer is positioned between at least two thermoplastic layers. In some embodiments, a closure further includes an adhesive between the at least one paper layer and the at least one thermoplastic layer. In some embodiments, the adhesive includes a food-grade adhesive. In some embodiments, the adhesive is applied evenly across the at least one thermoplastic layer. In some embodiments, the at least one paper layer has a thickness up to about 1 mm. In some embodiments, the at least one thermoplastic layer includes a recyclable polymer. In some embodiments, the at least one thermoplastic layer includes a polystyrene, a polyolefin, a polycarbonate, a polyester, or a combination thereof. In some embodiments, the at least one thermoplastic layer includes high-densi ty polyethyleng (HDPE), PET, polyhydroxyalkanoates (PHA), polylactic acid (PLA), polyethylene furanoate (PEF) or any combination thereof. In some embodiments, the at least one thermoplastic layer has a thickness of less than about 0.5 mm. In some embodiments, the closure includes a cover wall and a side wall,Atorney Docket No. 227254-747601 wherein the side wall is integrally connected to the cover wall and oriented transversely to the cover wall. In some embodiments, the side wall is circumferentially closed. In some embodiments, the interior surface is partially bounded by the cover wall and the side wall. In some embodiments, a closure further includes an opening opposite to the cover wall. In some embodiments, a closure further includes a plurality of external knurls distributed around a circumference of the side wall. In some embodiments, a closure further includes a plurality of slits along a circumference of the side wall, wherein the plurality of slits form a tamper evidence band. In some embodiments, a closure further includes a plurality of knurls distributed around a circumference of the tamper evidence band. In some embodiments, each of the plurality of slits includes a length of less than about 30 mm. In some embodiments, a closure further includes a plurality of threads along an internal surface of the side wall, wherein the plurality of threads are configured to engaging with the finish portion of the container. In some embodiments, a closure further includes at least one seal layer coupled to one or more of the at least one paper layer and the at least one thermoplastic layer, wherein the at least one seal layer is configured to receive the finish portion of the container.

[0006] Also disclosed herein is a process for thermoforming a closure for a container, the process including: (a) assembling a multilayer structure that includes at least one paper layer coupled to at least one thermoplastic layer; (b) curing the multilayer structure; (c) thermoforming the multilayer structure into a closure by placing the multilayer structure into or onto a mold; and (d) removing the closure from the mold. In some embodiments, the at least one thermoplastic layer includes a thermoplastic coating. In some embodiments, the multilayer structure includes the at least one paper layer positioned between at least two thermoplastic layers. In some embodiments, the assembling includes applying an adhesive to the at least one thermoplastic layer and applying a sufficient pressure so as to bond the at least one paper layer to the at least one thermoplastic layer. In some embodiments, the pressure is sufficient to shape the multilayer structure into the closure without causing damage to the multilayer structure. In some embodiments, the pressure is from about 4 bar to about 10 bar to the multilayer structure. In some embodiments, the curing is performed at a temperature of from about 70°C to about 90°C. In some embodiments, the curing is performed at a temperature of about 80°C. In some embodiments, the curing is performed for a duration of from about 1 hour to about 3 hours. In some embodiments, the curing is performed for a duration of about 2 hours. In some embodiments, the mold further includes a knurled portion configured to form a plurality of knurls onto an exterior of the closure. In some embodiments, a process further includes adjusting a size and / or a shape of each of the plurality of knurls after the removing. In some embodiments, a process further includes forming cams on the closure prior to removing the closure from the mold. In some embodiments, the cams are formed using a cam-forming tool while the multilayer structure is warm and pliable. In someAttorney Docket No. 227254-747601 embodiments, the cams are formed using the cam-forming tool after the closure has cooled to room temperature. In some embodiments, the cams are formed in steps at angles ranging from about -10 degrees to about 190 degrees. In some embodiments, the cams are formed by folding tabs in steps including about 30 degrees, about 60 degrees, about 90 degrees, or about 140 degrees, then inverting the tabs with a plunger, wherein the tabs are pre-trimmed at an edge of the closure. In some embodiments, the tabs are folded along a circumference of the closure using a ramp. In some embodiments, the tabs are folded by pushing the closure through a tube, thereby folding the tabs into a vertical position. In some embodiments, the tube is cylindrically or conically shaped. In some embodiments, the mold includes a threaded portion configured to form a plurality of threads on the closure during the thermoforming. In some embodiments, the threaded portion of the mold is shaped to form undercuts in the plurality of threads. In some embodiments, the undercuts are formed with a depth ranging from 0.1 mm to 1 mm. In some embodiments, the undercuts are formed at an angle ranging from -10 degrees to 190 degrees, with respect to a base of the mold. In some embodiments, the removing includes rotating at least the threaded portion of the mold or lifting the closure at an axial rate timed with the rotating. In some embodiments, the rotating of at least the threaded portion of the mold is performed manually by an operator. In some embodiments, the rotating of at least the threaded portion of the mold is performed using an automated rotation system. In some embodiments, the automated rotation system rotates the threaded portion of the mold at a speed ranging from about 10 RPM and about 20 RPM. In some embodiments, the removing of the closure from the mold further includes applying clearance to ensure smooth removal of the closure. In some embodiments, the clearance is applied using a clearance mechanism to ensure a thread path follows a contour of the rotating as the closure is removed from the mold. In some embodiments, the clearance mechanism allows for vents in the closure. In some embodiments, the axial rate includes 1-2 mm / s. In some embodiments, a process further includes slitting the closure to form a tamper evidence band. In some embodiments, the thermoforming is performed using a thermoforming machine. In some embodiments, a process further includes heating the multilayer structure to a temperature ranging from about 80 °C and about 120 °C prior to the thermoforming. In some embodiments, a process further includes cooling the closure prior to removing from the mold. In some embodiments, the cooling includes allowing the closure to cool to room temperature. In some embodiments, the cooling is performed using water cooling channels in the mold to cool the closure. In some embodiments, the water cooling channels are arranged in a 3D network of cooling channels to reduce a pitch between individual forming portions of the mold. In some embodiments, the at least one paper layer has a thickness of up to about 1 mm. In some embodiments, the at least one thermoplastic layer includes a recyclable polymer. In some embodiments, the at least one thermoplastic layer includes a polystyrene, a polyolefin, a polycarbonate, a polyester, or a combination thereof. In some embodiments, the atAtorney Docket No. 227254-747601 least one thermoplastic layer includes HDPE, PET, PHA, PLA, PEF, or any combination thereof. In some embodiments, the at least one thermoplastic layer has a thickness less than about 0.5 mm. In some embodiments, the multilayer structure includes a cover wall and a side wall, wherein the side wall is integrally connected to the cover wall and oriented transversely to the cover wall. In some embodiments, the side wall is circumferentially closed. In some embodiments, an interior surface of the closure is partially bounded by the cover wall and the side wall. In some embodiments, the multilayer structure further includes at least one seal layer coupled to one or more of the at least one paper layer and the at least one thermoplastic layer, wherein the at least one seal layer is configured to receive a finish portion of the container.

[0007] Also disclosed herein is a system for thermoforming a closure for a container, the system including: (a) a multilayer structure including at least one paper layer coupled to at least one thermoplastic layer; (b) a thermoforming machine; (c) a mold; and (d) an automated rotation system. In some embodiments, the thermoforming machine includes a rotary thermoforming machine. In some embodiments, the rotary thermoforming machine rotates at a speed ranging from about 1 RPM to about 80 RPM.

[0008] These and other features of the concepts provided herein may be better understood with reference to the drawings, description, and appended claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The drawings refer to embodiments of the present disclosure in which:

[0010] FIGS. 1A-1K illustrate an exemplary embodiment of a multilayered closure of the present disclosure. FIG. 1A illustrates a multilayered closure with a paper layer having substantially the same thickness throughout the layer; FIG. IB illustrates a multilayered closure with a paper layer having a changing thickness; FIG. 1C illustrates a domed multilayered closure with a paper layer having substantially the same thickness throughout the layer; FIG. ID illustrates a multilayered closure with a paper layer having a changing thickness; FIG. IE illustrates an exemplary embodiment of multilayered closure with a flatter paper layer and a foil layer, without a plug seal and including a folding tab. FIG. IF illustrates an exemplary embodiment of multilayered closure with a flatter paper layer and a foil layer, without a plug seal and excluding a folding tab. FIGS. 1G-1H illustrate a cross- sectional view and a perspective view, respectively, of an exemplary embodiment of multilayered closure with the paper layer including cams; FIG. II illustrates an exemplary embodiment of multilayered closure further including at least one seal layer under the thermoplastic layer; FIG. 1 J illustrates a multilayered closure having additional variations in thickness throughout a length of theAtorney Docket No. 227254-747601 paper layer; FIG. IK illustrates a paper layer of a multilayered closure with additional variations in thickness throughout a length of the paper layer and a rectangular shape.

[0011] FIGS. 2A-2B illustrate a perspective view and a side view, respectively, of an exemplary embodiment of a multilayered closure of the present disclosure with a plurality of external knurls distributed around the circumference of a threaded portion of the closure.

[0012] FIGS. 3A-3B illustrate an exemplary embodiment of a multilayered closure 300 when a paper layer and a thermoplastic layer in separate and combined configurations, respectively.

[0013] FIG. 4 illustrates an exemplary embodiment of a chuck for fitting a multilayered closure of the present disclosure.

[0014] FIG. 5A is a flowchart of an example process for thermoforming a closure for a container comprising each of at least one paper layer and at least one thermoplastic layer. FIG. 5B is a flowchart of example process 600 relates to a process for thermoforming a closure that further includes at least one seal layer.

[0015] While the present disclosure is subject to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. The present disclosure should be understood to not be limited to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.DETAILED DESCRIPTION

[0016] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one of ordinary skill in the art that the processes disclosed herein may be practiced without these specific details. In other instances, specific numeric references such as “first container,” may be made. However, the specific numeric reference should not be interpreted as a literal sequential order but rather interpreted that the “first container” is different than a “second container.” Thus, the specific details set forth are merely exemplary. The specific details may be varied from and still be contemplated to be within the spirit and scope of the present disclosure. The term “coupled” is defined as meaning connected either directly to the component or indirectly to the component through another component. Further, as used herein, the terms “about,” “approximately,” or “substantially” for any numerical values or ranges indicate a suitable dimensional tolerance that allows the part or collection of components to function for its intended purpose as described herein. As used herein, “recyclable” may refer to a paper-basedAtorney Docket No. 227254-747601 product that can be eligible for acceptance into paper recycling programs, including curbside collection programs and recycling programs that use drop-off locations, including products that comply with one or more promulgated standards or guidelines for recyclability, and including materials that are sufficiently free of plastic materials. As used herein, “repulpable” may refer to a product that can be reused or remade into paper (e.g., at a paper mill), including products that comply with one or more promulgated standards or guidelines for repulpability, and including materials that are sufficiently free of plastic materials.

[0017] Disclosed herein is a closure having a multilayered structure that comprises at least one paper layer coupled to at least one thermoplastic layer, and an interior surface that can be configured to receive a finish portion of a container. In some embodiments, the multilayered structure comprises at least one paper layer positioned between at least two thermoplastic layers, and an interior surface that can be configured to receive a finish portion of a container. In some embodiments, the multilayer structure comprises at least one seal layer coupled to one or more of the at least one paper layer and the at least one thermoplastic layer. Further disclosed herein is a process for thermoforming a closure for a container. In some embodiments, the process includes assembling a multilayer structure that comprises at least one paper layer positioned between at least two thermoplastic layers. In some embodiments, the process includes curing the multilayer structure. In some embodiments, the process includes thermoforming the multilayer structure into a closure by placing the multilayer structure into or onto a mold. In some embodiments, the process includes removing the closure from the mold. Further disclosed herein is a system for thermoforming a closure for a container. In some embodiments, the system includes a multilayer structure comprising at least one paper layer positioned between at least two thermoplastic layers. In some embodiments, the system includes a thermoforming machine. In some embodiments, the system includes a mold. In some embodiments, the system includes an automated rotation system.

[0018] The field of packaging technology has seen significant advancements over the years, particularly in the design and manufacturing of caps and closures. These are integral components of various products, serving as protective covers that preserve the quality and integrity of the contents. The materials used in the production of these caps and closures play a crucial role in their performance and environmental impact. Traditionally, these have been made from materials such as steel, aluminum, plastic, or a combination of both. However, there has been a growing emphasis on using more sustainable and eco-friendly materials, such as paper, due to increasing environmental concerns.

[0019] Currently, one of the common solutions for producing paper bottles is through the use of a polymer sheet with a thin layer of polyethylene terephthalate (PET). Along with its recyclabilityAtorney Docket No. 227254-747601 and sustainability, this material is chosen for its strength, durability, and resistance to moisture and oxygen, which are essential properties for preserving the contents of the package. Another approach can be to use a recyclable polymer with a bonded paper layer on top. This method also combines the benefits of both paper and polymer, providing a strong yet flexible material that can be easily recycled. In some cases, a pure paper layer can be used instead of a polymer layer, offering a more environmentally friendly alternative, but with severe limitations on performance as the resistance to moisture and fouling in general can be poor.

[0020] Despite the advancements in this field, there are still several challenges and limitations associated with the current technology. One of the main issues can be the difficulty in achieving a balance between the strength and flexibility of the material. While polymers provide the necessary strength, they are not perceived as environmentally friendly as paper. On the other hand, while paper can be perceived as more sustainable, it may not be as durable or effective at preserving the contents of the package. Additionally, the process of bonding the paper layer to the polymer sheet can be complex and costly, which can increase the overall cost of production. Furthermore, the disposal of these composite articles after use can also pose environmental challenges, as they may not be easily recyclable or biodegradable.

[0021] Regarding design considerations for closures relative to bottles, closures are generally required to provide a seal to protect product integrity by preventing leaks, contamination and spoilage while providing controlled access to the contents that may need to be resealable and / or tamperevidence. On the contrary, the bottle or container of which the closure is intended to seal is generally designed for material efficiency to provide structural stability during filling, shipping and use, while also being required to merely store the contents. Greater material efficiency and lower cost typically can require a tradeoff with precision and accuracy of the produced part, even over larger length scales for containers versus closures. For example, a blow molded container can have a diameter variation of many millimeters, but since it is one piece, the contents can be retained. The designer can make up for this container size variation by providing sufficient headspace or brimful volume to allow the desired volume to still be contained in a variable size container. However, the finish and closure of a typical stretch blow molded container can be formed using a more precise process, such as injection molding, and therefore can interface with the precision requirements of the seal provided by the closure. Such precision can be typically sub-millimeter, and even commonly hundredths of a millimeter. Such a precision difference is also observed in cartons. The folded container, while less precise in shape overall, can be sealed using an insert of a more precisely formed polymer finish to interface with the closure. Another option is to use a more dimensionally tolerant sealing mechanism such as an inductively heated foil seal to tolerate less accurate blown finishes or a compliant elastomerAtorney Docket No. 227254-747601 as a second layer in a closure to interact with similarly less accurate finish types. For example, glass finishes are less precise than injection molded PET finishes. While compliant materials like elastomers can provide added dimensional tolerance, multi-material solutions for seals can reduce recycle stream compatibility of the closure. This results in a broader material variety for containers, while materials and shapes for closures can be carefully chosen to maintain seal performance and handle the high mechanical stress from the initial machine applied torque of capping and repeated opening and / or closing of the container.

[0022] Compared to existing technology, the closures described herein primarily solve technical problems such as 1) the difficulty in achieving a balance between the strength, flexibility, and user experience of the material used in caps and closures, 2) the complexity and high cost of bonding the paper layer to the polymer sheet, and 3) the environmental challenges posed by the disposal of caps and closures after use, which may not be easily recyclable or biodegradable.

[0023] Provided herein are (1) multilayered closures; (2) processes for thermoforming multilayered closures; (3) systems for thermoforming multilayered closures. It should be noted that the features of each of the multilayered closures and processes and systems therefor are shown for illustrative purposes only. It should further be understood that the features of each of the process steps and system elements may be provided separately or in any suitable combination in operating the processes and systems of the present disclosure.I. Multilayered Closures

[0024] In some embodiments, a multilayered closure comprises at least one paper layer coupled to at least one thermoplastic layer, and an interior surface that can be configured to receive a finish portion of a container. FIGS. 1A-1K illustrate an exemplary embodiment of a multilayered closure100 of the present disclosure with an even thickness of the at least one paper layer (FIGS. 1A, 1C, and 1E-1I) or a changing thickness (FIG. IB, ID, and 1J-1K) of the at least one paper layer, respectively. As shown, the multilayered closure may comprise at least one paper layer 101, at least one thermoplastic layer 102, and a folding tab 103. As shown in FIGS. 1A and 1C, the paper layer(s)101 has substantially the same thickness throughout the layer, and can include a plug seal (see below for more detail). The multilayered closure 100 in FIG. 1C further illustrates an inverted dome structure, as evidenced by the curved plug seal. As shown in FIG. IB and ID, the paper layer(s) 101 has a changing thickness, which is illustrated, for example, as a thicker paper layer(s) 101’ on a top portion of the closure 100 and a thinner paper layer(s) 101 at a bottom portion of the closure 100. The multilayered closure 100 in FIG. ID further includes a flat plug seal as compared to the plug seal inAtorney Docket No. 227254-747601FIG. 1C. FIG. IE illustrates an exemplary embodiment of multilayered closure 100 with a flatter paper layer 101 and a foil layer 108, without a plug seal and including a folding tab 103. FIG. IF illustrates an exemplary embodiment of multilayered closure 100 with a flatter paper layer 101 and a foil layer 108, without a plug seal and excluding a folding tab 103.

[0025] FIG. 1G-1H illustrate a cross-sectional view and a perspective view, respectively, of an exemplary embodiment of multilayered closure 100 whereby the paper layer 101 includes cams 105, which can allow the closure 100 to latch onto the finish for the lower portion of the closure 100. The cams 105 are attached to the rest of the paper layer 101 via one or more perforations 106 to provide a tamper evidence feature. The one or more perforations 106 can either cut partially through the paper layer 101 or all the way through the paper layer 101. In some embodiments, the one or more perforations 106 can cut all the through the paper layer 101 between bridges embedded in the paper layer 101. Further, the at least one thermoplastic layer 102 is illustrated as being shorter than a length of the paper layer 101, showing the ability to have a closure 100 with less thermoplastic material relative to paper material, if desired.

[0026] FIG. II illustrates an exemplary embodiment of multilayered closure 100 further including at least one seal layer 107 under the thermoplastic layer 102. The seal layer 107 is shown as a small fraction of the total closure volume of material.

[0027] FIG. 1J illustrates an exemplary embodiment of a multilayered closure 100 with additional variations in thickness throughout a length of the paper layer(s) 101. FIG. IK illustrates an exemplary embodiment of a paper layer of a multilayered closure 100 with additional variations in thickness throughout a length of the paper layer(s) 101 and a rectangular shape.

[0028] As shown in FIG. 1A, the multilayered closure 100 has a plug seal, illustrated by cover wall 110 and a side wall 112 integrally connected to the cover wall 110 and oriented transversely to the cover wall 110. The interior may be partially bounded by the cover wall and the side wall. The closure may include an opening opposite to the cover wall, through which “access” to the interior is possible. The multilayered closure 100 further includes an annular wall 114 and a cylindrical wall 116 that extends downwardly from the annular wall 114 and surrounds the cover wall 110.

[0029] In some embodiments, the at least one thermoplastic layer comprises a thermoplastic coating. In some embodiments, the thermoplastic coating comprises one or more thermoplastic materials, described throughout this application, that are applied to a surface of the at least one paper layer. In some embodiments, the thermoplastic coating can be applied to the at least one paper layerAtorney Docket No. 227254-747601 using one or more post-processing steps. In some embodiments, the thermoplastic coating can be applied to the paper using one or more of an adhesive, a binder, an additive, or a combination thereof.

[0030] In some embodiments, a multilayered closure comprises at least one paper layer coupled to at least one thermoplastic layer. In some embodiments, a multilayer closure comprises at least one paper layer positioned between at least two thermoplastic layers. In some embodiments, each of the at least two thermoplastic layers includes a polymer sheet of thermoplastic material. In some embodiments, the polymer sheet includes a very thin layer or recyclable polymer sheet. Such a polymer sheet may be used as the base material for caps and closures described herein. This polymer sheet provides the necessary strength and flexibility required for caps and closures. In some embodiments, the polymer sheet comprises a thickness of less than 5 mm, less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm, less than 0.5 mm., less than 0.4 mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm.

[0031] In some embodiments, 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, PHA, polybutylene terephthalate (PBT) or PEF. Further, in some embodiments, the polymer sheet can be made from a single thermoplastic material or can be made from a plurality of thermoplastic materials. In one embodiment, the thermoplastic material comprises PET, and the container, which is to be closed with the closure, can also be made of PET. The use of PET allows for making mono-material recyclable containers. However, PHA or PLA are also practical options to allow for the manufacture of bio-degradable closures. Further, 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.

[0032] In some embodiments, the at least one paper layer can be bonded onto at least one thermoplastic sheet using a suitable adhesive or direct heat forming. This paper layer not only adds to the aesthetic appeal of the caps and closures but also enhances their bio-content and, with the right selection of polymer, biodegradability when the polymer can be minimized with a higher ratio of paper to polymer than previously used. The combination of the polymer sheet and the bonded paper layer creates a composite or sandwich structure. This unique structure allows for the creation of "paper" caps for various sectors in the caps and closures market.

[0033] In some embodiments, the at least one paper layer comprises a paper or paper-based substrate. In some embodiments, a paper or paper-based substrate comprises a paper or paperboard.Atorney Docket No. 227254-747601In some embodiments, a paper or paper-based substrate comprises organic fibers, cornstarch, bamboo, peanut hulls which are made into sheet, carton board, corrugated cardboard, tissue paper, kraft paper, natural kraft (SUS), coated unbleached kraft (CUK), cellulose wadding, solid bleached sulfate (SBS), clay coated backboard (CCNB), or folding box board (FBB). In some embodiments, a paper or paper-based substrate comprises a recyclable paper and / or a repulpable paper. In embodiments, a paper or paper-based substrate comprises a type having a machine glazed (MG) or a machine finished (MF) type finish. In embodiments, paper or paper-based substrate comprises clay coated paper. In embodiments, paper or paper-based substrate comprises cork or agglomerated cork. In embodiments, paper or paper-based substrate comprises bleached or unbleached paper. In embodiments, paper or paper-based substrate comprises a Kraft, ground wood, recycled, or sulfite furnish type, or the like or a combination thereof. In some embodiments, the at least one paper layer comprises a thickness of less than 5 mm, less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm, less than 0.5 mm., less than 0.4 mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm.

[0034] The use of a recyclable polymer sheet and the incorporation of a paper layer in the caps and closures design has an added benefit of reducing the environmental impact. By making the caps and closures more easily recyclable and biodegradable, there may be a reduction in the environmental challenges associated with their disposal. Further, the use of a very thin polymer sheet and the bonding processes described herein reduces the complexity and cost of manufacturing the caps and closures. This makes the production process more cost-effective and accessible to a wider range of industries.

[0035] In some embodiments, a thermoplastic sheet includes an additive. In some embodiments, each of the at least one paper layer includes an additive. In some embodiments, resistance to water or oil dissolving in the fiber can be provided by the lamination or thin polymer layer. In some embodiments, resistance to water or oil dissolving in the fiber can be provided by an additive in the fiber mixture which can be activated during formation of the closure during the heating and forming step.

[0036] In some embodiments, the additive comprises hydrothermal carbon (HTC). HTC may be employed in addition to traditional fibers for this application, such that the at least one paper layer can be a composite of traditional fibers and HTC. HTC benefits from the advantage that lamination as described above provides. In embodiments, paper or paper-based substrate can be a composite that comprises HTC.Atorney Docket No. 227254-747601

[0037] In some embodiments, the additive comprises plasticizers, coupling agents, flexomers, stabilizers (e.g., heat stabilizers, UV stabilizers, viscosity stabilizers, hydrolytic stabilizers, or the like), antioxidants, UV absorbers, anti-static agents, dyes, pigments or other coloring agents, inorganic fillers, fire-retardants, lubricants, reinforcing agents (e.g., glass fiber and flakes or the like), processing aids, antiblock agents, release agents, slip agents, nucleating agents, clarifying agents, retention agents, sizing agents, wet strength agents, dry strength agents, defoamers, antimicrobial agents, binders (e.g., polyvinyl alcohol, polyamide-epichlorohydrin, polychloride emulsion, modified starch such as hydroxyethyl starch, starch, polyacrylamide, modified polyacrylamide, polyol, polyol carbonyl adduct, ethanedial / polyol condensate, polyamide, epichlorohydrin, glyoxal, glyoxal urea, ethanedial, aliphatic polyisocyanate, isocyanate, 1,6 hexamethylene diisocyanate, diisocyanate, polyisocyanate, polyester, polyester resin, polyacrylate, polyacrylate resin, acrylate, carboxymethyl cellulose, urea, sodium nitrate, and methacrylate), fillers (e.g., clay, calcium carbonate, calcium sulfate hemihydrate, and calcium sulfate dehydrate), thickeners, preservatives, brighteners, process aids, perfumes, flavors, silicas (e.g., colloids, sols, sodium silicate, borosilicates, or the like), bulk enhancing agents, porosity enhancing agents, coagulation agents, flocculation agents, entrapment agents, dispersants, fluorescent dyes, surfactants, deforming agents, pH control agents, coating releasing agents, laminate materials (e.g., polyethylene, polyvinyl alcohol, or the like) or a combination thereof. In some embodiments, a laminate material comprises a resin, e.g., a thermoplastic resin. In some embodiments, a resin comprises a synthetic resin, e.g., polyester, nylon, polypropylene, or the like. In some embodiments, a laminate material can be selected to provide resistance to fluids, e.g., water or oil, as well as resistance to microwave heating. In some embodiments, a laminate material can be bonded to both sides of the at least one paper layer.

[0038] In some embodiments, a multilayered closure comprises at least one seal layer. Seal layers are conventionally either excluded from the closure and applied directly to a surface of the container. Further, seal layers are generally not incorporated into existing paper-based closures. A seal layer incorporated into a closure during manufacturing of the closure can provide built-in protection for product integrity, e.g., by providing tamper evidence, with fewer steps required during downstream assembly with a container or bottle.

[0039] In some embodiments, at least one seal layer comprises at least one foil layer. In some embodiments, a foil layer may be a metal foil. In some embodiments, a metal foil may be made from aluminum, iron oxide, copper, brass, nickel, stainless steel, or the like or alloys or combinations thereof.Atorney Docket No. 227254-747601

[0040] In some embodiments, at least one seal layer comprises at least one foam layer. In some embodiments, a foam layer comprises a foamed material or a foamed thermoplastic material as described herein.

[0041] In some embodiments, a multilayered closure comprises at least one paper layer, at least one thermoplastic layer, and at least one seal layer coupled to either the at least one paper layer or the at least one thermoplastic layer. Such a seal layer may be configured as a tamper evidence feature for caps and closures described herein that indicates whether a container has been opened by breaking contact between a circumference of a seal and a top surface of a finish of a container. In some embodiments, a seal layer comprises a thickness of less than 5 mm, less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm, less than 0.5 mm., less than 0.4 mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm. In some embodiments, a seal layer can be selected to be compatible with thermoforming processes described herein. An additional compatibility consideration can include, for example, compatibility with the contents of the container, such as resisting wetting, acidity, or swelling. If the sealing layer is incorporated as the A layer in an A / B / A or A / B film, then the compatibility with thermoforming extends to rolling onto a roll, heating in the oven (or not blocking the heat transfer to the PET), and stretching - such as when heated, for example - to form the final closure shape.

[0042] If the seal layer is provided directly to the mold, independent of the thermoformed sheet, then tolerance to heating and stretching is not required. A dark or light elastomeric foam for example could be applied to the mold this way, for example and the color and presence of the elastomer would not impact the way the sheet heats in the oven. Another important detail is to not contaminate the regrind. If the sealing layer is only applied to a small part of the mold and not allowed to contact the web, then it will not go into the regrind used to make subsequent closures.

[0043] In some embodiments, a multilayered closure only includes a seal layer across a portion of the multilayered closure. In some embodiments, a portion of the multilayered closure includes a cover wall of the closure, a side wall of the closure, portions thereof or a combination thereof.

[0044] In some embodiments, a multilayered closure comprises at least one paper layer positioned between at least one thermoplastic layer and at least one seal layer. A multilayered closure can be configured so as to attach a seal layer to a top surface of a finish of a container about a circumference of the seal layer. In some embodiments, a multilayered closure comprises at least one paper layer andAtorney Docket No. 227254-747601 at least one first thermoplastic layer positioned between at least one second thermoplastic layer and at least one seal layer, thereby creating a multilayered closure with at least four layers.

[0045] In some embodiments, a multilayered closure comprises at least one thermoplastic layer positioned between at least one paper layer and at least one seal layer. In some embodiments, a multilayered closure comprises at least one thermoplastic layer and at least one first paper layer positioned between at least one second paper layer and at least one seal layer, thereby creating a multilayered closure with at least four layers.

[0046] In some embodiments, at least one seal layer comprises one or more vents, thereby allowing for heat or pressure regulation during storage of the container. In some embodiments, a vent may include one or more apertures extending through the at least one seal layer to create one or more opening through which air or the like can escape from within the container. A vent may be spaced apart along the at least one seal layer.

[0047] In some embodiments, the seal, or at least one seal layer of the seal, can be formed from a foamed thermoplastic material. By using a foamed material, various advantages can be realized, such as an increased surface roughness of the foamed material, which leads to better gripping and handling of the closure if the seal as a whole or an outer seal layer can be formed from the foamed thermoplastic material.

[0048] Furthermore, foaming makes the thermoplastic material opaque, which may be beneficial for optical reasons, whereas many of the preferred employed amorphous and semi-crystalline thermoplastic polymers are transparent. This applies in particular to PET, PEF and PET / PEF copolymers as closure materials due to their resulting transparency, so as to make them opaque instead, as desired. For example, an opaque material for a closure can make it difficult to see residue on the threads, which, if visible, could dissuade a buyer from purchasing the product in a store. An opaque material can also make it obvious to see that there is a closure on the container.

[0049] In some embodiments, the seal can be formed in a single layer from a foamed thermoplastic material. Similarly, in combination with embodiments described above, it may be provided that the seal comprises two or three (or more) seal layers, wherein in particular the outer seal layer can be formed from a foamed thermoplastic material. As already mentioned, this achieves a better grip on the outside of the closure body, while a non-foamed material can be preferably used for the inner seal layer in order to achieve a better sealing effect of the closure.Atorney Docket No. 227254-747601

[0050] Alternatively, the surface roughness of the seal layer can be controlled by, for example, smoothing the surface of the mold used in the thermoforming process. For example, a mirror finish or a finish with an RZ value of, for example, 0.5 microns, 1 micron, or up to 2 microns, can be applied to the mold surface in order to produce a correspondingly smoother surface on the seal layer, as compared to the smoothness of the seal layer produced without the finish. By smoothing the surface of the mold and thereby smoothing the surface of the seal layer, the seal layer can achieve better sealing effect, such as, for example, a more robust tamper evidence effect. Further, the use of a finish described herein that smooths the surface of the mold may also increase the shelf-life of the mold.

[0051] In some embodiments, the foamed thermoplastic material can be a foamed thermoplastic polymer selected from PET, PEF and PET / PEF copolymers. Special advantages of said polymers have already been explained above, these can be combined with the advantages of a foamed material.

[0052] The foamed thermoplastic material typically has a pore volume from about 10% or more, preferably from about 15% or more, more preferably from about 15% to about 20%. Thus, the foamed thermoplastic material can be preferably a rigid foam. The pore volume corresponds to the reduction in density compared to the unfoamed material, e.g. the density of PET can be reduced from 1.38 g / cm3 to about 1.1 g / cm3. Thus, the foamed material also enables a certain saving in weight and material.

[0053] As already mentioned, the foamed thermoplastic material typically has an increased surface roughness, which improves grip and handling on the outer face of the closure body. The foamed thermoplastic material preferably has a surface roughness from about 10 to about 100 pm, and / or a surface roughness resulting from a pore size of the foamed material from about 10 to about 100 pm.

[0054] In some embodiments, the seal, or at least one seal layer of the seal, can be formed from a wax layer. A wax or other binder material may be used as a layer or a matrix to hold the paper fibers together. The addition of such a layer as an outer layer can provide additional resistance to moisture attacking the fibers. In some embodiments, if a wax layer behaves as the seal layer, a polyester layer could be removed entirely. In some embodiments, a wax layer can function as either a seal layer, a binder, or both. In some embodiments, a wax layer may be natural, chemically-modified or synthetic. In some embodiments, a wax layer comprises vegetable wax, animal wax, mineral wax, petrochemical wax, or the like. In some embodiments, a wax layer comprise hard wax, polyalkylene wax, or polyethylene glycol wax, petrolatum, paraffin wax, microwax, polyethylene wax,Atorney Docket No. 227254-747601 microcrystalline wax, or the like. In some embodiments, a wax layer or similar binder can be used to hold paper fibers of a paper layer together, resulting in a sealing wax working as a sealing layer.

[0055] In some embodiments, the closure comprises an interior surface that can be configured to receive a finish portion of a container. In some embodiments, the interior surface comprises internal threads. In some embodiments, the closure comprises a threaded portion. In some embodiments, the closure comprises an access feature such as an embossment or tab (e.g. a pull tab). This access feature can be used as tear away section or opening to provide access to an interior surface of a closure. In some embodiments, the closure may be a monolithic portion of the multilayered structure and produced by thermoforming with a mold, described in more detail herein. Further details regarding techniques for forming the closure 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.

[0056] In some embodiments, a multilayer closure comprises a tamper evidence feature. Tamper evidence can be more difficult to form on smaller parts (less than 30 mm) than larger ones (>40 mm in diameter). To facilitate the formation of tamper evidence, a secondary folding process can be used, as described in more detail below.

[0057] In some embodiments, the multilayer closure comprises folding tabs (i.e., “flaps”) arranged around the circumference of the tamper evidence feature. The folding tabs form a tamper- evident device on the closure; when a corresponding closure closes a container, increased effort and in particular increased force must be exerted at least when the container can be first opened due to the presence of the folding tabs. In some embodiments, the tamper evidence feature comprises a tether that retains or holds the multilayer closure onto the container. In some embodiments, the folding tabs are integrally connected to a tamper evidence feature, which may be imparted to the closure by a tamper evidence feature of a mold. In some embodiments, the folding tabs may be manufactured as “pre-fold tabs” integrally with the closure. In a pre-fold state, the folding tabs may be arranged in an outward ring that surrounds the tamper evidence feature and an opening of the closure. In some embodiments, the folding tabs are arranged and formed in such a way that they can be folded into the opening and positioned in the interior of the closure.

[0058] In some embodiments, each of the folding tabs are shaped to include a two-dimensional (2D) geometry, three-dimensional (3D) geometry, or a combination thereof. In some embodiments, the geometry may comprise an associated height increment along any number of portions of the geometry. In some embodiments, not all of the folding tabs have the same geometry. In someAtorney Docket No. 227254-747601 embodiments, each of the folding tabs are of a different geometry or shape from others of the folding tabs.

[0059] In some embodiments, the closure has a cover wall and a side wall. In some embodiments, the side wall can be integrally connected to the cover wall and oriented transversely to the cover wall. The side wall may be circumferentially closed. The closure may have an interior configured to receive a finish portion of the container to be closed with the closure. The interior may be partially bounded by the cover wall and the side wall. The closure may include an opening opposite to the cover wall, through which “access” to the interior is possible.

[0060] In some embodiments, the closure includes an annular wall and a cylindrical wall that extends downwardly from the annular wall and surrounds the cover wall. In some embodiments, interior surfaces of the annular wall and the cylindrical wall comprise a plug seal for scaling against an inner surface of a finish portion of the container to be closed with the closure. An interior surface of the annular wall 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 may be dimensioned for an interference fit with a corresponding inwardly facing surface of rim of finish for scaling. As the closure is threaded onto the finish, the plug seal can be forced into a mouth of the finish and into a compressed state in which the outwardly facing radial surface of the cylindrical wall pushes against the inwardly facing surface of finish, thereby forming a seal.

[0061] In some embodiments, as shown in each of a perspective view and a side view, respectively, of an illustrative embodiment in FIGS. 2A-2B, a multilayered closure 200 includes a plurality of external knurls 203 distributed around the circumference of a threaded portion of the multilayered closure 200. The external knurls serve in particular to improve the grip of the threaded portion of the closure. Further, the multilayered closure 200 includes a plurality of knurls 204, which can be optionally included, distributed around the circumference of the tamper evidence feature. In some embodiments, the plurality of knurls are distributed along an upper circumference or a lower circumference of the multilayered closure, or therebetween. In some embodiments, the plurality of knurls are retained on an underside or polymer side of the closure, and either (a) included on the outside of the closure, or (b) or excluded on the outside of the closure such that the outside of the closure appears flat.

[0062] In some embodiments, the closure includes one or more internal threads formed into the side wall for engaging with external threads of the finish portion of the container to be closed with the closure. The threads may be continuous threads or may be interrupted threads. In someAtorney Docket No. 227254-747601 embodiments, the closure includes one thread, with one thread start at the beginning of the thread. In some embodiments, however, the closure may include a plurality of threads, such as, for example, three threads distributed uniformly around the side wall of closure. As such, each of the plurality of threads includes one of a corresponding plurality of thread starts. In some embodiments, as the closure is threaded onto a finish portion of a container, the tamper evidence feature rides over a ledge of the finish portion, clears the ledge, and fits into place beneath ledge.

[0063] In some embodiments, the closure includes a plurality of external knurls distributed around the circumference of the threaded portion. The external knurls serve in particular to improve the grip of the threaded portion of the closure. Further, the closure includes a plurality of knurls distributed around the circumference of the tamper evidence feature.

[0064] In some embodiments, the closure includes a plurality of knurls about the circumference of an inner surface of a tamper evidence feature. The plurality of internal knurls may be distributed evenly or unevenly about the circumference of the inner surface of tamper evidence feature.

[0065] In some embodiments, the tamper evidence feature may include a plurality of spaced-apart bridges that connect the tamper evidence feature to the threaded portion of the closure. In the event that the closure is unthreaded from the finish portion, tamper evidence feature will be retained in position by the ledge of the finish portion. The upward force from unthreading of the closure will eventually cause sufficient stress on the bridges that they will break, providing evidence that the closure has been tampered with.

[0066] In some embodiments, a closure and / or a container configured to receive the closure may be transparent. In some embodiments, one or more of at least one paper layer, at least one thermoplastic layer, or at least one seal layer of the closure can be transparent. Transparency of either of the paper layer(s), thermoplastic layer(s) or seal layer(s) may enhance sterilizing of the closure and / or the container configured to receive the closure, where such sterilizing may be performed through exposure of the closure and / or the container to a source of electromagnetic radiation capable of inactivating pathogens, described in more detail below. In some embodiments, the closure and / or container may include an antimicrobial coating on an outer surface or on an inner surface.

[0067] FIGS. 3A-3B are illustrations of an exemplary embodiment of a multilayered closure 300 when a paper layer and a thermoplastic layer in separate and combined configurations, respectively. As shown on the right side of FIG. 3A, a plurality of knurls 304 may be isolated to just a paper layer 301. As shown on the left side of FIG. 3A, internal threading may be isolated to just a thermoplasticAtorney Docket No. 227254-747601 layer 302. A folding tab 306 may also be isolated to just the thermoplastic layer 302. FIG. 3B shows a combined configuration of the multilayered closure 300 when applied to a bottle finish 305.II. Processes for Forming Closures

[0068] Disclosed herein is a process for thermoforming a closure for a container. In some embodiments, the process includes assembling a multilayer structure that comprises at least one paper layer coupled to at least one thermoplastic layer. In some embodiments, the process includes assembling a multilayer structure that comprises at least one paper layer, at least one thermoplastic layer, and at least one seal layer. In some embodiments, the process includes curing the multilayer structure. In some embodiments, the process includes thermoforming the multilayer structure into a closure by placing the multilayer structure into or onto a mold. In some embodiments, the process includes removing the closure from the mold.

[0069] In some embodiments, the process for thermoforming a closure includes selecting the materials and / or structure for the thermoplastic layer(s), the paper layer(s), and the seal layer(s). In some embodiments, the thermoplastic layer(s) comprise a polymer sheet. In some embodiments, the polymer sheet can be a very thin layer or recyclable polymer. The polymer sheet should be sufficiently thick and an appropriate combination of materials so as to provide the necessary strength and flexibility required for the caps and closures. In some embodiments, the strength and flexibility of the polymer sheet are evaluated based on at least one of a resulting seal performance, a drop test performance, a tamper evidence performance, or a capping performance of the closure. In some embodiments, a 3- or 4-point bending test can be performed on the closure with the layers tested at different thicknesses to determine the minimum thickness for each layer. Such a test allows for measuring a load displacement curve to predict behavior (e.g., doming) directly and as input to finite element analysis (FEA) models of a closure-finish dispensing system.

[0070] In some embodiments, a polymer sheet should be sufficiently thick to be compatible with capping equipment. For example, the diameter and thickness may be sufficient so as to be properly intact with a chuck that applies the closure to the finish.

[0071] In some embodiments, a seal layer comprises a foil layer, a foam layer, a wax layer, or a combination thereof, as described herein. The seal layer should sufficiently contact a top surface of a finish of a container to provide a tamper evidence feature for caps and closures described herein. In some embodiments, the at least one paper layer comprises a paper or paper-based substrate. In some embodiments, a paper or paper-based substrate comprises organic fibers, cornstarch, bamboo, peanut hulls which are made into sheet, carton board, corrugated cardboard, tissue paper, kraft paper, naturalAtorney Docket No. 227254-747601 kraft (SUS), coated unbleached kraft (CUK), cellulose wadding, solid bleached sulfate (SBS), clay coated backboard (CCNB), or folding box board (FBB). In some embodiments, the paper or paperbased substrate should be sufficiently recyclable and / or repulpable. In some embodiments, selecting the materials comprises selecting one or more additives.

[0072] In some embodiments, a closure includes one or more layers of each of a thermoplastic layer, an adhesive layer, a foil layer, a paper layer, or any other layer described herein or any permutation thereof. For example, a closure a include a sequence of a polymer layer, an adhesive layer, a foil layer, an additional adhesive layer, and a paper, and optionally including another layer of wax, adhesive, or polymer as an outer coating.

[0073] In some embodiments, a closure includes a combination of a foil layer for a barrier and a thermoplastic layer to protect the foil from corrosion and direct liquid contact. For example, if a foil layer is thick enough (e.g., 50-300 microns), then the foil layer can support enough current motion for an eddy current to be useful in heating the closure.

[0074] In another example, a common induction foil liner comprises:

[0075] A paper layer: in some cases this layer can be a two-piece liner that separates from the foil and stays in the closure after opening. In some cases, the full structure stays with the container.

[0076] A wax layer: this layer can hold the paper layer and a foil layer together. During the sealing process, the wax layer can melt and be absorbed by the paper layer.

[0077] A foil layer: this layer can heat up from an electromagnetic field, causing the wax layer to melt and release the heat to a thermoplastic layer.

[0078] A thermoplastic layer: this layer, which can be, for example, a heat-seal layer, that can bond to a container's opening, creating an airtight seal. The type of polymer for the thermoplastic layer can be chosen based on the container material (e.g., PET or HDPE).

[0079] In some embodiments, a thickness of a thermoplastic layer can be controlled so as to adjust a capacity for heating and therefore bonding to a container opening. For example, if a lower sealing thermoplastic layer is thin enough (e.g., around 400 micron but under 1 mm), then it can heat fast enough to bond with the container in an inductive sealing environment. If it is too thick, the thermoplastic layer can soften and not bond.

[0080] In some embodiments, the process for thermoforming a closure includes bonding the at least one paper layer onto at least one thermoplastic sheet using a suitable adhesive or direct heatAtorney Docket No. 227254-747601 forming. In some embodiments, the process for thermoforming a closure includes bonding the at least one seal layer onto at least one thermoplastic sheet using a suitable adhesive or direct heat forming. In some embodiments, the process for thermoforming a closure includes bonding the at least one seal layer onto at least one thermoplastic sheet that is already bonded to the at least one paper layer.

[0081] In some embodiments, the process for thermoforming a closure includes application of adhesive to one or more thermoplastic layers, one or more seal layers, or a combination thereof. In some embodiments, the adhesive can be applied onto the polymer sheet or the seal layer. In some embodiments, the adhesive can be a food-grade adhesive, ensuring that it is safe for use in food packaging. In some embodiments, the adhesive can be applied evenly across the surface of the polymer sheet, ensuring a consistent bond with the paper layer. In some embodiments, an adhesive can be selected from the group comprising polyurethane adhesives, acrylic adhesives, natural rubber latex adhesives, non-polyethylene or non-polypropylene based adhesives, bio-polymer based adhesives, such as starch, cellulose, protein, and itaconic acid, water-based adhesives, solvent-based adhesives, hot melts, hide glue, aqua seal, gummed paper tape, starch based, dextrin glue, wood glue, cyanoacrylate (e.g., super glue), methyl methacrylate adhesives (MMA), or a combination thereof.

[0082] In some embodiments, the process for thermoforming a closure includes bonding of the paper layer(s) to the thermoplastic layers, thereby forming the multilayer structure for the closure. In some embodiments, the process for thermoforming a closure includes bonding of the seal layers to the paper layer(s) or the thermoplastic layers so as to form the multilayer structure for the closure. In some embodiments, the paper layer(s) are bonded onto one or more thermoplastic layers or one or more seal layers using the applied adhesive. In some embodiments, the paper layer can be placed on top of the adhesive-coated thermoplastic layer(s) or adhesive-coated seal layers and pressed down firmly to ensure a strong bond. In some embodiments, the paper layer can be placed on top of one of the adhesive-coated thermoplastic layers or one of the adhesive-coated seal layers, then placed on top of the second of the adhesive-coated thermoplastic layers or the second of the adhesive-coated seal layers.

[0083] In some embodiments, the process for thermoforming a closure includes curing of the bond. In some embodiments, the bonded thermoplastic layers and paper layer(s) are then cured under controlled conditions. In some embodiments, the bonded seal layers and thermoplastic layers or paper layer(s) are then cured under controlled conditions. In some embodiments, the curing process can be carried out at a curing temperature and a curing duration. This process ensures that the adhesive fully sets, creating a strong and durable bond between the polymer sheet and the paper layer, the polymer sheet and the seal layer, or the paper layer and the seal layer. In some embodiments, a curingAtorney Docket No. 227254-747601 temperature can be in a range of from 0 °C to 150 °C, from 0 °C to 100 °C, from 0 °C to 90 °C, from 0 °C to 80 °C, from 0 °C to 70 °C, from 0 °C to 60 °C, from 0 °C to 50 °C, from 0 °C to 40 °C, from 0 °C to 30 °C, from 0 °C to 20 °C, from 0 °C to 10 °C, from 10 °C to 70 °C, from 10 °C to 60 °C, from 10 °C to 50 °C, from 10 °C to 40 °C, from 10 °C to 30 °C, from 10 °C to 20 °C, from 20 °C to 70 °C, from 20 °C to 60 °C, from 20 °C to 50 °C, from 20 °C to 40 °C, from 20 °C to 30 °C, from 30 °C to 70 °C, from 30 °C to 60 °C, from 30 °C to 50 °C, from 30 °C to 40 °C, or from 70 °C to 90 °C. In some embodiments, the curing duration can be in a range of from 0 to 1 hours, from 1 to 2 hours, from 2 to 3 hours, or from 3 to 4 hours.

[0084] In some embodiments, the process for thermoforming a closure includes thermoforming of the multilayer structure into the desired shape of the caps and closures. In some embodiments, the thermoforming can be done using a thermoforming machine, which shapes the material into the desired size and shape.

[0085] In some embodiments, using the thermoforming processes described herein, consistent threads can be formed on a thermoformed closure without causing damage. In some embodiments, the thermoforming begins wherein the multilayer structure can be heated in an industrial oven to a temperature that allows the materials to become more flexible and easier to shape. In some embodiments, ceramic heating elements are used to heat the material. In some embodiments, the temperature ranges between about 80°C and about 120°C. This temperature range has been found for both HDPE and PET materials, allowing for effective thermoforming while minimizing the risk of degradation.

[0086] In some embodiments, the heated multilayer structure can be placed into a mold, such as the molds described herein. In some embodiments, the heated multilayer structure can be placed into a thermoforming machine comprising the mold. In some embodiments, the heated multilayer structure may, alternatively, be compression molded. 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 thermoforming mold can be configured to operate at a pressure ranging between about 4 bar to about 10 bar and a temperature range between about 80°C and about 120°C. Experimental observations have demonstrated that these conditions are optimal for forming threads in container closures. Experimental observations have also demonstrated that this pressure can be sufficient to shape the PET material into the desired closure design but not so high as to cause damage to the PET material. Cams may be formed on the flaps during this step or the flaps themselves can be left to form cams in later steps.Atorney Docket No. 227254-747601

[0087] After the thermoforming process is complete, the molded closure can be cooled to room temperature. In some embodiments, the cooling takes place in the thermoforming machine. This cooling step helps to set the shape of the closure and solidify the threads. In some embodiments, water cooling channels are provided in the mold to cool the closure. In order to reduce the pitch or distance between individual forming portions of the mold, a 3D network of cooling channels can be beneficial. These can be machined by brazing mold parts together after milling the cooling channels or through additive manufacturing instead of typical gun drilling methods that are used to form conventional cooling channels.

[0088] In some embodiments, while the closure is allowed to cool or after the closure has cooled, the closure can be then trimmed from the thermoformed web in a pre-folded state. The trimming of the closure from the thermoformed web can be configured in a way that allows for the formation of cams at various angles, overcoming the limitations of traditional methods. While the PET material is warm and pliable, but optionally after cooling to room temperature, cams can be formed on the closure using a cam-forming tool. The cams can be formed in steps at angles ranging between about -10 degrees and about 190 degrees, with an emphasis on starting with 90-degree flaps. This configuration maximizes the distance between the skirt of the closure to the trimming surface, providing clearance and eliminating a need for the closure to stretch when being removed from the mold.

[0089] In the case of 90-degree flaps, however, the centering of a trimming tool can limit the accuracy of the formed cams. Too much trimming offset can lead to cams that are short or long and then reduce the consistent effectiveness of tamper evidence. This can be sufficient to form functional tamper evidence. However, expanding the precision limitation opens up the option to increase the number of cavities in the mold. This can be enabled by thermoforming cams directly on the tab before folding and allow the flat part of the tab that remains for trimming to extend past the tamper evidence bead upon application of the closure to a finish portion of a container.

[0090] In some embodiments, folding of the tabs may be done sequentially. In some embodiments comprising tabs, the tabs can be folded in steps, such as 30 degrees, 60 degrees, 90 degrees, 140 degrees and then finally invert the tabs with a plunger. Folding can be done along the circumference using a ramp or all at once through a cylinder or a conically shaped tube. Keeping the closure aligned with the folding tool can be important and can be done with an internal drive that drives the closure along the folding ramp engaging with optional knurls formed in the band. In some embodiments, the tabs are pre-trimmed at an edge of the closure.Atorney Docket No. 227254-747601

[0091] Pushing the closure with flaps through a cylinder or a conically shaped tube to encourages the flaps to fold into a vertical position. This creates a cap that can be shaped in a more usual fashion that can then be presented to typical closure folding equipment for further processing. Experimental observations have demonstrated that moving from a multi-step folding process, as described above, to a continuous folding process provides an all-at-once folding step that benefits the cycle time of the process.

[0092] In some embodiments, a slitting process can be applied to form a tamper evidence band on the closure. This process ensures that the closure remains intact until it is opened on a container for the first time, providing a clear indication of potential tampering. This embodiment provides a feasible process for producing closures with tamper evidence using thermoforming techniques and specific cam designs. The use of outer facing portions eliminates the need for the closure to stretch when being removed from the mold, a process that is not possible with cooled parts. In some embodiments, each of the plurality of slits comprises a length of less than about 60 mm, less than about 50 mm, less than about 40 mm, less than about 30 mm, less than about 20 mm, or less than about 10 mm.

[0093] After the cooling, trimming, and / or slitting processes, the closure can be removed from the mold. In some embodiments, the closure can be removed by rotating the mold manually by an operator. In some embodiments, the closure can be removed by using a controlled rotation system. In some embodiments, the controlled rotation system comprises a servo, a belt, or a chain drive system that can be configured to ensure consistent and accurate rotation of the threads. In some embodiments, the controlled rotation system operates at a speed ranging between about 10 RPM and about 20 RPM, which has been found to be optimal for removing closures without causing damage.

[0094] In some embodiments, a clearance mechanism can be used as the closure is removed from the mold. The clearance mechanism can be configured to ensure the thread path follows the contour of the rotation while the closure is being removed. Along the threads, a clearance may be provided to allow for smooth removal of the closure from the mold. This clearance could allow for vents or other interruptions, which may be provided through a vertically moving part that slips from the closure after formation. This clearance allows for smooth removal of the closure from the mold and prevents damage to the threads.

[0095] In some embodiments, a timing mechanism can be used to lift the closure at an axial rate that is correctly timed with the rotation of the thread component. Timing of lifting the closure when the thread forming component is moving can be critical to prevent deformation and unwanted heightAtorney Docket No. 227254-747601 variation. In some embodiments, the closure can be removed at an axial rate of 1-2 mm / s, which has been found to be optimal for preventing deformation and unwanted height variation.

[0096] It should be understood that the controlled rotation system, the clearance mechanism, and the timing mechanism cooperate to prevent damage to the closure during removal from the mold. As such, the thermoforming advantageously allows for removing HDPE, PET, PHA, PLA, PEF or any type or combination of polymer closures from molds without causing damage.

[0097] In some embodiments, the process for thermoforming a closure includes inspection of the closure for quality assurance. In some embodiments, this includes checking for any defects in the bond between the polymer sheet and the paper layer, the polymer sheet and the seal layer, or the paper layer and seal layer, as well as ensuring that the caps and closures are of the correct size and shape. This method allows for the production of "paper" caps for all sectors in the caps and closures market. The use of a recyclable polymer sheet and the incorporation of a paper layer in the caps and closures design reduces the environmental impact. The process can also be cost-effective due to the use of a very thin polymer sheet and a simple bonding process.

[0098] In some embodiments, rather than use an adhesive layer, the option exists to fill a female mold with pulp and line that with a heated sheet out of an oven as can be typical in thermoforming and pull a vacuum on that sheet to force it to adhere to the female mold. In some embodiments, the female mold can then be penetrated with a male mold to compress the formation of threads into place. Subsequently, the female portion of the mold can be unscrewed from the male mold. In some embodiments, the closure can be trimmed from the multilayer structure as a final part or an intermediate part with features on the periphery designed for forming tamper evidence.

[0099] In some embodiments, the paper layer can be removed from the folding tabs or flaps attached to the tamper evidence band. If curing is extended and done via an adhesive, then this can be done more easily before curing is complete. In some embodiments, a brush or tool can be used to scrap the polymer flaps clean before folding. In some embodiments, the use of very thin paper layers (on the order of 0.3 mm or less) can be left in place and folded in conjunction with the polymer layer, the seal layer or a combination thereof to form the locking feature for the tamper evidence band.

[0100] In some embodiments, a closure and / or container configured to receive the closure can be sterilized. In some embodiments, the sterilizing comprises exposing a closure and / or container to a source of electromagnetic radiation capable of inactivating pathogens. In some embodiments, sterilizing of the closure and / or the container can be enhanced through transparency of one or more of a closure and / or a container. In some embodiments, the closure may be exposed to the source ofAtorney Docket No. 227254-747601 electromagnetic radiation before or after the closure is applied to the container. In some embodiments, the electromagnetic radiation may be capable of inactivating pathogens. For example, electromagnetic radiation may be 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. In still other examples, the source of electromagnetic radiation may be of a wavelength of less than 10-7 meters. In still other examples, the source of electromagnetic radiation may be of a wavelength of less than 10-11 meters. In still other examples, the source of electromagnetic radiation may be of a wavelength of up to 10-6 m. The source of electromagnetic radiation may also be of a wavelength within a range formed by any two foregoing wavelengths, including any subranges therebetween. In still other examples, the exposure may be to bursts of electromagnetic radiation of the same or varying wavelengths in a series. Examples of sources of electromagnetic radiation may include a low-pressure mercury lamp, ultraviolet light-emitting diodes, and a pulsed-xenon lamp. I n still other examples, the closure may include an antimicrobial coating on an outer surface or on an inner surface.

[0101] FIGS. 5A-5B are flowcharts of example processes 500 and 600, respectively, for thermoforming a closure for a container. Process 500 relates to a process for thermoforming a closure comprising each of at least one paper layer coupled to at least one thermoplastic layer, while process 600 relates to a process for thermoforming a closure that further includes at least one seal layer.

[0102] The process 500 begins at step 510, which includes assembling a multilayer structure that comprises at least one paper layer coupled to at least one thermoplastic layer. In some embodiments, the assembling includes applying an adhesive to the at least one thermoplastic layer and applying a sufficient pressure so as to bond the at least one paper layer to the at least one thermoplastic layer. In some embodiments, the pressure can be sufficient to shape the multilayer structure into the closure without causing damage to the multilayer structure. In some embodiments, the pressure can be from about 4 bar to about 10 bar to the multilayer structure.Atorney Docket No. 227254-747601

[0103] At step 520, the multilayer structure can be cured. In some embodiments, the curing can be performed at a temperature of from about 70°C to about 90°C. In some embodiments, the curing can be performed at a temperature of about 80°C. In some embodiments, the curing can be performed for a duration of from about 1 hour to about 3 hours. In some embodiments, the curing can be performed for a duration of about 2 hours.

[0104] At step 530, the multilayer structure can be thermoformed into a closure by placing the multilayer structure into or onto a mold. In some embodiments, the thermoforming can be performed using a thermoforming machine. In some embodiments, the multilayer structure may be heated to a temperature ranging from about 80 °C and about 120 °C prior to the thermoforming.

[0105] In some embodiments, cams may be formed on the closure prior to removing the closure from the mold in step 540. In some embodiments, the cams are formed using a cam-forming tool while the multilayer structure can be warm and pliable. In some embodiments, the cams are formed using the cam-forming tool after the closure has cooled to room temperature. In some embodiments, the cams are formed in steps at angles ranging from about -10 degrees to about 190 degrees. In some embodiments, the cams are formed by folding tabs in steps comprising about 30 degrees, about 60 degrees, about 90 degrees, or about 140 degrees, then inverting the tabs with a plunger, wherein the tabs are pre-trimmed at an edge of the closure. In some embodiments, the tabs are folded along a circumference of the closure using a ramp. In some embodiments, the tabs are folded by pushing the closure through a tube, thereby folding the tabs into a vertical position. In some embodiments, the closure may further be slit to form a tamper evidence band, either prior to or after removing from the mold.

[0106] In some embodiments, the closure may be cooled prior to removing from the mold at step 540. In some embodiments, the cooling comprises allowing the closure to cool to room temperature. In some embodiments, the cooling can be performed using water cooling channels in the mold to cool the closure. In some embodiments, the water cooling channels are arranged in a 3D network of cooling channels to reduce a pitch between individual forming portions of the mold.

[0107] At step 540, the closure can be removed from the mold. In some embodiments, the removing comprises rotating at least the threaded portion of the mold or lifting the closure at an axial rate timed with the rotating. In some embodiments, the axial rate comprises 1-2 mm / s. In some embodiments, wherein the rotating of at least the threaded portion of the mold can be performed manually by an operator. In some embodiments, the rotating of at least the threaded portion of the mold can be performed using an automated rotation system. In some embodiments, the automated rotation systemAtorney Docket No. 227254-747601 rotates the threaded portion of the mold at a speed ranging from about 10 RPM and about 20 RPM. In some embodiments, the removing of the closure from the mold further comprises applying clearance to ensure smooth removal of the closure. In some embodiments, the clearance can be applied using a clearance mechanism to ensure a thread path follows a contour of the rotating as the closure is removed from the mold. In some embodiments, the clearance mechanism allows for vents in the closure. In some embodiments, after being removed from the mold, a size and / or a shape of each of the plurality of knurls may be further adjusted.

[0108] The process 600 begins at step 610, which includes assembling a multilayer structure that comprises at least one paper layer, at least one thermoplastic layer and at least one foil layer. In some embodiments, the assembling includes applying an adhesive to the at least one thermoplastic layer and applying a sufficient pressure so as to bond the at least one paper layer to the at least one thermoplastic layer. In some embodiments, the assembling further includes an adhesive to the at least one paper layer and applying a sufficient pressure so as to bond the at least one seal layer to the at least one paper layer. In some embodiments, the pressure can be sufficient to shape the multilayer structure into the closure without causing damage to the multilayer structure. In some embodiments, the pressure can be from about 4 bar to about 10 bar to the multilayer structure.

[0109] In some embodiments, the at least one seal layer can be applied to a portion of the at least one paper layer. In some embodiments, a portion of the at least one paper layer comprises a portion to be designated as a cover wall of the closure, a side wall of the closure, portions thereof or a combination thereof

[0110] At step 620, the multilayer structure can be cured. In some embodiments, the curing can be performed at a temperature of from about 70°C to about 90°C. In some embodiments, the curing can be performed at a temperature of about 80°C. In some embodiments, the curing can be performed for a duration of from about 1 hour to about 3 hours. In some embodiments, the curing can be performed for a duration of about 2 hours.[OHl] At step 630, the multilayer structure can be thermoformed into a closure by placing the multilayer structure into or onto a mold. In some embodiments, the thermoforming can be performed using a thermoforming machine. In some embodiments, the multilayer structure may be heated to a temperature ranging from about 80 °C and about 120 °C prior to the thermoforming.

[0112] In some embodiments, cams may be formed on the closure prior to removing the closure from the mold in step 640. In some embodiments, the cams are formed using a cam-forming tool while the multilayer structure is warm and pliable. In some embodiments, the cams are formed using the cam-Atorney Docket No. 227254-747601 forming tool after the closure has cooled to room temperature. In some embodiments, the cams are formed in steps at angles ranging from about -10 degrees to about 190 degrees. In some embodiments, the cams are formed by folding tabs in steps comprising about 30 degrees, about 60 degrees, about 90 degrees, or about 140 degrees, then inverting the tabs with a plunger, wherein the tabs are pretrimmed at an edge of the closure. In some embodiments, the tabs are folded along a circumference of the closure using a ramp. In some embodiments, the tabs are folded by pushing the closure through a tube, thereby folding the tabs into a vertical position. In some embodiments, the closure may further be slit to form a tamper evidence band, either prior to or after removing from the mold.

[0113] In some embodiments, the closure may be cooled prior to removing from the mold at step 640. In some embodiments, the cooling comprises allowing the closure to cool to room temperature. In some embodiments, the cooling can be performed using water cooling channels in the mold to cool the closure. In some embodiments, the water cooling channels are arranged in a 3D network of cooling channels to reduce a pitch between individual forming portions of the mold.

[0114] At step 640, the closure can be removed from the mold. In some embodiments, the removing comprises rotating at least the threaded portion of the mold or lifting the closure at an axial rate timed with the rotating. In some embodiments, the axial rate comprises 1-2 mm / s. In some embodiments, wherein the rotating of at least the threaded portion of the mold can be performed manually by an operator. In some embodiments, the rotating of at least the threaded portion of the mold can be performed using an automated rotation system. In some embodiments, the automated rotation system rotates the threaded portion of the mold at a speed ranging from about 10 RPM and about 20 RPM. In some embodiments, the removing of the closure from the mold further comprises applying clearance to ensure smooth removal of the closure. In some embodiments, the clearance can be applied using a clearance mechanism to ensure a thread path follows a contour of the rotating as the closure is removed from the mold. In some embodiments, the clearance mechanism allows for vents in the closure. In some embodiments, after being removed from the mold, a size and / or a shape of each of the plurality of knurls may be further adjusted.

[0115] As another exemplary embodiment, a seal layer can be applied (e.g., coated, painted, or the like) to a sealing surface of the mold during an open cycle, and the sealing surface can be captured by the PET layer during the closing cycle. In some embodiments, a seal layer - made of, for example, an elastomer, an uncured elastomer, or other adhesive material - can be applied as a viscous fluid to a top surface of a mold, e.g., a lower portion of the mold. In some embodiments, a ring of material of the seal layer can be applied onto a core of a mold. In some embodiments, the seal layer is applied using a roller to transfer the seal layer material to the mold. In some embodiments, a heatedAtorney Docket No. 227254-747601 thermoplastic layer (e.g., PET layer) adheres to the sealing material when thermoforming in the initial forming process. As the closure cools and the core of the mold (e.g., a spin core) is removed from a sheet of closures, the seal layer is left behind on the thermoplastic layer. In some embodiments, for such a seal layer configuration, a paper layer is optional and can be applied after thermoforming forming at a later station or during thermoforming in the first mold.

[0116] As another exemplary embodiment, a thermoplastic layer can be selected that is compliant and acts as a seal itself or, upon heating, can bond to a container. Heating and bonding to the container can provide an anti-counterfeit feature. In some embodiments, heating of the thermoplastic layer, e.g., a PET layer, to bond with a thermoplastic container can be done through the paper layer. In some embodiments, this bonding can be performed using ultrasonic welding, targeted microwave heating, or the like. In some embodiments, if a foil layer is included in the multilayered closure, induction current can be used to generate the heat to bond the closure to the container.III. Systems for Forming Closures

[0117] Disclosed herein is a system for thermoforming a closure for a container. In some embodiments, the system includes a multilayer structure comprising at least one paper layer coupled to at least one thermoplastic layer. In some embodiments, the system includes a multilayer structure comprising at least one paper layer, at least one thermoplastic layer and at least one seal layer. In some embodiments, the system includes a thermoforming machine. In some embodiments, the system includes a mold. In some embodiments, the system includes an automated rotation system.

[0118] In some embodiments, the thermoforming machine comprises a rotary thermoforming machine. In some embodiments, the rotary thermoforming machine comprises a rotary mold system. In some embodiments, the rotary thermoforming machine rotates at a desired speed, such as, for example, a speed less than 1 RPM or greater than 80 RPM, or a speed ranging from about 1 to about 80 RPM, such as from about 1 to about 5 RPM, from about 5 to about 10 RPM, from about 10 to about 20 RPM, from about 20 to about 30 RPM, from about 30 to about 40 RPM, from about 40 to about 50 RPM, from about 50 to about 60 RPM, from about 60 to about 70 RPM, or from about 70 to about 80 RPM.

[0119] In some embodiments, the mold can be particularly well suited for including one or more threads formed by way of the thermoforming processes described herein. In general, 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. Upon thermoforming of the closure, the mold rotates to unthread from the molded part.Atorney Docket No. 227254-747601

[0120] In some embodiments, the mold can be a monolithic structures. In some embodiments, the mold comprises a stack of portions, including at least a primary portion and a secondary portion that does not rotate but rather demolds vertically. In some embodiments, the secondary portion can be removed from the primary portion by applying torque to the secondary portion. In some embodiments, the secondary portion can be slipped out from the primary portion. In some embodiments, the mold comprises one or more vents. The vents allow air that would otherwise be trapped to escape from underneath the sheet that is forming on the mold, thereby improving formation of the multilayer structure to the mold.

[0121] In some embodiments, the mold can be configured to operate at a pressure ranging between about 4 bar to about 10 bar and a temperature range between about 80°C and about 120°C. In some embodiments, the mold can be made of aluminum, steel, stainless steel, brass, copper, bronze, or various grades, alloys, a tool steel, or combinations thereof. In some embodiments, the aluminum comprises Aluminum T-300, Aluminum 6061-T6, Aluminum 2024-T4, Aluminum 7075-T6, or the like or a combination thereof. In some embodiments, the steel comprises P20 / 30 / 40, H-13, 4140 prehard steel, or the like. In some embodiments, the stainless steel comprises 420 Stainless Steel, Stainless Steel 400 series, HH Stainless Steel or the like. In some embodiments, the copper comprises C-18, high copper alloys 83, 940, 88, 972, 95 or the like. In some embodiments, the bronze comprises SAE660 or the like. In some embodiments, the mold can be made of Aluminum Bronze Alloys 18, 25, 21, 45 or the like. In some embodiments, the tool steel comprises O-l, A-2, A-6, A-8, D-2, D-3, S-7, W-l series, DC-53, Vanadis 4 / 6 / 10, Ml, M2, M3, T-3, T-16, or the like. In some embodiments, the mold comprises a coating for improving resistance to wear or corrosion. In some embodiments, the coating comprises anodized aluminum, PTFE-anodized aluminum, electroless nickel plating, ferrous metals (e.g., NiB, TiN, Ni-PTFE, diamond chrome plating), or the like.

[0122] In some embodiments, the mold comprises a threaded portion configured to form an outer cylindrical wall of the closure that comprises threads, wherein the outer cylindrical wall extends downward from the annular wall, and wherein the threads of the outer cylindrical wall engage with external threads of the container. In some embodiments, the threaded portion includes one or more external threads formed into the side wall for forming internal threads in the closure. In some embodiments, the external threads are confined to a primary portion. The resulting internal threads are configured to engage with external threads of the finish portion of the container to be closed with the closure. The threads may be continuous threads or may be interrupted threads. In some embodiments, the mold may include a plurality of threads, such as, for example, three threads distributed uniformly around the side wall of mold.Atorney Docket No. 227254-747601

[0123] In some embodiments, the threaded portion of the mold can be shaped to form undercuts in the threads. In some embodiments, the undercuts are formed with a depth ranging from 0.1 mm to 1 mm. In some embodiments, the undercuts are formed at an angle ranging from a slight draft of a few minutes to -30 degrees. With -10 degrees being relatively easy to release. Alternatively hinges can be molded with even a positive 190 degree angle, with respect to a base of the mold, which also requires an undercut that must be released.

[0124] In some embodiments, the mold further includes a knurled portion configured to form a plurality of knurls onto an exterior of the closure. In some embodiments, the knurled portion includes a plurality of knurls distributed around the circumference of the mold. In some embodiments, a size and / or a shape of each of the plurality of knurls may be adjusted as needed. In some embodiments, the mold may further include a tamper evidence feature distributed around the circumference of the mold.

[0125] In some embodiments, a plurality of external knurls are distributed around the circumference of the external threads. The external knurls may serve in particular to improve the grip of the external threads of the resulting closure.

[0126] In some embodiments, the external threads may form partial threads. In some embodiments, the partial threads can be removed if the thread is interrupted. A partial twist may be an option to slip the closure out through gaps (i.e., vents) between the threads.

[0127] In some embodiments, the mold comprises a female mold. Such a female mold would comprise inverting the mold such that the thermoforming material would be inserted into the female mold to impart features from the female mold, rather than the thermoforming material being placed onto the mold to impart features from the mold.

[0128] In some embodiments, the side wall extends along a vertical axis that is transverse and in particular perpendicular to the cover wall. In some embodiments, the vertical axis comprises an axis of rotational symmetry of the mold. In some embodiments, the closure may be removed from the mold via controlled rotation and lifting of the mold along the vertical axis. The controlled rotation allows for precise timing of lifting the thermoformed closure away from the mold when the thread forming component is rotating. In some embodiments, the controlled rotation can be performed by applying a torque to the mold. In some embodiments, torque on the closure may be distributed throughout the closure. In some embodiments, the closure may be held in place by a clamp on the sheet. In some embodiments, closure may be held in place by neighboring cavities.Atorney Docket No. 227254-747601

[0129] In some embodiments, the system includes an automated rotation system, also referred herein as a controlled rotation system. The controlled rotation system allows for removing the closure from the mold. In some embodiments, the controlled rotation system comprises a servo, a belt, or a chain drive system that can be configured to ensure consistent and accurate rotation of the threads. In some embodiments, the controlled rotation system operates at a speed ranging between about 10 RPM and about 20 RPM.

[0130] In some embodiments, the controlled rotation system comprises a clearance mechanism, which can be configured to ensure the thread path follows the contour of the rotation while the closure is being removed. In particular, along the threads, a clearance may be provided to allow for smooth removal of the closure from the mold. This clearance could allow for vents or other interruptions, which may be provided through a vertically moving part that slips from the closure after formation. This clearance allows for smooth removal of the closure from the mold and prevents damage to the threads.

[0131] In some embodiments, the controlled rotation system comprises a timing mechanism, which can be used to lift the closure at an axial rate that is correctly timed with the rotation of the thread component. Timing of lifting the closure when the thread forming component is moving can be critical to prevent deformation and unwanted height variation. In some embodiments, the closure can be removed at an axial rate of 1-2 mm / s.

[0132] In some embodiments, the cap or closure can be configured to fit in existing capper chucks. FIG. 4 illustrates a standard chuck 401 for fitting an exemplary closure 402. The standard chuck 401 shown may be used for applying the cap or closure on a commercial filling line.

[0133] Compared with existing technology, there are numerous beneficial effects of this technology. Regarding sustainability, by using a paper shell cap with a PET inner layer, the multilayered closure provides a more sustainable alternative to traditional caps and closures made from aluminum or plastic such as HDPE. The use of a recyclable polymer with a bonded paper layer or a pure paper layer further enhances the environmental friendliness of the product. Regarding durability, despite being made from paper, the sandwich structure of the paper shell cap with a PET inner layer ensures that the cap is durable and resistant to moisture and oxygen. This property allows for preserving the quality and integrity of the contents of the package. Regarding cost, the process of thermoforming a paper shell cap with a PET inner layer can be more cost-effective than the current methods of using a polymer sheet with a thin layer of PET or a recyclable polymer with a bonded paper layer. The use of a very thin layer of PET or a recyclable polymer reduces the amount ofAtorney Docket No. 227254-747601 material needed, which can lower the production cost. Regarding production, the use of a paper shell cap with a PET inner layer simplifies the process of creating a cap or closure as the knurls can be applied in the outer paper layer and the thickness of the closure can fit in existing capper chucks (such as the chuck 401 illustrated in FIG. 4). There is less need for a complex bonding process, which can save time and resources during the manufacturing process and the capping process does not need to change. Regarding greater recyclability, unlike traditional caps and closures made of HDPE or PP, which may not be easily recyclable or biodegradable, the paper shell cap with a PET inner layer can be recycled. This makes it a more environmentally friendly option for the disposal of caps and closures after use. This method could be expanded to thin PLA composite closures for enhanced biodegradability or even PEF or PHA for increased bio-content or biodegradability. Furthermore, if performance dictates the use of HDPE, this method can similarly use HDPE.

[0134] As an additional benefit, the added thickness and stiffness from a paper layer on top of a thermoplastic layer can add creep resistance to a closure for situations when the container or contents are heated. The seal layer can also add to the seal integrity for resisting seal failure in extreme situations, such as heating. As a result, less polymer can be necessary in a multi-layer closure to have the same performance or strength that would be present in a mono-layer thermoplastic closure. Such benefits include: fast production, secure seal, is controlled via torque, re-sealing capability, withstands the contents, leaves the contents unaffected (i.e., does not affect a taste profile of the contents), and / or extends a shelf life of the contents.

[0135] The paper surface can also be well suited for decoration including printing. It also provides light blocking which has an advantage that dried liquid found on the threads of the bottle are not visible when left on a table or shelf. In some embodiments, the paper surface enlarges the diameter of the closure vs a solely plastic version and can enhance the user interaction with lower torque requirements and higher friction for grip.

[0136] The application prospects of this invention are promising, particularly in the packaging industry, food and beverage sector, and pharmaceutical industry. In the packaging industry, this technology can revolutionize the way caps and closures are produced. It offers a more sustainable and eco-friendly alternative to traditional materials such as aluminum and polyolefin plastic, which are not as environmentally friendly. This could lead to a reduction in the carbon footprint of packaging, aligning with the growing emphasis on sustainability in the industry. In the food and beverage sector, this technology can be particularly beneficial. Paper caps and closures are often used in this sector due to their ability to preserve the freshness and quality of the contents. This invention, with its improved strength and flexibility, could enhance this preservation ability, leading to longerAtorney Docket No. 227254-747601 shelf lives for food and beverage products. In the pharmaceutical industry, this technology could also find extensive application. Paper caps and closures could be used in this sector due to their ability to protect sensitive medications from light and with a PET or PEF layer moisture and oxygen. This invention, with its enhanced barrier properties, could improve the effectiveness of these protective measures, ensuring the quality and efficacy of the medications. In terms of market demand, there is a growing trend towards more sustainable and eco-friendly packaging solutions. Consumers are increasingly seeking out products that are environmentally friendly, and companies are responding by adopting more sustainable practices. This invention, with its use of a recyclable polymer and paper layers, could meet this consumer demand, providing a more sustainable alternative to traditional packaging materials. Furthermore, the potential cost savings associated with the use of a thinner polymer layer and the potential for easier recycling could make this invention an attractive option for manufacturers, further driving market demand.

[0137] While the thermoforming process has been described in terms of particular variations and illustrative figures, those of ordinary skill in the art will recognize that the process is not limited to the variations or figures described. In addition, where methods and steps described above indicate certain events occurring in certain order, those of ordinary skill in the art will recognize that the ordering of certain steps may be modified. Additionally, certain of the steps may be performed concurrently in a parallel process, when possible, as well as performed sequentially as described above. To the extent there are variations of the thermoforming process, which are within the spirit of the disclosure or equivalent to the process found in the claims, it is the intent that this patent will cover those variations as well. Therefore, the present disclosure is to be understood as not limited by the specific embodiments described herein, but only by scope of the appended claims.

[0138] Illustrative Embodiments

[0139] Embodiment 1. A closure that comprises:

[0140] (a) a multilayered structure that comprises at least one paper layer coupled to at least one thermoplastic layer, and

[0141] (b) an interior surface configured to receive a finish portion of a container.

[0142] Embodiment 2. The closure of Embodiment 1, wherein the at least one thermoplastic layer comprises a thermoplastic coating.

[0143] Embodiment 3. The closure of Embodiment 1, wherein the at least one paper layer is positioned between at least two thermoplastic layers.Atorney Docket No. 227254-747601

[0144] Embodiment 4. The closure of 1, further comprising an adhesive between the at least one paper layer and the at least one thermoplastic layer.

[0145] Embodiment 5. The closure of Embodiment 4, wherein the adhesive comprises a foodgrade adhesive.

[0146] Embodiment 6. The closure of Embodiment 4, wherein the adhesive is applied evenly across the at least one thermoplastic layer.

[0147] Embodiment 7. The closure of Embodiment 1, wherein the at least one paper layer has a thickness up to about 1 mm.

[0148] Embodiment 8. The closure of Embodiment 1, wherein the at least one thermoplastic layer comprises a recyclable polymer.

[0149] Embodiment 9. The closure of Embodiment 1, wherein the at least one thermoplastic layer comprises a polystyrene, a polyolefin, a polycarbonate, a polyester, or a combination thereof.

[0150] Embodiment 10. The closure of Embodiment 1, wherein the at least one thermoplastic layer comprises HDPE, PET, PHA, PLA, or any combination thereof.

[0151] Embodiment 11. The closure of Embodiment 1, wherein the at least one thermoplastic layer has a thickness of less than about 0.5 mm.

[0152] Embodiment 12. The closure of Embodiment 1, wherein the closure comprises a cover wall and a side wall, wherein the side wall is integrally connected to the cover wall and oriented transversely to the cover wall.

[0153] Embodiment 13. The closure of Embodiment 12, wherein the side wall is circumferentially closed.

[0154] Embodiment 14. The closure of Embodiment 12, wherein the interior surface is partially bounded by the cover wall and the side wall.

[0155] Embodiment 15. The closure of Embodiment 12, further comprising an opening opposite to the cover wall.

[0156] Embodiment 16. The closure of Embodiment 12, further comprising a plurality of external knurls distributed around a circumference of the side wall.Atorney Docket No. 227254-747601

[0157] Embodiment 17. The closure of Embodiment 12, further comprising a plurality of slits along a circumference of the side wall, wherein the plurality of slits form a tamper evidence band.

[0158] Embodiment 18. The closure of Embodiment 17, further comprising a plurality of knurls distributed around a circumference of the tamper evidence band.

[0159] Embodiment 19. The closure of Embodiment 17, wherein each of the plurality of slits comprises a length of less than about 30 mm.

[0160] Embodiment 20. The closure of Embodiment 12, further comprising a plurality of threads along an internal surface of the side wall, wherein the plurality of threads are configured to engaging with the finish portion of the container.

[0161] Embodiment 21. The closure of Embodiment 1, further comprising at least one seal layer coupled to one or more of the at least one paper layer and the at least one thermoplastic layer, wherein the at least one seal layer is configured to receive the finish portion of the container.

[0162] Embodiment 22. A process for thermoforming a closure for a container, the process comprising:

[0163] (a) assembling a multilayer structure that comprises at least one paper layer coupled to at least one thermoplastic layer;

[0164] (b) curing the multilayer structure;

[0165] (c) thermoforming the multilayer structure into a closure by placing the multilayer structure into or onto a mold; and

[0166] (d) removing the closure from the mold.

[0167] Embodiment 23. The process of Embodiment 22, wherein the at least one thermoplastic layer comprises a thermoplastic coating.

[0168] Embodiment 24. The process of Embodiment 22, wherein the multilayer structure comprises the at least one paper layer positioned between at least two thermoplastic layers.

[0169] Embodiment 25. The process of Embodiment 22, wherein the assembling comprises applying an adhesive to the at least one thermoplastic layer and applying a sufficient pressure so as to bond the at least one paper layer to the at least one thermoplastic layer.Atorney Docket No. 227254-747601

[0170] Embodiment 26. The process of Embodiment 25, wherein the pressure is sufficient to shape the multilayer structure into the closure without causing damage to the multilayer structure.

[0171] Embodiment 27. The process of Embodiment 25, wherein the pressure is from about 4 bar to about 10 bar to the multilayer structure.

[0172] Embodiment 28. The process of Embodiment 22, wherein the curing is performed at a temperature of from about 70°C to about 90°C.

[0173] Embodiment 29. The process of Embodiment 22, wherein the curing is performed at a temperature of about 80°C.

[0174] Embodiment 30. The process of Embodiment 22, wherein the curing is performed for a duration of from about 1 hour to about 3 hours.

[0175] Embodiment 31. The process of Embodiment 22, wherein the curing is performed for a duration of about 2 hours.

[0176] Embodiment 32. The process of Embodiment 22, wherein the mold further comprises a knurled portion configured to form a plurality of knurls onto an exterior of the closure.

[0177] Embodiment 33. The process of Embodiment 32, further comprising adjusting a size and / or a shape of each of the plurality of knurls after the removing.

[0178] Embodiment 34. The process of Embodiment 22, further comprising forming cams on the closure prior to removing the closure from the mold.

[0179] Embodiment 35. The process of Embodiment 34, wherein the cams are formed using a cam-forming tool while the multilayer structure is warm and pliable.

[0180] Embodiment 36. The process of Embodiment 35, wherein the cams are formed using the cam-forming tool after the closure has cooled to room temperature.

[0181] Embodiment 37. The process of Embodiment 34, wherein the cams are formed in steps at angles ranging from about -10 degrees to about 190 degrees.

[0182] Embodiment 38. The process of Embodiment 34, wherein the cams are formed by folding tabs in steps comprising about 30 degrees, about 60 degrees, about 90 degrees, or about 140 degrees, then inverting the tabs with a plunger, wherein the tabs are pre-trimmed at an edge of the closure.Atorney Docket No. 227254-747601

[0183] Embodiment 39. The process of Embodiment 38, wherein the tabs are folded along a circumference of the closure using a ramp.

[0184] Embodiment 40. The process of Embodiment 38, wherein the tabs are folded by pushing the closure through a tube, thereby folding the tabs into a vertical position.

[0185] Embodiment 41. The process of Embodiment 40, wherein the tube is cylindrically or conically shaped.

[0186] Embodiment 42. The process of Embodiment 22, wherein the mold comprises a threaded portion configured to form a plurality of threads on the closure during the thermoforming.

[0187] Embodiment 43. The process of Embodiment 42, wherein the threaded portion of the mold is shaped to form undercuts in the plurality of threads.

[0188] Embodiment 44. The process of Embodiment 43, wherein the undercuts are formed with a depth ranging from 0.1 mm to 1 mm.

[0189] Embodiment 45. The process of Embodiment 43, wherein the undercuts are formed at an angle ranging from -10 degrees to 190 degrees, with respect to a base of the mold.

[0190] Embodiment 46. The process of Embodiment 42, wherein the removing comprises rotating at least the threaded portion of the mold or lifting the closure at an axial rate timed with the rotating.

[0191] Embodiment 47. The process of Embodiment 46, wherein the rotating of at least the threaded portion of the mold is performed manually by an operator.

[0192] Embodiment 48. The process of Embodiment 46, wherein the rotating of at least the threaded portion of the mold is performed using an automated rotation system.

[0193] Embodiment 49. The process of Embodiment 48, wherein the automated rotation system rotates the threaded portion of the mold at a speed ranging from about 10 RPM and about 20 RPM.

[0194] Embodiment 50. The process of Embodiment 46, wherein the removing of the closure from the mold further comprises applying clearance to ensure smooth removal of the closure.

[0195] Embodiment 51. The process of Embodiment 50, wherein the clearance is applied using a clearance mechanism to ensure a thread path follows a contour of the rotating as the closure is removed from the mold.Atorney Docket No. 227254-747601

[0196] Embodiment 52. The process of Embodiment 51, wherein the clearance mechanism allows for vents in the closure.

[0197] Embodiment 53. The process of Embodiment 46, wherein the axial rate comprises 1-2 mm / s.

[0198] Embodiment 54. The process of Embodiment 22, further comprising slitting the closure to form a tamper evidence band.

[0199] Embodiment 55. The process of Embodiment 22, wherein the thermoforming is performed using a thermoforming machine.

[0200] Embodiment 56. The process of Embodiment 22, further comprising heating the multilayer structure to a temperature ranging from about 80 °C and about 120 °C prior to the thermoforming.

[0201] Embodiment 57. The process of Embodiment 22, further comprising cooling the closure prior to removing from the mold.

[0202] Embodiment 58. The process of Embodiment 57, wherein the cooling comprises allowing the closure to cool to room temperature.

[0203] Embodiment 59. The process of Embodiment 57, wherein the cooling is performed using water cooling channels in the mold to cool the closure.

[0204] Embodiment 60. The process of Embodiment 59, wherein the water cooling channels are arranged in a 3D network of cooling channels to reduce a pitch between individual forming portions of the mold.

[0205] Embodiment 61. The process of Embodiment 22, wherein the at least one paper layer has a thickness of up to about 1 mm.

[0206] Embodiment 62. The process of Embodiment 22, wherein the at least one thermoplastic layer comprises a recyclable polymer.

[0207] Embodiment 63. The process of Embodiment 22, wherein the at least one thermoplastic layer comprises a polystyrene, a polyolefin, a polycarbonate, a polyester, or a combination thereof.

[0208] Embodiment 64. The process of Embodiment 22, wherein the at least one thermoplastic layer comprises HDPE, PET, PHA, PLA, or any combination thereof.Atorney Docket No. 227254-747601

[0209] Embodiment 65. The process of Embodiment 22, wherein the at least one thermoplastic layer has a thickness less than about 0.5 mm.

[0210] Embodiment 66. The process of Embodiment 22, wherein the multilayer structure comprises a cover wall and a side wall, wherein the side wall is integrally connected to the cover wall and oriented transversely to the cover wall.

[0211] Embodiment 67. The process of Embodiment 66, wherein the side wall is circumferentially closed.

[0212] Embodiment 68. The process of Embodiment 66, wherein an interior surface of the closure is partially bounded by the cover wall and the side wall.

[0213] Embodiment 69. The process of Embodiment 66, wherein the multilayer structure further comprises at least one seal layer coupled to one or more of the at least one paper layer and the at least one thermoplastic layer, wherein the at least one seal layer is configured to receive a finish portion of the container.

[0214] Embodiment 70. A system for thermoforming a closure for a container, the system comprising:

[0215] (a) a multilayer structure comprising at least one paper layer coupled to at least one thermoplastic layer;

[0216] (b) a thermoforming machine;

[0217] (c) a mold; and

[0218] (d) an automated rotation system.

[0219] Embodiment 71. The system of 70, wherein the thermoforming machine comprises a rotary thermoforming machine.

[0220] Embodiment 72. The system of Embodiment 71, wherein the rotary thermoforming machine rotates at a speed ranging from about 1 RPM to about 80 RPM.

Claims

Attorney Docket No. 227254-747601CLAIMSWhat is claimed is:

1. A closure that comprises:(a) a multilayered structure that comprises at least one paper layer coupled to at least one thermoplastic layer, and(b) an interior surface configured to receive a finish portion of a container.

2. The closure of claim 1 , wherein the at least one thermoplastic layer comprises a thermoplastic coating.

3. The closure of claim 1, wherein the at least one paper layer is positioned between at least two thermoplastic layers.

4. The closure of claim 1, further comprising an adhesive between the at least one paper layer and the at least one thermoplastic layer.

5. The closure of claim 4, wherein the adhesive comprises a food-grade adhesive.

6. The closure of claim 4, wherein the adhesive is applied evenly across the at least one thermoplastic layer.

7. The closure of claim 1, wherein the at least one paper layer has a thickness up to about 1 mm.

8. The closure of claim 1, wherein the at least one thermoplastic layer comprises a recyclable polymer.

9. The closure of claim 1, wherein the at least one thermoplastic layer comprises a polystyrene, a polyolefin, a polycarbonate, a polyester, or a combination thereof.

10. The closure of claim 1, wherein the at least one thermoplastic layer comprises HDPE, PET, PHA, PLA, PEF, or any combination thereof.

11. The closure of claim 1, wherein the at least one thermoplastic layer has a thickness of less than about 0.5 mm.

12. The closure of claim 1, wherein the closure comprises a cover wall and a side wall, wherein the side wall is integrally connected to the cover wall and oriented transversely to the cover wall.

13. The closure of claim 12, wherein the side wall is circumferentially closed.

14. The closure of claim 12, wherein the interior surface is partially bounded by the cover wall and the side wall.

15. The closure of claim 12, further comprising an opening opposite to the cover wall.

16. The closure of claim 12, further comprising a plurality of external knurls distributed around a circumference of the side wall.Atorney Docket No. 227254-74760117. The closure of claim 12, further comprising a plurality of slits along a circumference of the side wall, wherein the plurality of slits form a tamper evidence band.

18. The closure of claim 17, further comprising a plurality of knurls distributed around a circumference of the tamper evidence band.

19. The closure of claim 17, wherein each of the plurality of slits comprises a length of less than about 30 mm.

20. The closure of claim 12, further comprising a plurality of threads along an internal surface of the side wall, wherein the plurality of threads are configured to engaging with the finish portion of the container.

21. The closure of claim 1, further comprising at least one seal layer coupled to one or more of the at least one paper layer and the at least one thermoplastic layer, wherein the at least one seal layer is configured to receive the finish portion of the container.

22. A process for thermoforming a closure for a container, the process comprising:(a) assembling a multilayer structure that comprises at least one paper layer coupled to at least one thermoplastic layer;(b) curing the multilayer structure;(c) thermoforming the multilayer structure into a closure by placing the multilayer structure into or onto a mold; and(d) removing the closure from the mold.

23. The process of claim 22, wherein the at least one thermoplastic layer comprises a thermoplastic coating.

24. The process of claim 22, wherein the multilayer structure comprises the at least one paper layer positioned between at least two thermoplastic layers.

25. The process of claim 22, wherein the assembling comprises applying an adhesive to the at least one thermoplastic layer and applying a sufficient pressure so as to bond the at least one paper layer to the at least one thermoplastic layer.

26. The process of claim 25, wherein the pressure is sufficient to shape the multilayer structure into the closure without causing damage to the multilayer structure.

27. The process of claim 25, wherein the pressure is from about 4 bar to about 10 bar to the multilayer structure.

28. The process of claim 22, wherein the curing is performed at a temperature of from about 70°C to about 90°C.Atorney Docket No. 227254-74760129. The process of claim 22, wherein the curing is performed at a temperature of about 80°C.

30. The process of claim 22, wherein the curing is performed for a duration of from about 1 hour to about 3 hours.

31. The process of claim 22, wherein the curing is performed for a duration of about 2 hours.

32. The process of claim 22, wherein the mold further comprises a knurled portion configured to form a plurality of knurls onto an exterior of the closure.

33. The process of claim 32, further comprising adjusting a size and / or a shape of each of the plurality of knurls after the removing.

34. The process of claim 22, further comprising forming cams on the closure prior to removing the closure from the mold.

35. The process of claim 34, wherein the cams are formed using a cam-forming tool while the multilayer structure is warm and pliable.

36. The process of claim 35, wherein the cams are formed using the cam-forming tool after the closure has cooled to room temperature.

37. The process of claim 34, wherein the cams are formed in steps at angles ranging from about - 10 degrees to about 190 degrees.

38. The process of claim 34, wherein the cams are formed by folding tabs in steps comprising about 30 degrees, about 60 degrees, about 90 degrees, or about 140 degrees, then inverting the tabs with a plunger, wherein the tabs are pre-trimmed at an edge of the closure.

39. The process of claim 38, wherein the tabs are folded along a circumference of the closure using a ramp.

40. The process of claim 38, wherein the tabs are folded by pushing the closure through a tube, thereby folding the tabs into a vertical position.

41. The process of claim 40, wherein the tube is cylindrically or conically shaped.

42. The process of claim 22, wherein the mold comprises a threaded portion configured to form a plurality of threads on the closure during the thermoforming.Atorney Docket No. 227254-74760143. The process of claim 42, wherein the threaded portion of the mold is shaped to form undercuts in the plurality of threads.

44. The process of claim 43, wherein the undercuts are formed with a depth ranging from 0.1 mm to 1 mm.

45. The process of claim 43, wherein the undercuts are formed at an angle ranging from -10 degrees to 190 degrees, with respect to a base of the mold.

46. The process of claim 42, wherein the removing comprises rotating at least the threaded portion of the mold or lifting the closure at an axial rate timed with the rotating.

47. The process of claim 46, wherein the rotating of at least the threaded portion of the mold is performed manually by an operator.

48. The process of claim 46, wherein the rotating of at least the threaded portion of the mold is performed using an automated rotation system.

49. The process of claim 48, wherein the automated rotation system rotates the threaded portion of the mold at a speed ranging from about 10 RPM and about 20 RPM.

50. The process of claim 46, wherein the removing of the closure from the mold further comprises applying clearance to ensure smooth removal of the closure.

51. The process of claim 50, wherein the clearance is applied using a clearance mechanism to ensure a thread path follows a contour of the rotating as the closure is removed from the mold.

52. The process of claim 51, wherein the clearance mechanism allows for vents in the closure.

53. The process of claim 46, wherein the axial rate comprises 1-2 mm / s.

54. The process of claim 22, further comprising slitting the closure to form a tamper evidence band.

55. The process of claim 22, wherein the thermoforming is performed using a thermoforming machine.

56. The process of claim 22, further comprising heating the multilayer structure to a temperature ranging from about 80 °C and about 120 °C prior to the thermoforming.Atorney Docket No. 227254-74760157. The process of claim 22, further comprising cooling the closure prior to removing from the mold.

58. The process of claim 57, wherein the cooling comprises allowing the closure to cool to room temperature.

59. The process of claim 57, wherein the cooling is performed using water cooling channels in the mold to cool the closure.

60. The process of claim 59, wherein the water cooling channels are arranged in a 3D network of cooling channels to reduce a pitch between individual forming portions of the mold.

61. The process of claim 22, wherein the at least one paper layer has a thickness of up to about 1 mm.

62. The process of claim 22, wherein the at least one thermoplastic layer comprises a recyclable polymer.

63. The process of claim 22, wherein the at least one thermoplastic layer comprises a polystyrene, a polyolefin, a polycarbonate, a polyester, or a combination thereof.

64. The process of claim 22, wherein the at least one thermoplastic layer comprises HDPE, PET, PHA, PLA, PEF, or any combination thereof.

65. The process of claim 22, wherein the at least one thermoplastic layer has a thickness less than about 0.5 mm.

66. The process of claim 22, wherein the multilayer structure comprises a cover wall and a side wall, wherein the side wall is integrally connected to the cover wall and oriented transversely to the cover wall.

67. The process of claim 66, wherein the side wall is circumferentially closed.

68. The process of claim 66, wherein an interior surface of the closure is partially bounded by the cover wall and the side wall.

69. The process of claim 66, wherein the multilayer structure further comprises at least one seal layer coupled to one or more of the at least one paper layer and the at least one thermoplastic layer, wherein the at least one seal layer is configured to receive a finish portion of the container.Atorney Docket No. 227254-74760170. A system for thermoforming a closure for a container, the system comprising:(a) a multilayer structure comprising at least one paper layer coupled to at least one thermoplastic layer;(b) a thermoforming machine;(c) a mold; and(d) an automated rotation system.

71. The system of claim 70, wherein the thermoforming machine comprises a rotary thermoforming machine.

72. The system of claim 71, wherein the rotary thermoforming machine rotates at a speed ranging from about 1 RPM to about 80 RPM.

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