Collapsible mold for thermoforming pet container closures

Abstract

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

Description

Docket No. 227254-754601 / PCTCOLLAPSIBLE MOLD FOR THERMOFORMING PET CONTAINER CLOSURESCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 742,172, filed January 6, 2025, 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 processes for forming features on thermoformed container closures using collapsible molds.BACKGROUND

[0003] The field of Plastics Forming, specifically Thermoforming, has seen significant advancements in recent years. Thermoforming involves heating a plastic sheet to a pliable forming temperature, stretching it over a mold, and then cooling it to a rigid state. The resulting product is a hollow shape that matches the contour of the mold. In the context of High-Density Polyethylene (HDPE) caps, this process is used to create consistent closures for applications. However, when it comes to Polyethylene Terephthalate (PET), the same process often results in damaged, inconsistent parts due to the material’s tendency to be brittle and crack or remain deformed under heat and pressure. Therefore, a need exists for methods or processes to effectively form consistent features on thermoformed PET caps without damaging the cap during removal from the mold, in particular for features that cannot be formed using rotating molds.SUMMARY

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

[0005] In some aspects, the techniques described herein relate to a process for thermoforming a closure for a container, including: (a) providing a heated thermoplastic material and a collapsible mold, wherein the collapsible mold includes: one or more movable portions configured to axially translate from a first position to a second position, the first position being in contact with the heated thermoplastic material and the second position being spatially retractable from the heated thermoplastic material, and wherein, when each of the one or more movable portions is in the first position, the collapsible mold is configured to form: (i) a plug seal of the closure, wherein the plugDocket No. 227254-754601 / PCTseal seats against an inner surface of the container; (ii) an annular wall of the closure, wherein the annular wall seats against a top surface of a rim of the container; and (iii) a threaded portion configured to form an outer cylindrical wall of the closure that includes 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; (b) thermoforming the heated thermoplastic material into a closure by placing the heated thermoplastic material into or onto the collapsible mold, wherein each of the one or more movable portions of the collapsible mold are in the first position; and (c) removing the closure from the collapsible mold by: (i) axially translating the one or more movable portions of the collapsible mold to the second position, and (ii) lifting the closure at an axial rate timed with the translating.

[0006] In some aspects, each of the one or more movable portions is axially translated at a different time than others of the one or more movable portions.

[0007] In some aspects, each of the one or more movable portions is axially translated simultaneously to others of the one or more movable portions.

[0008] In some aspects, the one or more movable portions include a projection configured to form one or more vents in the thermoplastic material.

[0009] In some aspects, the collapsible mold further includes a knurled portion configured to form a plurality of knurls onto an exterior of the closure.

[0010] In some aspects, the process further includes adjusting a size and / or a shape of each of the plurality of knurls.

[0011] In some aspects, the process further includes forming cams on the closure prior to removing the closure from the collapsible mold.

[0012] In some aspects, the cams are formed using a cam-forming tool.

[0013] In some aspects, the cams are formed using the cam-forming tool after the thermoplastic material has cooled to room temperature.

[0014] In some aspects, the cams are formed in steps at angles ranging between about -10 degrees and about 190 degrees.Docket No. 227254-754601 / PCT

[0015] In some aspects, 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.

[0016] In some aspects, the tabs are folded along a circumference of the closure using a ramp.

[0017] In some aspects, the tabs are folded by pushing the closure through a tube, thereby folding the tabs into a vertical position.

[0018] In some aspects, the tube is cylindrically or conically shaped.

[0019] In some aspects, the threaded portion of the collapsible mold is shaped to form undercuts in the threads.

[0020] In some aspects, the undercuts are formed with a depth ranging from 0.1 mm to 1 mm.

[0021] In some aspects, the undercuts are formed at an angle ranging from -10 degrees to 190 degrees, with respect to a base of the collapsible mold.

[0022] In some aspects, the process further includes slitting the closure to form a tamper evidence band.

[0023] In some aspects, the thermoplastic material is selected from the group consisting of: HDPE, PET, PHA, PLA, PETF, or any combination thereof.

[0024] In some aspects, the thermoforming of the thermoplastic material includes applying pressure to the thermoplastic material using a thermoforming machine.

[0025] In some aspects, the pressure is sufficient to shape the thermoplastic material into the closure without causing damage to the thermoplastic material.

[0026] In some aspects, the pressure is from about 4 bar to about 10 bar to the thermoplastic material.

[0027] In some aspects, the heated thermoplastic material is heated to a temperature ranging from about 80 °C and about 120 °C prior to the thermoforming.

[0028] In some aspects, the process further includes cooling the closure prior to removing from the collapsible mold.Docket No. 227254-754601 / PCT

[0029] In some aspects, the cooling includes allowing the closure to cool to room temperature.

[0030] In some aspects, the cooling is performed using water cooling channels in the collapsible mold to cool the closure.

[0031] In some aspects, the water cooling channels are arranged in a 3D network of cooling channels to reduce a pitch between individual forming portions of the collapsible mold.

[0032] In some aspects, the axially translating of the one or more movable portions of the collapsible mold is performed using a controlled removal system that is one or more of spring-loaded, pneumatic, or hydraulic.

[0033] In some aspects, the axially translating of the one or more movable portions further includes rotating of the one or more movable portions, the rotating being performed using a controlled rotation system.

[0034] In some aspects, the controlled rotation system includes a servo, a belt, a chain drive system, or a combination thereof.

[0035] In some aspects, the controlled rotation system rotates the threaded portion of the collapsible mold at a speed ranging from about 10 RPM and about 20 RPM.

[0036] In some aspects, the removing of the closure from the collapsible mold further includes applying clearance to ensure smooth removal of the closure.

[0037] In some aspects, the clearance is applied using a clearance mechanism to ensure a thread path follows a contour of rotating of the one or more movable portions as the closure is removed from the collapsible mold.

[0038] In some aspects, the clearance mechanism allows for vents in the closure.

[0039] In some aspects, the axial rate includes 1-2 mm / s.

[0040] In some aspects, the techniques described herein relate to a collapsible mold for thermoforming a closure for a container, including: one or more movable portions configured to axially translate from a first position to a second position, the first position being in contact with a heated thermoplastic material and the second position being spatially retractable from the heated thermoplastic material.Docket No. 227254-754601 / PCT

[0041] In some aspects, when each of the one or more movable portions is in the first position, the collapsible mold is configured to form: (a) a first portion configured to form a plug seal of the closure, wherein the plug seal seats against an inner surface of the container; (b) a second portion configured to form an annular wall of the closure, wherein the annular wall seats against a top surface of a rim of the container; and (c) a threaded portion configured to form an outer cylindrical wall of the closure that includes 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

[0042] In some aspects, the threaded portion of the collapsible mold is shaped to form undercuts in the threads.

[0043] In some aspects, the collapsible mold further includes a knurled portion configured to form a plurality of knurls onto an exterior of the closure.

[0044] In some aspects, the one or more movable portions include one or more projections configured to form one or more vents in the thermoplastic material.

[0045] In some aspects, the one or more projections are retractable.

[0046] In some aspects, the one or more projections are configured to form one or more hinges.

[0047] In some aspects, each of the one or more movable portions is configured to axially translate at a different time than others of the one or more movable portions.

[0048] In some aspects, each of the one or more movable portions is configured to axially translate simultaneously to others of the one or more movable portions.

[0049] In some aspects, a collapsible mold further includes a static portion from which the one or more movable portions are configured to axially translate.

[0050] In some aspects, the static portion includes one or more projections connected to a base of the static portion.

[0051] In some aspects, the one or more projections are configured to form one or more vents in the thermoplastic material.

[0052] In some aspects, the one or more projections are retractable.Docket No. 227254-754601 / PCT

[0053] In some aspects, at least one of the one or more movable portions is flexible.

[0054] In some aspects, at least one of the one or more movable portions is rigid.

[0055] In some aspects, the techniques described herein relate to a system for thermoforming a closure for a container, the system including: (a) a collapsible mold including one or more movable portions configured to axially translate from a first position to a second position, the first position being in contact with a heated thermoplastic material and the second position being spatially retractable from the heated thermoplastic material; and (b) a controlled removal system configured to axially translate the one or more movable portions of the collapsible mold.

[0056] In some aspects, when each of the one or more movable portions is in the first position, the collapsible mold is configured to form: (a) a first portion configured to form a plug seal of the closure, wherein the plug seal seats against an inner surface of the container; (b) a second portion configured to form an annular wall of the closure, wherein the annular wall seats against a top surface of a rim of the container; and (c) a threaded portion configured to form an outer cylindrical wall of the closure that includes 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.

[0057] In some aspects, the threaded portion of the collapsible mold is shaped to form undercuts in the threads.

[0058] In some aspects, the collapsible mold further includes a knurled portion configured to form a plurality of knurls onto an exterior of the closure.

[0059] In some aspects, the one or more movable portions include one or more projections configured to form one or more vents in the thermoplastic material.

[0060] In some aspects, the one or more projections are retractable.

[0061] In some aspects, the one or more projections are configured to form one or more hinges.

[0062] In some aspects, each of the one or more movable portions is configured to axially translate at a different time than others of the one or more movable portions.

[0063] In some aspects, each of the one or more movable portions is configured to axially translate simultaneously to others of the one or more movable portions.Docket No. 227254-754601 / PCT

[0064] In some aspects, a system further includes a static portion from which the one or more movable portions are configured to axially translate.

[0065] In some aspects, the static portion includes one or more projections connected to a base of the static portion.

[0066] In some aspects, the one or more projections are configured to form one or more vents in the thermoplastic material.

[0067] In some aspects, the one or more projections are retractable.

[0068] In some aspects, at least one of the one or more movable portions is flexible.

[0069] In some aspects, at least one of the one or more movable portions is rigid.

[0070] In some aspects, the heated thermoplastic material is selected from the group consisting of: HDPE, PET, PHA, PLA, PETF, or any combination thereof.

[0071] In some aspects, the controlled removal system is spring-loaded, pneumatic, hydraulic, or a combination thereof.

[0072] In some aspects, the controlled removal system includes a spreader tool configured to be pushed into the collapsible mold to expand at least one of the one or more movable portions during forming of a closure, and then lowered from the collapsible mold to release the closure.

[0073] In some aspects, the controlled removal system is configured to key or hook the one or more movable portions onto a lever connected to a rail that determines a position of a respective movable portion.

[0074] In some aspects, the controlled removal system includes at least one drive wheel configured to rotate to be positioned with an opening and closing of the collapsible mold, wherein an outward position of the at least one drive wheel is configured force one or more projections out of one of the one or more movable portions to form a closure.

[0075] In some aspects, the controlled removal system operates at a speed ranging between about 1-2 mm / s.

[0076] In some aspects, the controlled removal system is configured to lift the closure at an axial rate timed with the translating of the one or more movable portions of the collapsible mold.Docket No. 227254-754601 / PCT

[0077] 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

[0078] The drawings refer to embodiments of the present disclosure in which:

[0079] Figures 1A-1B illustrate perspective and cross-sectional views, respectively, of an exemplary embodiment of a thermoformed PET container closure thermoformed by a collapsible mold, including folding tabs arranged around a circumference of a tamper evidence feature, according to the present disclosure; and

[0080] Figure 2 illustrates a perspective view of an exemplary embodiment of a thermoformed PET container closure including a thread about a circumference of the closure, according to the present disclosure;

[0081] Figure 3 illustrates a side view of an exemplary embodiment of a thermoformed PET container closure including a thread about a circumference of the closure in accordance with the present disclosure;

[0082] Figure 4 illustrates a top view of an exemplary embodiment of a thermoformed PET container closure including a thread about a circumference of the closure, according to the present disclosure;

[0083] Figures 5A-5B illustrate an exemplary embodiment of a collapsible mold in both assembled and separated configurations, respectively;

[0084] Figures 6A-6B illustrate another exemplary embodiment of a collapsible mold in both assembled and separated configurations, respectively;

[0085] Figure 7 illustrates a side view of an exemplary embodiment of a thermoformed PET container closure formed by way of a retraction functionality of a collapsible mold described herein; and

[0086] Figure 8 illustrates an exemplary embodiment of a thermoforming process whereby consistent threads can be formed on a thermoformed PET container closure by a thermoforming mold, in accordance with the present disclosure.Docket No. 227254-754601 / PCT

[0087] 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

[0088] 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.

[0089] In general, there is a need for processes for effectively forming consistent threads on thermoformed PET caps without damaging the caps during removal from the mold. Embodiments provided in the present disclosure provide processes for forming features (e.g., threads, vents, or the like) on thermoformed PET container closures. The processes disclosed herein solve technical problems encountered with conventional methods, such as 1) the inability to effectively remove PET caps from the mold without causing damage, 2) the inconsistency of features when formed from the outside of the mold, and 3) the difficulty in timing the lifting of the closure when the feature forming component is moving to prevent deformation and unwanted height variation.

[0090] The present disclosure provides a collapsible mold for thermoforming a closure for a container. The collapsible mold includes one or more movable portions configured to translate from a first position to a second position, the first position being in contact with the heated thermoplastic material and the second position being spatially retracted from the heated thermoplastic material. In some embodiments, the translating comprises axial movement, lateral movement, rotational movement, or a combination thereof. When each of the one or more movableDocket No. 227254-754601 / PCTportions is in the first position, the collapsible mold is configured to form at least a plug seal of the closure, wherein the plug seal seats against an inner surface of the container; an annular wall of the closure, wherein the annular wall seats against a top surface of a rim of the container; and 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.

[0091] Collapsible molds provided herein may include movable components, where the movable components are movable from a core of a mold to form threads, vents, or other features of the closure that would otherwise cause negative draft angles or otherwise locked in components. Such components may include downward facing features on a positive (male) mold and can be obtained with downward motion rather than rotation that pulls back a portion of the mold that would otherwise lock a part on an undercut. As an example, once the threads are formed this way, the retraction can be done while the rest of the closure or feature is still cooling. Collapsing can be spring loaded, pneumatic, or hydraulic, depending on the size of the part and what room is available in the core of the mold stack. This also allows for keeping an orientation of the mold and / or closure to be consistent between cycles of thermoforming with the mold.

[0092] In some embodiments, a collapsible mold includes one or more segment cores. In some embodiments, a collapsible mold includes a dual-segment core. In some embodiments, a collapsible mold includes one or more thread segments (i.e., thread portions) separated by each of the one or more segment cores. In some embodiments, each of the one or more segment cores are interconnected. In some embodiments, each of the one or more thread segments are configured to retract inwardly, thereby allowing to release a formed closure for ejection. In some embodiments, such retraction may be performed using a cam on a retractable rod, such that the rod can be pulled down to let the threads on the thread segments to retract, such as, for example by spring action, on a rail guide, or through some other drive mechanism.

[0093] Collapsible molds allow for more complex features that otherwise would not be achievable using rotation to be formed. In closures, thread vents (i.e., segments) may be formed from stripped components in injection mold tools on HDPE, but cannot be easily formed this way in PET or other materials that are stiffer or have a higher glass transition temperature (Tg). Further, less space is needed for rotating or driving components of the closure that allows for less skeleton waste for smaller closures.Docket No. 227254-754601 / PCT

[0094] In some embodiments, the one or more segment cores are interconnected via a dovetail connect, mortise and tenon, a bridle joint, a knapp joint, a box joint, a half-lap joint, or the like. Such connections can allow for undercut formation in the molded part while minimizing the need for screwing and sliding mechanisms.

[0095] In some embodiments, each of the one or more segment cores is rigid. In some embodiments, any number of the one or more segment cores is made of a metal, e.g., steel, aluminum, copper, nickel, or alloys or combinations thereof. In some embodiments, a metal comprises a hardened steel or a pre-hardened steel. In some embodiments, a metal comprises stainless steel, tool steel, or the like. In some embodiments, any number of the one or more segment cores is made of a casting material, e.g., sand, ceramic, plaster, or the like. In some embodiments, any number of the one or more segment cores is made of an inorganic material or an organic material.

[0096] In some embodiments, at least one of the one or more segment cores is flexible. A flexible segment core allows for release of a molded part through deformation of the flexible segment, rather than a sole-reliance on mechanical movement or collapsing of the cores to allow for the molded part to be removed. In some embodiments, a flexible segment core comprises a flexing or springing steel material or the like. In some embodiments, a flexible segment core comprises silicone, epoxy, rubber, polyurethane, latex, plaster, or the like.

[0097] In some embodiments, at least one of the one or more segment cores comprises both a rigid material and a flexible material. Such a situation can arise when a segment core comprises multiple components that are pre-coupled or connected, such as, for example, by coating, layering, covering, bonding, cooling, or the like. Such components, for example, can include a rigid core with flexible outer layer, a flexible core with a rigid outer layer, or a rigid portion with a flexible portion adjacent to the rigid portion. Such combinations may vary based on the part to be molded, or for varying combinations of removal of each of the one or more segment cores from the resulting closure.

[0098] In some embodiments, any number of materials for the one or more segment cores can be chosen to satisfy various design requirements such that those related to, for example, cost-efficiency, durability, temperature corrosion, low-volume or prototyping runs, fast production runs, durability of fine details (e.g., features or projections) in the one or more segment cores, biodegradability, etc.Docket No. 227254-754601 / PCT

[0099] The present disclosure further provides a process for thermoforming a closure for a container. In some embodiments, the process includes providing a heated thermoplastic material and a collapsible mold provided herein. In some embodiments, the process further includes thermoforming the heated thermoplastic material into a closure by placing the heated thermoplastic material into or onto the collapsible mold when each of the one or more movable portions of the collapsible mold are in the first position. In some embodiments, the process further includes removing the closure from the collapsible mold by axially translating the one or more movable portions of the collapsible mold to the second position, and lifting the closure at an axial rate timed with the translating.

[0100] In some embodiments, each of the one or more movable portions is axially translated at a different time than others of the one or more movable portions. In some embodiments, each of the one or more movable portions is axially translated simultaneously to others of the one or more movable portions.

[0101] In some embodiments, the one or more movable portions include one or more projections configured to form one or more vents in the thermoplastic material. In some embodiments, each of the one or more projections is connected to a base of a portion of a collapsible mold, whereby the base and the one or more projections (i.e., cores) are part of a static component of a collapsible mold. In some embodiments, a base of the collapsible mold can translate downward (i.e., axially or vertically) or, optionally, the projections can translate down immediately after threaded portions or other interlocked features are released to let a sheet of the closures release from the rest of the collapsible mold. In some embodiments, a base of the collapsible mold can translate laterally (i.e., horizontally) from a different portion of the one or more movable portions.

[0102] In some embodiments, the one or more projections are configured to form one or more hinges for tethers or flip tops. Such features can be formed using a retraction functionality of the collapsible mold. Lips or pull taps for flip top like closures may also be formed this way. In some embodiments, the one or more projections are configured to form one or more grip sections or a bulb on the top of the closure. In some embodiments, the one or more projections are configured to form aesthetic features or patterns, e.g., a trade-marked design or other artistic feature formed with some otherwise mold-locking features. In some embodiments, an aesthetic feature or pattern can also embed additional functional features into the thermoplastic material.Docket No. 227254-754601 / PCT

[0103] In some embodiments a collapsible mold is broadened at a crown portion of the mold relative to other portions of the mold at different heights. Such a design allows for a broadened crown to form on the closure. Such a broadened crown may also be formed using a retraction functionality of the collapsible mold. In some embodiments, a crown portion of the closure can have a uniform height throughout the closure. In some embodiments, a crown portion of the closure can have a varying height throughout the closure.

[0104] In some embodiments, the collapsible mold further includes a knurled portion configured to form a plurality of knurls onto an exterior of the closure. In some embodiments, a size and / or a shape of each of the plurality of knurls may be adjusted. In some embodiments, the knurled portion may be configured to expand past a lower diameter of the collapsible mold. Such a knurled portion may be performed using a retraction functionality of the collapsible mold, allowing for knurls to form in the closures such as at a crown portion of the closures. In some embodiments, a knurled portion of the closure can have a uniform height throughout the closure. In some embodiments, a knurled portion of the closure can have a varying height throughout the closure.

[0105] In some embodiments, the process further includes forming cams on the closure prior to removing the closure from the collapsible mold, described in more detail below.

[0106] In some embodiments, the threaded portion of the collapsible mold is 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 -10 degrees to 190 degrees, with respect to a base of the collapsible mold.

[0107] In some embodiments, the translating of the one or more movable portions of the collapsible mold is performed using a controlled removal system described herein.

[0108] In some embodiments, translating (i.e., axially or laterally) of the one or more movable portions further includes rotating of the one or more movable portions, the rotating being performed using a controlled rotation system, found in US Provisional Application, entitled “Device and Method for Thermoforming PET Container Closures,” filed on August 26, 2024, and having application serial number 63 / 687,094, the entirety of said application being incorporated herein by reference. In some embodiments, an axial rate for lifting the closure from the collapsible mold ranges from 0.1 to 0.2, 0.1 to 0.5, 0.2 to 08, 0.3 to 0.9, 0.5 to 1, 0.5 to 1.5, 0.8 to 1.5, 1 to 2,Docket No. 227254-754601 / PCT0.5 to 2, 1.5 to 2, 1 to 3, 2 to 3, 2 to 4, 1.2 to 1.5, 1.5 to 2.5, 2.5 to 3.5, 3.5 to 4, 4 to 5, 4.5 to 5, or greater than 5 mm / s.

[0109] The present disclosure further provides a system for thermoforming a closure for a container, the system including a collapsible mold provided herein, a thermoplastic material, and a controlled removal system configured to axially translate the one or more movable portions of the collapsible mold.

[0110] In some embodiments, a controlled removal system may be one or more of spring-loaded, pneumatic, or hydraulic. For example, if the retracting parts (i.e., the one or more movable portions) are spring loaded or under tension to move inward, then a spreader tool can be configured to push up into the collapsible mold to expand the retracting parts during forming of the closure. The spreader tool may then be lowered to release the closure from the collapsible mold. This vertical motion is simple to drive the collapsible mold up and down and can be controlled from a master plate so that only one drive (e.g., motor, pneumatic, or hydraulic) is needed. Therefore, a pitch of the collapsible mold is not limited by individual drives at each core. Even though this vertical or axial motion is simple, complex shapes can still be formed on the closure. The motion could be along any axis such that retraction does not need to be at a right angle to the axis of the mold. In some embodiments, motion of each core is kept at a right angle for closures that would screw around a central axis. In some embodiments, a second motion would be possible to form other features. In some embodiments, such features may be used for aesthetic, e.g., brand logos, or functional purposes.[oni] In some embodiments, besides a spring-loaded removal system, the retracting parts can be keyed or hooked onto a lever connected to a rail that determines the position of the respective retracting part. In some embodiments, a drive wheel or a set of drive wheels could be used and rotated to be positioned with an opening and closing of the collapsible mold. In some embodiments, an outward position of each of the drive wheel(s) is configured force the retractable parts out of a core to form the closure.

[0112] FIGS. 1 A-1B illustrate an exemplary embodiment of a closure 200 thermoformed by a collapsible mold 100. Features of the mold 100 are imparted to the closure 200, discussed in more detail below with respect to FIGS. 2-4. In general, the closure 200 may be a monolithic portion of thermoplastic material and produced by thermoforming with the mold 100. The thermoplastic material may include a polystyrene such as SAN or ABS, or a polyolefin such as PP or PE, or a polycarbonate or, in particular, a polyester such as PET, PBT or PEF. Further, in someDocket No. 227254-754601 / PCTembodiments, the closure 200 can be made from a single thermoplastic material or can be made from a plurality of thermoplastic materials. In one embodiment, the material of the closure 200 includes PET, and the container, which is to be closed with the closure 200, is also made of PET. The thermoformed closure 200 further has an interior (not illustrated) configured to receive a finish portion of the container to be closed with the closure 200. Further details regarding techniques for forming the closure 200 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.

[0113] In some embodiments, as shown in FIGS. 1A-1B, folding tabs 300 (i.e., “flaps”) are arranged around the circumference of the tamper evidence feature 240. The folding tabs 300 form a tamper-evident device on the closure 200; when a corresponding closure 200 closes a container, increased effort and in particular increased force must be exerted at least when the container is first opened due to the presence of the folding tabs 300. The folding tabs 300 are integrally connected to a tamper evidence feature 240, which has been imparted to the closure 200 by the tamper evidence feature 140 of the mold 100. The folding tabs 300 may be manufactured as “prefold tabs” integrally with the closure 200. In a pre-fold state, the folding tabs 300 are arranged in an outward ring that surrounds the tamper evidence feature 240 and an opening of the closure 200. The folding tabs 300 are arranged and formed in such a way that they can be folded into the opening and positioned in the interior of the closure 200.

[0114] In some embodiments, each of the folding tabs 300 are shaped to include a two-dimensional (2D) geometry, three-dimensional (3D) geometry, or a combination thereof. In some embodiments, the geometry may include an associated height increment along any number of portions of the geometry. In some embodiments, not all of the folding tabs 300 have the same geometry. In some embodiments, each of the folding tabs 300 are of a different geometry or shape from others of the folding tabs 300.

[0115] FIGS. 2-4 illustrate perspective, side, and top views, respectively, of an exemplary embodiment of a thermoformed PET container closure 200 that is particularly well suited for including one or more threads formed by way of the thermoforming processes described herein.

[0116] As shown in FIGS. 2-4, the closure 200 has a cover wall 204 and a side wall 208. The side wall 208 is integrally connected to the cover wall 204 and oriented transversely to the cover wall 204. The side wall 208 is circumferentially closed. The closure 200 has an interior (not illustrated) configured to receive a finish portion of the container to be closed with the closure 200.Docket No. 227254-754601 / PCTThe interior is partially bounded by the cover wall 204 and the side wall 208. The closure 200 includes an opening 212 (see FIG. 3) opposite to the cover wall 204, through which “access” to the interior is possible.

[0117] In some embodiments, shown in FIGS. 2-4, the closure 200 includes an annular wall 220 and a cylindrical wall 224 that extends downwardly from the annular wall 220 and surrounds the cover wall 204. Interior surfaces of the annular wall 220 and the cylindrical wall 224 include a plug seal (not shown) for scaling against an inner surface of a finish portion of the container to be closed with the closure 200. An interior surface of the annular wall 220 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 224 may be dimensioned for an interference fit with a corresponding inwardly facing surface of rim of finish for scaling. As the closure 200 is threaded onto the finish, the plug seal is forced into a mouth of the finish and into a compressed state in which the outwardly facing radial surface of the cylindrical wall 224 pushes against the inwardly facing surface of finish, thereby forming a seal.

[0118] As shown in FIG. 3, the closure 200 has a vertical axis 216. The side wall 208 extends along this vertical axis 216. The vertical axis 216 is transverse and in particular perpendicular to the cover wall 204. The opening 212 is also oriented transversely and in particular perpendicular to the vertical axis 216. In some embodiments, the vertical axis 216 includes an axis of rotational symmetry of the closure 200. In some embodiments, wherein the closure 200 serves as a closure cap for a bottle, the closure 200 is at least approximately cylindrical with the side wall 208 disposed symmetrically around the vertical axis 216.

[0119] As shown in FIGS. 2-3, the closure 200 includes a plurality of external knurls 244 distributed around the circumference of the threaded portion 236. The external knurls 244 serve in particular to improve the grip of the threaded portion 236 of the closure 200. Further, the closure 200 includes a plurality of knurls 248 distributed around the circumference of the tamper evidence feature 240. In some embodiments, the plurality of knurls 248 are distributed along an upper circumference or a lower circumference of the closure 200, or therebetween.

[0120] In some embodiments, shown in FIGS. 2-4, the closure 200 includes one or more internal threads 228 formed into the side wall 208 for engaging with external threads of the finish portion of the container to be closed with the closure 200. The threads 228 may be continuous threads or may be interrupted threads. In the illustrated embodiment, the closure 200 includes one thread 228, with one thread start 232 at the beginning of the thread 228. In some embodiments,Docket No. 227254-754601 / PCThowever, the closure 200 may include a plurality of threads 228, such as, for example, three threads distributed uniformly around the side wall 208 of closure 200. As such, each of the plurality of threads 228 includes one of a corresponding plurality of thread starts 232.

[0121] With continuing reference to FIGS. 2-4, the closure 200 may be viewed as broadly including a threaded portion 236 and a tamper evidence feature 240. As the closure 200 is threaded onto a finish portion of a container, the tamper evidence feature 240 rides over a ledge of the finish portion, clears the ledge, and fits into place beneath ledge.

[0122] As shown in Figs. 2-4, the closure 200 includes a plurality of external knurls 244 distributed around the circumference of the threaded portion 236. The external knurls 244 serve in particular to improve the grip of the threaded portion 236 of the closure 200. Further, the closure 200 includes a plurality of knurls 248 distributed around the circumference of the tamper evidence feature 240.

[0123] In some embodiments, the closure 200 includes a plurality of knurls (not shown) about the circumference of an inner surface of a tamper evidence feature 240. The plurality of internal knurls may be distributed evenly or unevenly about the circumference of the inner surface of tamper evidence feature 240.

[0124] In some embodiments, the tamper evidence feature 240 may include a plurality of spaced-apart bridges (not shown) that connect the tamper evidence feature 240 to the threaded portion 236 of the closure 200. In the event that the closure 200 is unthreaded from the finish portion, tamper evidence feature 240 will be retained in position by the ledge of the finish portion. The upward force from unthreading of the closure 200 will eventually cause sufficient stress on the bridges that they will break, providing evidence that the closure 200 has been tampered with.

[0125] FIGS. 5A-5B illustrate an exemplary embodiment of a collapsible mold 600 in both assembled and separated configurations, respectively. FIG. 5A illustrates a perspective view of a collapsible mold 600 when assembled, which is used as a mold for forming the closure. FIG. 5B illustrates a perspective view of the collapsible mold 600 when separated into a movable component 601 and a static component 602. The movable component 601 includes a plurality of threaded portions 611 (i.e., thread segments) that, upon twisting or rotating of the movable component 601 after forming threads in the closure, may be removed from the closure. The static component 602 includes a plurality of cores 621 attached to a base 622. The cores 621 may form vents in the closure between threads, which simplifies the threads in making them easier to collapseDocket No. 227254-754601 / PCTinto the core(s). In some embodiments, the cores may be configured to retract as part of a wedge. By allowing the cores to retract, vents formed in the closure that interrupt the threads can interact with cores, giving more room for the collapsing action. The static component includes a plurality of cores 621 attached to a base 622.

[0126] FIGS. 6A-6B illustrate another exemplary embodiment of a collapsible mold 700 in both assembled and separated configurations, respectively. FIG. 6A illustrates a perspective view of a collapsible mold 700 when assembled, which is used as a mold for forming the closure. FIG.6B illustrates a perspective view of the collapsible mold 700 when separated into a movable component 701 and a static component 702. The movable component 701 includes a plurality of threaded portions 711. Here, the static component 702 includes a plurality of cores 721 that are connected and retractable. Rather than being separate as are the cores 621 in FIG. 5B, the static component 702 in FIG. 6B folds over, as shown by the arrows, after forming the closure, and the movable component 701 may slightly twist or rotate (e.g., about 30-degrees), as shown by the semi-circular arrow, to free the closure from a sheet. This may be easier and faster than a higher degree rotation (e.g., up to 360-degrees) as is conventionally done.

[0127] FIG. 7 illustrates a side view of an exemplary embodiment of a thermoformed PET container closure 800 that is particularly well suited for including one or more threads formed by way of the retraction functionality of the collapsible molds described herein. In particular, knurls 801 (i.e., 801a, 801b, 801c) may be added at various heights of the closure (e.g., top, middle, bottom, or anywhere therebetween) as formed by a retractable core or other movable portions of the collapsible mold. As shown, knurls 801 may expand past a lower diameter of the closure, which may be achieved via the retractable functionality.

[0128] FIG. 8 illustrates an exemplary embodiment of a thermoforming process 400 whereby consistent threads can be formed on a thermoformed PET container closure, such as the closure 200 shown in FIGS. 1-4, without causing damage, as described herein. The process 400 begins at step 410, wherein a thermoplastic material, such as HDPE or PET, is heated in an industrial oven to a temperature that allows the material to become more flexible and easier to shape. In some embodiments, ceramic heating elements are used to heat the material. For injection molding, the closure can be formed from a molten state with a polymer delivered via a hot runner. 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.Docket No. 227254-754601 / PCT

[0129] In step 420, the heated HDPE or PET material is placed into a mold. In some embodiments, the heated HDPE or PET material is placed into a thermoforming machine including the mold. It is contemplated that in some embodiments, the heated HDPE or PET material may, alternatively, be injection molded or compression molded. The mold is designed with precision to create the desired features on the inside of the closure, including the threads and other internal components. The thermoforming mold is 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 is 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.

[0130] After the thermoforming process is complete, the process 400 advances to step 430, wherein the molded closure is 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 is 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.

[0131] In some embodiments, while the closure is allowed to cool or after the closure has cooled, the closure is then trimmed from the thermoformed web in a pre-folded state. The trimming of the closure from the thermoformed web is configured in a way that allows for the formation of cams at various angles, overcoming the limitations of traditional methods. Ideally 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.

[0132] 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 longDocket No. 227254-754601 / PCTand then reduce the consistent effectiveness of tamper evidence. This is 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.

[0133] In all cases, folding of the tabs may be done sequentially. In some embodiments including 90-degree 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 is 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.

[0134] 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 is 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.

[0135] 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 PET 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 PET parts.

[0136] After the cooling, trimming, and / or slitting processes, in step 440, the closure is removed from the mold by using a controlled removal system. In some embodiments, the controlled removal system includes a spring-loaded, pneumatic, hydraulic, servo, a belt, or a chain drive system that is configured to ensure consistent and accurate axial translation of one or more movable portions of the mold from the closure. In some embodiments, the controlled removal system operates at a speed ranging between about 1-2 mm / s, which has been found to be optimalDocket No. 227254-754601 / PCTfor removing closures without causing damage. In some embodiments, the controlled removal system is configured to lift the closure at an axial rate timed with the translating.

[0137] In some embodiments, a clearance mechanism is used as the closure is removed from the mold, as described in connection with step 440. The clearance mechanism is configured to ensure the thread path follows the contour of features in the closure, e.g., threading, vents, etc., 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 before step 440. This clearance allows for smooth removal of the closure from the mold and prevents damage to the threads.

[0138] In step 450, a timing mechanism is used to lift the closure at an axial rate that is correctly timed with the translating of the one or more movable portions of the mold. Timing of lifting the closure when the thread forming component is moving is critical to prevent deformation and unwanted height variation. In some embodiments, the closure is removed at an axial rate of 1-2 mm / s, which has been found to allow for preventing deformation and unwanted height variation.

[0139] It should be understood that the controlled removal system, the clearance mechanism, and the timing mechanism, described in steps 176-450, cooperate to prevent damage to the closure during removal from the mold. As such, the process 400 advantageously enables removing HDPE, PET, PHA, PLA or any type or combination of polymer closures from molds without causing damage.

[0140] Compared with conventional methods, the beneficial effects of the thermoforming process 400 provided herein are as follows:

[0141] 1. Improved Consistency: The thermoforming process 400 provided herein ensures a higher level of consistency in the quality of the threads by enabling the formation of threads from the inside of the closure. This is a significant improvement over the conventional methods of forming the threads from the outside, which results in less consistent threads.

[0142] 2 Reduced Damage: The thermoforming process 400 provided herein enables removing PET closures from the mold without causing damage. This is a major breakthrough in the field of Plastics Forming, particularly by employing Thermoforming, where previous attemptsDocket No. 227254-754601 / PCTusing injection or compression molding have resulted in damaged or inconsistent parts due to the tendency of the material to crack or deform under heat and pressure.

[0143] 3 Enhanced Control: The thermoforming process 400 disclosed herein introduces a controlled removal technology that allows for precise timing of lifting the closure when the feature forming component is translating. This not only prevents deformation of the closure but also minimizes unwanted height variation. This level of control is not achievable with the conventional processes.

[0144] 4. Versatility: The thermoforming process 400 is not limited to a specific type of mold or plastic material. The process 400 can be applied to any mold and any plastic material that is suitable for thermoforming. Similarly, it is contemplated that the process 400 can be applied to injection or compression molding for ejecting PET closures. This makes the thermoforming process 400 a versatile solution that can be used in a wide range of applications, without limitation.

[0145] 5. Efficiency: The thermoforming process 400 includes the use of a servo, belt, or chain drive system to remove the features as the closure is lifted from the mold. This not only speeds up the process but also reduces the risk of human error, making it a more efficient solution than the conventional methods.

[0146] It is contemplated, therefore, that the thermoforming process of the present disclosure provides a practical and efficient solution to the technical problem of threads on the inside of thermoformed PET closures or thermoformed caps from any polymer, offering significant improvements over existing approaches in terms of efficiency, quality control, versatility, enhanced user experience, and cost-effectiveness.

[0147] Moreover, as mentioned hereinabove, selecting PET is logical for this process in order to make mono-material recyclable containers. However, PHA or PLA are also practical options to enable 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.

[0148] The processes described in this patent has significant application prospects in the manufacturing industry, particularly in the production of plastic containers and packaging. Given the increasing demand for sustainable and cost-effective packaging solutions, the ability to effectively thermoform PET caps without causing damage or deformation could revolutionize the way these products are produced. Moreover, the thermoforming processes herein also findDocket No. 227254-754601 / PCTapplication in the pharmaceutical and food industries where consistent and reliable packaging is of utmost importance. By enabling the creation of high-quality, consistent PET caps, the present thermoforming processes can help companies in these sectors to improve product quality, reduce waste, and increase efficiency in their production processes. Furthermore, the processes provided herein can be adapted for use in other areas of plastics forming, such as injection molding and compression molding. This opens up new opportunities for thermoforming in the production of complex, precision-engineered plastic parts.

[0149] In terms of market demand, there is a growing need for innovative solutions in the packaging industry. As consumers become more environmentally conscious, there is a pressing need for sustainable packaging solutions that are both cost-effective and efficient. The ability to effectively thermoform PET caps can meet this demand, providing a more sustainable and cost-effective alternative to traditional packaging materials. Overall, the thermoforming processes described herein have significant application prospects and market demand, particularly in the packaging industry and related sectors. Overcoming the challenges long associated with thermoforming PET caps, the thermoforming processes disclosed herein can lead to significant improvements in product quality and efficiency, making for a valuable asset in today’s manufacturing landscape.Closures Made of Copolymers of PET and PEF (“PETF”)

[0150] In some embodiments, a closure may be made of a PET-based copolymer that may be particularly suited for injection molding and / or thermoforming. The PET-based copolymer incorporates a co-monomer to control crystallization and reduce melt processing temperatures. In some embodiments, the present disclosure provides a copolymer of PET and PET (also referred to as a FDCA-modified PET copolymer, or “PETF”). In some embodiments, the FDCA may be incorporated at a range of amounts such as to enhance the polymer reaction rates during both melt and solid state polymerization, and such as to allow polymer performance that may match traditional PET controlled by adding an amount of IPA. In some embodiments, FDCA may be substituted for or added to PET in addition to IPA so as to make PETF. In some embodiments, FDCA may be added in a low fraction, and the PETF copolymer product may be made following the same process as to make PET.

[0151] In some embodiments, the present disclosure provides a FDCA-modified PET copolymer that incorporates FDCA at an amount that may allow appropriate retardation of crystal formation in PET during closure forming. In some embodiments, the PETF may include less thanDocket No. 227254-754601 / PCT10 mole % FDCA, or less than 9 mole % FDCA, or less than 8 mole % FDCA, or less than 7 mole % FDCA, or less than 6 mole % FDCA, or less than 5 mole % FDCA, or less than 4 mole % FDCA, or less than 3 mole % FDCA, or less than 2 mole %, or less than 1 mole % FDCA, or an amount in a range formed from any two of the foregoing numbers, including all ranges and subranges therebetween. In some embodiments, the PETF may include as low as 0.5 mole % FDCA, and retard crystal formation sufficiently. In some embodiments, the PETF may include from 0.5 mole % to 5 mole % FDCA, of from 0.5 mole % to 4 mole % FDCA, or from 0.5 mole % to 3 mole % FDCA, or from 0.5 mole % to 2 mole % FDCA, or from 1 mole % to 5 mole % FDCA, or from 1 mole % to 4 mole % FDCA, or from 1 mole % to 3 mole % FDCA, or from 1 mole % to 2 mole % FDCA; or about 1.1 mole % FDCA. or about 1.2 mole % FDCA, or about 1.3 mole % FDCA, or about 1.4 mole % FDCA. or about 1.5 mol % FDCA, or about 1.7 mol % FDCA. or about 1.8 mol % FDCA, or about 1.9 mol % FDCA, or about 2 mol % FDCA, or an amount in a range formed from any two of the foregoing numbers, including all ranges and subranges therebetween.

[0152] In some embodiments, the copolymers provided herein may include repeating units (L), (M), and (N), or any salts thereof:

[0153] Repeating unit (L) may be a polyethylene furanoate (“PEF”) repeating unit based on furandicarboxylic acid (FDCA). In some embodiments, repeating unit (L) may be present in an amount of from 0.5 mol %, to 90.0 mol %, or to 85.0 mol %, or to 80.0 mol %, or to 75.0 mol %, or to 70.0 mol %, or to 65.0 mol %, or to 60.0 mol %, or to 55.0 mol %, or to 50.0 mol %, or to 45.0 mol %, or to 40.0 mol % or to 35.0 mol %, or to 30.0 mol %, or to 25.0 mol %, or to 20.0 molDocket No. 227254-754601 / PCT%, or to 15.0 mol %, or to 10.0 mol %, or to 9.5 mol %, or to 9.0 mol %, or to 8.5 mol %, or to 8.0 mol %, or to 7.5 mol %, or to 7.0 mol %, or to 6.5 mol %, or to 6.0 mol % of the copolymer; or from 6.5 mol %, or from 7.0 mol %, or from 7.5 mol %, or from 8.0 mol %, or from 8.5 mol %, or from 9.0 mol %, or from 9.5 mol %, or from 10.0 mol %, or from 15.0 mol %, or from 20.0 mol %, or from 25.0 mol %, or from 30.0 mol %, or from 35.0 mol %, or from 40.0 mol %, or from 45.0 mol %, or from 50.0 mol %, or from 55.0 mol %, or from 60.0 mol %, or from 65.0 mol %, or from 70.0 mol %, or from 75.0 mol %, or from 80.0 mol %, or from 85.0 mol % to 90.0 mol % of the copolymer; or any range made from any two of the foregoing numbers, including any subranges therebetween. In some embodiments, repealing unit (L) may be present in an amount of from 0.5 mol % to 6.0 mol % of the copolymer, including all subranges therebetween. In some embodiments, repealing unit (L) may be present in an amount of up to 90.0 mol % of the copolymer. As the mole percent of FDCA is increased, the rate and degree of crystallization of PET may decrease.

[0154] Repealing unit (M) is may be based on terephthalic acid (“PTA” or “TP A”). In some embodiments, repeating unit (M) may be present in an amount of from 10.0 mol % to 99.5 mol %, or to 99.0 mol %, or to 98.5 mol %, or to 98.0 mol %, or to 91.5 mol %, or to 97.0 mol %, or to 96.5 mol %, or to 96.0 mol %, or to 95.5 mol %, or to 95.0 mol %, or to 94.5 mol %, or to 94.0 mol%, or to 93.5 mol %, or to 93.0 mol%, or to 92.5 mol %, or to 92.0 mol %, or to 91.5 mol %, or to 91.0 mol %, or to 90.5 mol %, or to 90.0 mol %, or to 85.0 mol %, or to 80.0 mol %, or to 75.0 mol %, or to 70.0 mol %, or to 65.0 mol %, or to 60.0 mol %, or to 55.0 mol %, or to 50.0 mol %, or to 45.0 mol %, or to 40.0 mol %, or to 35.0 mol %, or to 30.0 mol %, or to 25.0 mol %, or to 20.0 mol %, or to 15.0 mol %, or to 10.0 mol %; or from 10.0 mol %, or from 15.0 mol %, or from 20.0 mol %, or from 25.0 mol %, or from 30.0 mol %, or from 35.0 mol %, or from 40.0 mol %, or from 45.0 mol %, or from 50.0 mol %, or from 55.0 mol %, or from 60.0 mol %, or from 65.0 mol %, or from 70.0 mol %, or from 75.0 mol %, or from 80.0 mol %, or from 85.0 mol %, or from 90.0 mol %, or from 90.5 mol %, or from 91.0 mol %, or from 91.5 mol %, or from 92.0 mol %, or from 92.5 mol %, or from 93.0 mol %, or f rom 93.5 mol %, or from 94.0 mol %, or from 94.5 mol %, or from 95.0 mol %, or from 95.5 mol %, or from 96.0 mol %, or from 96.5 mol %, or from 97.0 mol %, or from 97.5 mol %, or from 98.0 mol %, or from 98.5 mol % to 90.0 mol %; or any range made from any two of the foregoing numbers, including any subranges therebetween. In some embodiments, repeating unit (M) may be present in an amount of from 94 mol % to 99.5 mol %, including all subranges therebetween. In some embodiments, repeating unit (M) may be present in at least 10.0 mol % of the copolymer.Docket No. 227254-754601 / PCT

[0155] Repeating unit (N) is based on IP A, and may be optional. In some embodiments, repeating unit (N) may be present in an amount of from 0 mol % to 4 mol %, including all subranges therebetween.

[0156] In some embodiments, the FDCA-modified PET copolymers described herein may act as a polymerization / melt-processing aid and may lead to several processing advantages, including, for example: improving the melt-phase polymerization times and / or process temperatures; allowing lower melt-phase processing temperatures, which may reduce thermal degradation byproducts and may improve b* (yellow) color of the copolymer; as FDCA concentration increases, decreasing process temperatures and protecting the polymer from thermal degradation by-products that may be associated with FDCA polymers produced at typical, unmodified PET process temperatures; reducing the melt temperatures of the copolymer to allow lower processing temperatures in closure forming; reducing the melt temperatures without reducing the melt viscosity in closure forming; producing polymers with high intrinsic viscosity (“IV”) at polymerization times and temperatures associated with unmodified PET; and / or producing high IV polymers with high IV at solid-state polymerization times and temperatures associated with unmodified PET.

[0157] In some embodiments, crystal nucleation in PETF including FDCA in amounts of <2 mol % may be accelerated by nano-particles that have the ability to nucleate crystals in PET. In some embodiments, the rate nucleation of PETF including FDCA in amounts of >2 mol %, and even over 5 mol, may be increased by using crystallization additives such as graphene.

[0158] In some embodiments, a PEF component may have less entanglement density than PET.

[0159] In some embodiments, the PETF provided herein may have low PEF yellowing due to low FDCA fractions used.

[0160] In some embodiments, pellet blending for PETF concentration may be another route to PET with a low mole percent of FDCA.

[0161] In some embodiments, PETF for use in the polyester resin closures described herein may be made by esterification of ethylene glycol (“EG”) and PTA in the presence of FDCA and optionally IPA. In some embodiments. FDCA may be present in a range of from 0.05 mol % to 6 mol %, or from 1.5 mol % to 2 mol %, including all ranges and subranges therebetween. In someDocket No. 227254-754601 / PCTembodiments of PETF, in which IPA is also incorporated, IPA may be present in a range of from 0.01 mol % to 2 mol %, including all subranges therebetween.PTA-Based Melt Polymer Process

[0162] In some embodiments, the initial reaction of the PTA-based polymer process may react PTA with EG under a pressure of 40-50 psig at 250-270°C. Water may be evolved and separated using a distillation column. The reaction may be carried out under pressure because of the low solubility of PTA in EG at the boiling point of EG of 197°C. After most of the theoretical amount of water has been collected, the pressure may be reduced to atmospheric as the remaining water is evolved. The resulting bi s(2-hydroxy ethyl) terephthalate (“BHET”) may be heated in the presence of a suitable catalyst (such as antimony triglycolate), and EG is extracted in a kind of ester-interchange as two molecules of BHET form a dimer. If the released EG is removed from the system by distillation, further reactions may be possible. In some embodiments, a dimer may react with another BHET molecule to form a trimer; two molecules of dimer may form a tetramer. By such stepwise growth process, a high-molecular-weight polymer may be produced.

[0163] In some embodiments, suitable catalysts used for PET polymerization may include Sb-and Ti-based catalysts. In some embodiments, phosphoric acid and phosphates may be added to perform one or more of several roles, including, for example to serve as a catalyst or to minimize thermal oxidation. In some embodiments, impurities in PTA may be less than 1 ppm of one or more of Fe, Co, Mo, Ni, Ti, Cr, Ca, Al, MG, Na, and K. Impurities of greater quantity may be present in PTA, and the impurities may act as chain terminators or cause discoloration.

[0164] For melt-phase polymerization, high temperatures, such as from 265 to 300°C, may be required, and the pressure above the melt polymer must be reduced to approximately 1 torr so as to facilitate the high molecular weights required for polymer performance. In production plants, multi-stage steam or glycol ejectors may be used to achieve the low pressure of approximately I torr.PTA-Based Solid-State Polymerization (“SSP”)

[0165] Polyesters may be polymerized in the solid state as well as in the melt phase. In some embodiments, to achieve solid-state polymerization, the polymer chip produced in the melt polymer process may be heated to high temperatures, such as from 200 to 210°C, under vacuum or in a stream of inert gas, such as nitrogen. The SSP process may allow high molecular weights to be achieved without the problems associated with processing hot, extremely viscous melts.Docket No. 227254-754601 / PCTFurther, because the reaction temperature of the SSP process is lower than melt polymerization, thermal degradation of the polymer may be minimal.

[0166] During melt polymerization, degradation reactions may lead to the formation of acetaldehyde (“AA”) and carboxyl end groups. The SSP process acts as a “cleaning” process that may remove the melt phase degradation products and may reduce AA levels in polymer chips to 1 ppm or lower. Reduction of AA levels may be important for polymers used to make food-grade bottles destined to contain sodas and water, because even trace amounts of AA may produce off-flavors.

[0167] The main reaction in SSP is polyesterification, a result of the dehydration reaction between carboxyl and hydroxyl end groups on the polymer chains. The results of the polyesterification process gives SSP the ability to increase the viscosity and reduce the carboxyl end group (“CEG”) level in the polymer, both of which may be desirable properties in downstream applications. Furthermore, SSP also removes the cyclic oligomers formed in the melt phase polymers that may cause deposition problems in downstream polymer applications.

[0168] The rate of SSP may be governed by the diffusion of water and glycol out of the polymer chip and / or the rate of removal of AA. The reaction rate may be highly dependent upon a size of a polymer chip and there may be a molecular weight gradient from a surface to a center of a polymer chip.

[0169] In some embodiments, toners may be used to adjust a color of the resulting PETF.

[0170] In some embodiments, PETF for closures may be produced by melt mixing or blending pellets including FDCA in higher concentrations with PET that does not include FDCA. In some embodiments, 10 mol % PET including an FDCA content of 10% blended with 90 mol % PET without FDCA yields PET including 1% FDCA.

[0171] 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 isDocket No. 227254-754601 / PCTthe 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.Illustrative Embodiments

[0172] Embodiment 1. A process for thermoforming a closure for a container, comprising:

[0173] a. providing a heated thermoplastic material and a collapsible mold, wherein the collapsible mold comprises:

[0174] i. one or more movable portions configured to axially translate from a first position to a second position, the first position being in contact with the heated thermoplastic material and the second position being spatially retractable from the heated thermoplastic material, and wherein, when each of the one or more movable portions is in the first position, the collapsible mold is configured to form:

[0175] ii. a plug seal of the closure, wherein the plug seal seats against an inner surface of the container;

[0176] iii. an annular wall of the closure, wherein the annular wall seats against a top surface of a rim of the container; and

[0177] iv. 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;

[0178] b. thermoforming the heated thermoplastic material into a closure by placing the heated thermoplastic material into or onto the collapsible mold, wherein each of the one or more movable portions of the collapsible mold are in the first position; and

[0179] c. removing the closure from the collapsible mold by:

[0180] i. axially translating the one or more movable portions of the collapsible mold to the second position, and

[0181] ii. lifting the closure at an axial rate timed with the translating.Docket No. 227254-754601 / PCT

[0182] Embodiment 2. The process of Embodiment 1, wherein each of the one or more movable portions is axially translated at a different time than others of the one or more movable portions.

[0183] Embodiment s. The process of Embodiment 1, wherein each of the one or more movable portions is axially translated simultaneously to others of the one or more movable portions.

[0184] Embodiment 4. The process of Embodiment 1, wherein the one or more movable portions comprise a projection configured to form one or more vents in the thermoplastic material.

[0185] Embodiment 5. The process of Embodiment 1, wherein the collapsible mold further comprises a knurled portion configured to form a plurality of knurls onto an exterior of the closure.

[0186] Embodiment 6. The process of Embodiment 5, further comprising adjusting a size and / or a shape of each of the plurality of knurls.

[0187] Embodiment 7. The process of Embodiment 1, further comprising forming cams on the closure prior to removing the closure from the collapsible mold.

[0188] Embodiment 8. The process of Embodiment 7, wherein the cams are formed using a cam-forming tool.

[0189] Embodiment 9. The process of Embodiment 8, wherein the cams are formed using the cam-forming tool after the thermoplastic material has cooled to room temperature.

[0190] Embodiment 10. The process of Embodiment 7, wherein the cams are formed in steps at angles ranging between about -10 degrees and about 190 degrees.

[0191] Embodiment 11. The process of Embodiment 7, 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.

[0192] Embodiment 12. The process of Embodiment 11, wherein the tabs are folded along a circumference of the closure using a ramp.

[0193] Embodiment 13. The process of Embodiment 11, wherein the tabs are folded by pushing the closure through a tube, thereby folding the tabs into a vertical position.Docket No. 227254-754601 / PCT

[0194] Embodiment 14. The process of Embodiment 13, wherein the tube is cylindrically or conically shaped.

[0195] Embodiment 15. The process of Embodiment 1, wherein the threaded portion of the collapsible mold is shaped to form undercuts in the threads.

[0196] Embodiment 16. The process of Embodiment 15, wherein the undercuts are formed with a depth ranging from 0.1 mm to 1 mm.

[0197] Embodiment 17. The process of Embodiment 15, wherein the undercuts are formed at an angle ranging from -10 degrees to 190 degrees, with respect to a base of the collapsible mold.

[0198] Embodiment 18. The process of Embodiment 1, further comprising slitting the closure to form a tamper evidence band.

[0199] Embodiment 19. The process of Embodiment 1, wherein the thermoplastic material is selected from the group consisting of: HDPE, PET, PHA, PLA, PETF, or any combination thereof.

[0200] Embodiment 20. The process of Embodiment 1, wherein the thermoforming of the thermoplastic material comprises applying pressure to the thermoplastic material using a thermoforming machine.

[0201] Embodiment 21. The process of Embodiment 20, wherein the pressure is sufficient to shape the thermoplastic material into the closure without causing damage to the thermoplastic material.

[0202] Embodiment 22. The process of Embodiment 20, wherein the pressure is from about 4 bar to about 10 bar to the thermoplastic material.

[0203] Embodiment 23. The process of Embodiment 1, wherein the heated thermoplastic material is heated to a temperature ranging from about 80 °C and about 120 °C prior to the thermoforming.

[0204] Embodiment 24. The process of Embodiment 1, further comprising cooling the closure prior to removing from the collapsible mold.

[0205] Embodiment 25. The process of Embodiment 24, wherein the cooling comprises allowing the closure to cool to room temperature.Docket No. 227254-754601 / PCT

[0206] Embodiment 26. The process of Embodiment 24, wherein the cooling is performed using water cooling channels in the collapsible mold to cool the closure.

[0207] Embodiment 27. The process of Embodiment 26, wherein the water cooling channels are arranged in a 3D network of cooling channels to reduce a pitch between individual forming portions of the collapsible mold.

[0208] Embodiment 28. The process of Embodiment 1, wherein the axially translating of the one or more movable portions of the collapsible mold is performed using a controlled removal system that is one or more of spring-loaded, pneumatic, or hydraulic.

[0209] Embodiment 29. The process of Embodiment 1, wherein the axially translating of the one or more movable portions further comprises rotating of the one or more movable portions, the rotating being performed using a controlled rotation system.

[0210] Embodiment 30. The process of Embodiment 29, wherein the controlled rotation system comprises a servo, a belt, a chain drive system, or a combination thereof.

[0211] Embodiment 31. The process of Embodiment 29, wherein the controlled rotation system rotates the threaded portion of the collapsible mold at a speed ranging from about 10 RPM and about 20 RPM.

[0212] Embodiment 32. The process of Embodiment 1, wherein the removing of the closure from the collapsible mold further comprises applying clearance to ensure smooth removal of the closure.

[0213] Embodiment 33. The process of Embodiment 32, wherein the clearance is applied using a clearance mechanism to ensure a thread path follows a contour of rotating of the one or more movable portions as the closure is removed from the collapsible mold.

[0214] Embodiment 34. The process of Embodiment 33, wherein the clearance mechanism allows for vents in the closure.

[0215] Embodiment 35. The process of Embodiment 1, wherein the axial rate comprises 1-2 mm / s.

[0216] Embodiment 36. A collapsible mold for thermoforming a closure for a container, comprising:Docket No. 227254-754601 / PCT

[0217] a. one or more movable portions configured to axially translate from a first position to a second position, the first position being in contact with a heated thermoplastic material and the second position being spatially retractable from the heated thermoplastic material.

[0218] Embodiment 37. The collapsible mold of Embodiment 36, wherein, when each of the one or more movable portions is in the first position, the collapsible mold is configured to form:

[0219] a. a first portion configured to form a plug seal of the closure, wherein the plug seal seats against an inner surface of the container;

[0220] b. a second portion configured to form an annular wall of the closure, wherein the annular wall seats against a top surface of a rim of the container; and

[0221] c. 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

[0222] Embodiment 38. The collapsible mold of Embodiment 37, wherein the threaded portion of the collapsible mold is shaped to form undercuts in the threads.

[0223] Embodiment 39. The collapsible mold of Embodiment 36, wherein the collapsible mold further comprises a knurled portion configured to form a plurality of knurls onto an exterior of the closure.

[0224] Embodiment 40. The collapsible mold of Embodiment 36, wherein the one or more movable portions comprise one or more projections configured to form one or more vents in the thermoplastic material.

[0225] Embodiment 41. The collapsible mold of Embodiment 40, wherein the one or more projections are retractable.

[0226] Embodiment 42. The collapsible mold of Embodiment 40, wherein the one or more projections are configured to form one or more hinges.

[0227] Embodiment 43. The collapsible mold of Embodiment 36, wherein each of the one or more movable portions is configured to axially translate at a different time than others of the one or more movable portions.Docket No. 227254-754601 / PCT

[0228] Embodiment 44. The collapsible mold of Embodiment 36, wherein each of the one or more movable portions is configured to axially translate simultaneously to others of the one or more movable portions.

[0229] Embodiment 45. The collapsible mold of Embodiment 36, further comprising a static portion from which the one or more movable portions are configured to axially translate.

[0230] Embodiment 46. The collapsible mold of Embodiment 45, wherein the static portion comprises one or more projections connected to a base of the static portion.

[0231] Embodiment 47. The collapsible mold of Embodiment 46, wherein the one or more projections are configured to form one or more vents in the thermoplastic material.

[0232] Embodiment 48. The collapsible mold of Embodiment 46, wherein the one or more projections are retractable.

[0233] Embodiment 49. The collapsible mold of Embodiment 36, wherein at least one of the one or more movable portions is flexible.

[0234] Embodiment 50. The collapsible mold of Embodiment 36, wherein at least one of the one or more movable portions is rigid.

[0235] Embodiment 51. A system for thermoforming a closure for a container, the system comprising:

[0236] a. a collapsible mold comprising one or more movable portions configured to axially translate from a first position to a second position, the first position being in contact with a heated thermoplastic material and the second position being spatially retractable from the heated thermoplastic material; and

[0237] b. a controlled removal system configured to axially translate the one or more movable portions of the collapsible mold.

[0238] Embodiment 52. The system of Embodiment 51, wherein, when each of the one or more movable portions is in the first position, the collapsible mold is configured to form:

[0239] a. a first portion configured to form a plug seal of the closure, wherein the plug seal seats against an inner surface of the container;Docket No. 227254-754601 / PCT

[0240] b. a second portion configured to form an annular wall of the closure, wherein the annular wall seats against a top surface of a rim of the container; and

[0241] c. 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.

[0242] Embodiment 53. The system of Embodiment 52, wherein the threaded portion of the collapsible mold is shaped to form undercuts in the threads.

[0243] Embodiment 54. The system of Embodiment 51, wherein the collapsible mold further comprises a knurled portion configured to form a plurality of knurls onto an exterior of the closure.

[0244] Embodiment 55. The system of Embodiment 51, wherein the one or more movable portions comprise one or more projections configured to form one or more vents in the thermoplastic material.

[0245] Embodiment 56. The system of Embodiment 54, wherein the one or more projections are retractable.

[0246] Embodiment 57. The system of Embodiment 54, wherein the one or more projections are configured to form one or more hinges.

[0247] Embodiment 58. The system of Embodiment 51, wherein each of the one or more movable portions is configured to axially translate at a different time than others of the one or more movable portions.

[0248] Embodiment 59. The system of Embodiment 51, wherein each of the one or more movable portions is configured to axially translate simultaneously to others of the one or more movable portions.

[0249] Embodiment 60. The system of Embodiment 51, further comprising a static portion from which the one or more movable portions are configured to axially translate.

[0250] Embodiment 61. The system of Embodiment 60, wherein the static portion comprises one or more projections connected to a base of the static portion.

[0251] Embodiment 62. The system of Embodiment 61, wherein the one or more projections are configured to form one or more vents in the thermoplastic material.Docket No. 227254-754601 / PCT

[0252] Embodiment 63. The system of Embodiment 61, wherein the one or more projections are retractable.

[0253] Embodiment 64. The system of Embodiment 51, wherein at least one of the one or more movable portions is flexible.

[0254] Embodiment 65. The system of Embodiment 51, wherein at least one of the one or more movable portions is rigid.

[0255] Embodiment 66. The system of Embodiment 51, wherein the heated thermoplastic material is selected from the group consisting of: HDPE, PET, PHA, PLA, PETF, or any combination thereof.

[0256] Embodiment 67. The system of Embodiment 51, wherein the controlled removal system is spring-loaded, pneumatic, hydraulic, or a combination thereof.

[0257] Embodiment 68. The system of Embodiment 51, wherein the controlled removal system comprises a spreader tool configured to be pushed into the collapsible mold to expand at least one of the one or more movable portions during forming of a closure, and then lowered from the collapsible mold to release the closure.

[0258] Embodiment 69. The system of Embodiment 51, wherein the controlled removal system is configured to key or hook the one or more movable portions onto a lever connected to a rail that determines a position of a respective movable portion.

[0259] Embodiment 70. The system of Embodiment 51, wherein the controlled removal system comprises at least one drive wheel configured to rotate to be positioned with an opening and closing of the collapsible mold, wherein an outward position of the at least one drive wheel is configured force one or more projections out of one of the one or more movable portions to form a closure.

[0260] Embodiment 71. The system of Embodiment 51, wherein the controlled removal system operates at a speed ranging between about 1-2 mm / s.

[0261] Embodiment 72. The system of Embodiment 51, wherein the controlled removal system is configured to lift the closure at an axial rate timed with the translating of the one or more movable portions of the collapsible mold.Docket No. 227254-754601 / PCT

[0262] Embodiment 73. A process for thermoforming a closure for a container, comprising:

[0263] a. providing a heated thermoplastic material and a collapsible mold, wherein the collapsible mold comprises:

[0264] i. one or more movable portions configured to axially translate from a first position to a second position, the first position being in contact with the heated thermoplastic material and the second position being spatially retracted from the heated thermoplastic material, and wherein, when each of the one or more movable portions is in the first position, the collapsible mold is configured to form:

[0265] ii. a plug seal of the closure, wherein the plug seal seats against an inner surface of the container;

[0266] iii. an annular wall of the closure, wherein the annular wall seats against a top surface of a rim of the container; and

[0267] iv. 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;

[0268] b. thermoforming the heated thermoplastic material into a closure by placing the heated thermoplastic material into or onto the collapsible mold, wherein each of the one or more movable portions of the collapsible mold are in the first position; and

[0269] c. removing the closure from the collapsible mold by:

[0270] i. axially translating the one or more movable portions of the collapsible mold to the second position, and

[0271] ii. lifting the closure at an axial rate timed with the translating.

[0272] Embodiment 74. The process of Embodiment 73, wherein each of the one or more movable portions is axially translated at a different time than others of the one or more movable portions.

[0273] Embodiment 75. The process of Embodiment 73, wherein each of the one or more movable portions is axially translated simultaneously to others of the one or more movable portions.Docket No. 227254-754601 / PCT

[0274] Embodiment 76. The process of Embodiment 73, wherein the one or more movable portions comprise a projection configured to form one or more vents in the thermoplastic material.

[0275] Embodiment 77. The process of Embodiment 73, wherein the collapsible mold further comprises a knurled portion configured to form a plurality of knurls onto an exterior of the closure.

[0276] Embodiment 78. The process of Embodiment 77, further comprising adjusting a size and / or a shape of each of the plurality of knurls.

[0277] Embodiment 79. The process of Embodiment 73, further comprising forming cams on the closure prior to removing the closure from the collapsible mold.

[0278] Embodiment 80. The process of Embodiment 79, wherein the cams are formed using a cam-forming tool.

[0279] Embodiment 81. The process of Embodiment 80, wherein the cams are formed using the cam-forming tool after the thermoplastic material has cooled to room temperature.

[0280] Embodiment 82. The process of Embodiment 79, wherein the cams are formed in steps at angles ranging between about -10 degrees and about 190 degrees.

[0281] Embodiment 83. The process of Embodiment 79, wherein the cams are formed by folding 90-degree 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.

[0282] Embodiment 84. The process of Embodiment 83, wherein the 90-degree tabs are folded along a circumference of the closure using a ramp.

[0283] Embodiment 85. The process of Embodiment 83, wherein the 90-degree tabs are folded by pushing the closure through a tube, thereby folding the 90-degree tabs into a vertical position.

[0284] Embodiment 86. The process of Embodiment 85, wherein the tube is cylindrically or conically shaped.

[0285] Embodiment 87. The process of Embodiment 73, wherein the threaded portion of the collapsible mold is shaped to form undercuts in the threads.Docket No. 227254-754601 / PCT

[0286] Embodiment 88. The process of Embodiment 87, wherein the undercuts are formed with a depth ranging from 0.1 mm to 1 mm.

[0287] Embodiment 89. The process of Embodiment 87, wherein the undercuts are formed at an angle ranging from -10 degrees to 190 degrees, with respect to a base of the collapsible mold.

[0288] Embodiment 90. The process of Embodiment 73, further comprising slitting the closure to form a tamper evidence band.

[0289] Embodiment 91. The process of Embodiment 73, wherein the thermoplastic material is selected from the group consisting of: HDPE, PET, PHA, PLA, PETF, or any combination thereof.

[0290] Embodiment 92. The process of Embodiment 73, wherein the thermoforming of the thermoplastic material comprises applying pressure to the thermoplastic material using a thermoforming machine.

[0291] Embodiment 93. The process of Embodiment 92, wherein the pressure is sufficient to shape the thermoplastic material into the closure without causing damage to the thermoplastic material.

[0292] Embodiment 94. The process of Embodiment 92, wherein the pressure is from about 4 bar to about 10 bar to the thermoplastic material.

[0293] Embodiment 95. The process of Embodiment 73, wherein the heated thermoplastic material is heated to a temperature ranging from about 80 °C and about 120 °C prior to the thermoforming.

[0294] Embodiment 96. The process of Embodiment 73, further comprising cooling the closure prior to removing from the collapsible mold.

[0295] Embodiment 97. The process of Embodiment 96, wherein the cooling comprises allowing the closure to cool to room temperature.

[0296] Embodiment 98. The process of Embodiment 96, wherein the cooling is performed using water cooling channels in the collapsible mold to cool the closure.Docket No. 227254-754601 / PCT

[0297] Embodiment 99. The process of Embodiment 98, wherein the water cooling channels are arranged in a 3D network of cooling channels to reduce a pitch between individual forming portions of the collapsible mold.

[0298] Embodiment 100. The process of Embodiment 73, wherein the axially translating of the one or more movable portions of the collapsible mold is performed using a controlled removal system that is one or more of spring-loaded, pneumatic, or hydraulic.

[0299] Embodiment 101. The process of Embodiment 73, wherein the axially translating of the one or more movable portions further comprises rotating of the one or more movable portions, the rotating being performed using a controlled rotation system.

[0300] Embodiment 102. The process of Embodiment 101, wherein the controlled rotation system comprises a servo, a belt, a chain drive system, or a combination thereof.

[0301] Embodiment 103. The process of Embodiment 101, wherein the controlled rotation system rotates the threaded portion of the collapsible mold at a speed ranging from about 10 RPM and about 20 RPM.

[0302] Embodiment 104. The process of Embodiment 73, wherein the removing of the closure from the collapsible mold further comprises applying clearance to ensure smooth removal of the closure.

[0303] Embodiment 105. The process of Embodiment 104, 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 collapsible mold.

[0304] Embodiment 106. The process of Embodiment 105, wherein the clearance mechanism allows for vents in the closure.

[0305] Embodiment 107. The process of Embodiment 73, wherein the axial rate comprises 1-2 mm / s.

[0306] Embodiment 108. A collapsible mold for thermoforming a closure for a container, comprising:

[0307] a. one or more movable portions configured to axially translate from a first position to a second position, the first position being in contact with the heated thermoplastic material andDocket No. 227254-754601 / PCTthe second position being spatially retracted from the heated thermoplastic material, and wherein, when each of the one or more movable portions is in the first position, the collapsible mold is configured to form:

[0308] b. a first portion configured to form a plug seal of the closure, wherein the plug seal seats against an inner surface of the container;

[0309] c. a second portion configured to form an annular wall of the closure, wherein the annular wall seats against a top surface of a rim of the container; and

[0310] d. 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.

[0311] Embodiment 109. A system for thermoforming a closure for a container, the system comprising:

[0312] a. the collapsible mold of Embodiment 108;

[0313] b. a thermoplastic material; and

[0314] c. a controlled removal system configured to axially translate the one or more movable portions of the collapsible mold.

Claims

Docket No. 227254-754601 / PCTCLAIMSThe following claims are provided to add additional clarity to this disclosure. Future applications claiming priority to this application may or may not include the following claims, and may include claims broader, narrower, or entirely different from the following claims.What is claimed is:

1. A process for thermoforming a closure for a container, comprising:(a) providing a heated thermoplastic material and a collapsible mold, wherein the collapsible mold comprises:one or more movable portions configured to axially translate from a first position to a second position, the first position being in contact with the heated thermoplastic material and the second position being spatially retractable from the heated thermoplastic material, and wherein, when each of the one or more movable portions is in the first position, the collapsible mold is configured to form:(i) a plug seal of the closure, wherein the plug seal seats against an inner surface of the container;(ii) an annular wall of the closure, wherein the annular wall seats against a top surface of a rim of the container; and(iii) 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;(b) thermoforming the heated thermoplastic material into a closure by placing the heated thermoplastic material into or onto the collapsible mold, wherein each of the one or more movable portions of the collapsible mold are in the first position; and (c) removing the closure from the collapsible mold by:(i) axially translating the one or more movable portions of the collapsible mold to the second position, and(ii) lifting the closure at an axial rate timed with the translating.

2. The process of claim 1, wherein each of the one or more movable portions is axially translated at a different time than others of the one or more movable portions.Docket No. 227254-754601 / PCT3. The process of claim 1, wherein each of the one or more movable portions is axially translated simultaneously to others of the one or more movable portions.

4. The process of claim 1, wherein the one or more movable portions comprise a projection configured to form one or more vents in the thermoplastic material.

5. The process of claim 1, wherein the collapsible mold further comprises a knurled portion configured to form a plurality of knurls onto an exterior of the closure.

6. The process of claim 5, further comprising adjusting a size and / or a shape of each of the plurality of knurls.

7. The process of claim 1, further comprising forming cams on the closure prior to removing the closure from the collapsible mold.

8. The process of claim 7, wherein the cams are formed using a cam-forming tool.

9. The process of claim 8, wherein the cams are formed using the cam-forming tool after the thermoplastic material has cooled to room temperature.

10. The process of claim 7, wherein the cams are formed in steps at angles ranging between about -10 degrees and about 190 degrees.

11. The process of claim 7, 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.

12. The process of claim 11, wherein the tabs are folded along a circumference of the closure using a ramp.

13. The process of claim 11, wherein the tabs are folded by pushing the closure through a tube, thereby folding the tabs into a vertical position.

14. The process of claim 13, wherein the tube is cylindrically or conically shaped.

15. The process of claim 1, wherein the threaded portion of the collapsible mold is shaped to form undercuts in the threads.Docket No. 227254-754601 / PCT16. The process of claim 15, wherein the undercuts are formed with a depth ranging from 0.1 mm to 1 mm.

17. The process of claim 15, wherein the undercuts are formed at an angle ranging from -10 degrees to 190 degrees, with respect to a base of the collapsible mold.

18. The process of claim 1, further comprising slitting the closure to form a tamper evidence band.

19. The process of claim 1, wherein the thermoplastic material is selected from the group consisting of: HDPE, PET, PHA, PLA, PETF, or any combination thereof.

20. The process of claim 1 , wherein the thermoforming of the thermoplastic material comprises applying pressure to the thermoplastic material using a thermoforming machine.

21. The process of claim 20, wherein the pressure is sufficient to shape the thermoplastic material into the closure without causing damage to the thermoplastic material.

22. The process of claim 20, wherein the pressure is from about 4 bar to about 10 bar to the thermoplastic material.

23. The process of claim 1, wherein the heated thermoplastic material is heated to a temperature ranging from about 80 °C and about 120 °C prior to the thermoforming.

24. The process of claim 1, further comprising cooling the closure prior to removing from the collapsible mold.

25. The process of claim 24, wherein the cooling comprises allowing the closure to cool to room temperature.

26. The process of claim 24, wherein the cooling is performed using water cooling channels in the collapsible mold to cool the closure.

27. The process of claim 26, wherein the water cooling channels are arranged in a 3D network of cooling channels to reduce a pitch between individual forming portions of the collapsible mold.Docket No. 227254-754601 / PCT28. The process of claim 1, wherein the axially translating of the one or more movable portions of the collapsible mold is performed using a controlled removal system that is one or more of spring-loaded, pneumatic, or hydraulic.

29. The process of claim 1, wherein the axially translating of the one or more movable portions further comprises rotating of the one or more movable portions, the rotating being performed using a controlled rotation system.

30. The process of claim 29, wherein the controlled rotation system comprises a servo, a belt, a chain drive system, or a combination thereof.

31. The process of claim 29, wherein the controlled rotation system rotates the threaded portion of the collapsible mold at a speed ranging from about 10 RPM and about 20 RPM.

32. The process of claim 1, wherein the removing of the closure from the collapsible mold further comprises applying clearance to ensure smooth removal of the closure.

33. The process of claim 32, wherein the clearance is applied using a clearance mechanism to ensure a thread path follows a contour of rotating of the one or more movable portions as the closure is removed from the collapsible mold.

34. The process of claim 33, wherein the clearance mechanism allows for vents in the closure.

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

36. A collapsible mold for thermoforming a closure for a container, comprising:one or more movable portions configured to axially translate from a first position to a second position, the first position being in contact with a heated thermoplastic material and the second position being spatially retractable from the heated thermoplastic material.

37. The collapsible mold of claim 36, wherein, when each of the one or more movable portions is in the first position, the collapsible mold is configured to form:(a) a first portion configured to form a plug seal of the closure, wherein the plug seal seats against an inner surface of the container;(b) a second portion configured to form an annular wall of the closure, wherein the annular wall seats against a top surface of a rim of the container; andDocket No. 227254-754601 / PCT(c) 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 container38. The collapsible mold of claim 37, wherein the threaded portion of the collapsible mold is shaped to form undercuts in the threads.

39. The collapsible mold of claim 36, wherein the collapsible mold further comprises a knurled portion configured to form a plurality of knurls onto an exterior of the closure.

40. The collapsible mold of claim 36, wherein the one or more movable portions comprise one or more projections configured to form one or more vents in the thermoplastic material.

41. The collapsible mold of claim 40, wherein the one or more projections are retractable.

42. The collapsible mold of claim 40, wherein the one or more projections are configured to form one or more hinges.

43. The collapsible mold of claim 36, wherein each of the one or more movable portions is configured to axially translate at a different time than others of the one or more movable portions.

44. The collapsible mold of claim 36, wherein each of the one or more movable portions is configured to axially translate simultaneously to others of the one or more movable portions.

45. The collapsible mold of claim 36, further comprising a static portion from which the one or more movable portions are configured to axially translate.

46. The collapsible mold of claim 45, wherein the static portion comprises one or more projections connected to a base of the static portion.

47. The collapsible mold of claim 46, wherein the one or more projections are configured to form one or more vents in the thermoplastic material.

48. The collapsible mold of claim 46, wherein the one or more projections are retractable.

49. The collapsible mold of claim 36, wherein at least one of the one or more movable portions is flexible.Docket No. 227254-754601 / PCT50. The collapsible mold of claim 36, wherein at least one of the one or more movable portions is rigid.

51. A system for thermoforming a closure for a container, the system comprising:(a) a collapsible mold comprising one or more movable portions configured to axially translate from a first position to a second position, the first position being in contact with a heated thermoplastic material and the second position being spatially retractable from the heated thermoplastic material; and(b) a controlled removal system configured to axially translate the one or more movable portions of the collapsible mold.

52. The system of claim 51, wherein, when each of the one or more movable portions is in the first position, the collapsible mold is configured to form:(a) a first portion configured to form a plug seal of the closure, wherein the plug seal seats against an inner surface of the container;(b) a second portion configured to form an annular wall of the closure, wherein the annular wall seats against a top surface of a rim of the container; and(c) 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.

53. The system of claim 52, wherein the threaded portion of the collapsible mold is shaped to form undercuts in the threads.

54. The system of claim 51, wherein the collapsible mold further comprises a knurled portion configured to form a plurality of knurls onto an exterior of the closure.

55. The system of claim 51, wherein the one or more movable portions comprise one or more projections configured to form one or more vents in the thermoplastic material.

56. The system of claim 54, wherein the one or more projections are retractable.

57. The system of claim 54, wherein the one or more projections are configured to form one or more hinges.

58. The system of claim 51, wherein each of the one or more movable portions is configured to axially translate at a different time than others of the one or more movable portions.Docket No. 227254-754601 / PCT59. The system of claim 51, wherein each of the one or more movable portions is configured to axially translate simultaneously to others of the one or more movable portions.

60. The system of claim 51, further comprising a static portion from which the one or more movable portions are configured to axially translate.

61. The system of claim 60, wherein the static portion comprises one or more projections connected to a base of the static portion.

62. The system of claim 61, wherein the one or more projections are configured to form one or more vents in the thermoplastic material.

63. The system of claim 61, wherein the one or more projections are retractable.

64. The system of claim 51, wherein at least one of the one or more movable portions is flexible.

65. The system of claim 51, wherein at least one of the one or more movable portions is rigid.

66. The system of claim 51, wherein the heated thermoplastic material is selected from the group consisting of: HDPE, PET, PHA, PLA, PETF, or any combination thereof.

67. The system of claim 51, wherein the controlled removal system is spring-loaded, pneumatic, hydraulic, or a combination thereof.

68. The system of claim 51, wherein the controlled removal system comprises a spreader tool configured to be pushed into the collapsible mold to expand at least one of the one or more movable portions during forming of a closure, and then lowered from the collapsible mold to release the closure.

69. The system of claim 51, wherein the controlled removal system is configured to key or hook the one or more movable portions onto a lever connected to a rail that determines a position of a respective movable portion.

70. The system of claim 51, wherein the controlled removal system comprises at least one drive wheel configured to rotate to be positioned with an opening and closing of the collapsible mold, wherein an outward position of the at least one drive wheel is configured force one or more projections out of one of the one or more movable portions to form a closure.Docket No. 227254-754601 / PCT71. The system of claim 51, wherein the controlled removal system operates at a speed ranging between 1-2 mm / s.

72. The system of claim 51, wherein the controlled removal system is configured to lift the closure at an axial rate timed with the translating of the one or more movable portions of the collapsible mold.

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