Modified thread pattern for thermoformed pet container closures

Abstract

A thermoforming process is provided for forming threads on an interior of thermoformed PET container closures. The thermoforming process includes heating a thermoplastic material to a temperature that allows the material to become more flexible and easier to shape. The material is placed into a mold configured to create desired features on the inside of the closure.

Description

Attorney Docket No.: 00229-014W01 / OM0189.PCTMODIFIED THREAD PATTERN FOR THERMOFORMED PET CONTAINER CLOSURESCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 779,781, filed March 28, 2025, the disclosures of which are incorporated herein by reference in their entirety.FIELD

[0002] Embodiments of the present disclosure generally relate to container closures. More specifically, embodiments of the disclosure relate to processes for forming closures with thermoformed Poly ethylene Terephthalate (PET) and High-Density Polyethylene (HDPE).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.

[0004] Various solutions have been proposed to avoid damaging the PET matenal during the thermoforming process. One approach is to form threads from the outside of the mold, although this results in less consistent threads compared to forming them from the inside. Another method is to use alternative processes such as injection molding or compression molding. However, these methods also have their own challenges, and none of them have been able to effectively remove the PET cap from the mold without causing damage.SUMMARY

[0005] In some embodiments, the techniques described herein relate to a process for forming threads inside a thermoformed PET container closure, including: heating a thermoplastic material in a thermoforming machine; thermoforming the thermoplastic material into a closure having at least one thread, the at least one thread having a plurality of gaps therein; and cooling the closure in the thermoforming machine.Attorney Docket No.: 00229-014W01 / OM0189.PCT

[0006] In some embodiments, the techniques described herein relate to a spin core for thermoforming a closure for a container, including, (a) a threaded portion having a helical thread configured to form an outer cylindrical wall of the closure, the outer cylindrical wall including a closure thread; and (b) a plurality of gap forming features disposed along the helical thread, the plurality of gap forming features configured to interrupt the closure thread such that gaps are formed between closure thread segments.

[0007] In some embodiments, the techniques described herein relate to a method of forming a spin core for thermoforming a closure for a container, including, (a) providing a threaded portion having a helical thread configured to form an outer cylindrical wall of the closure, the outer cylindrical wall including a closure thread; and (b) disposing a plurality of gap forming features along the helical thread, the plurality’ of gap forming features configured to interrupt the closure thread such that gaps are formed between closure thread segments. In some embodiments, the techniques described herein relate to a closure formed using this method. In some embodiments, the techniques described herein relate to a sealed container including a container and a closure formed using this method.

[0008] In some embodiments, the techniques described herein relate to a mold for thermoforming a closure for a container, including: (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 having annularly spaced gaps, wherein the outer cylindrical wall extends downward from the annular wall, and w herein the threads of the outer cylindrical wall engage w ith external threads of the container. In an embodiment, a system is provided for thermoforming a closure for a container including the aforementioned mold, a thermoplastic material, and a controlled rotation system including a servo, belt, chain drive system, or combinations thereof.

[0009] The disclosure provides a process for forming threads inside a thermoformed PET container closure, comprising heating a thermoplastic material in a thermoforming machine; thermoforming the thermoplastic material with a mold into a closure having at least one thread, the at least one thread having a plurality of interruption gaps therein; and cooling the closure in the thermoforming machine. In a further example, the thermoplastic material includes any of HDPE. PET, PHA, PLA or any type of polymer that is suitable for forming closures. In another example of the disclosure the thermoplastic material includes heating the thermoplastic material to a temperature that allows the thermoplastic material to becomeAttorney Docket No.: 00229-014W01 / OM0189.PCTmore flexible and easier to shape. In still another example in the disclosure the thermoplastic material includes heating the thermoplastic material to a temperature ranging between about 80°C and about 170°C. In another example herein, the method includes injection molding or compression molding a HDPE or PET material. In yet another example, herein the thermoplastic material includes configuring the mold to create desired features on the inside of the closure. In yet another example described herein the thermoplastic material includes configuring the mold to accommodate the formation of threads on the inside of the closure. In another example, the thermoplastic material includes applying pressure to the thermoplastic material using the thermoforming machine. In still another example, the thermoplastic material includes applying a pressure that is sufficient to shape the thermoplastic material into the closure but not so high as to cause damage to the material. In another example described herein, cooling the closure includes allowing the closure to cool to between room temperature and the glass transition temperature of the thermoplastic material in the thermoforming machine. In certain examples described herein cooling the closure includes providing water cooling channels in the mold to cool the closure. In a further example, providing water cooling channels includes forming a 3D network of cooling channels to reduce the pitch between individual forming portions of the mold. In another example described herein, removing the closure includes using a controlled rotation system to ensure consistent and accurate rotation of the threads. In a further example, using a controlled rotation system includes using any one or more of a servo, a belt, a chain drive system, or any combination thereof. In still a further example, using the controlled rotation system includes operating the controlled rotation system at a speed ranging between about 10 RPM and about 20 RPM. In another example herein, applying clearance includes using a clearance mechanism to ensure a thread path follows the contour of the rotation as the closure is removed from the mold. In a further example, using the clearance mechanism includes providing clearance along the threads to enable smooth removal of the closure from the mold. In still a further example, using the clearance mechanism includes allowing for vents or other interruptions in the closure. In another example, the method further comprises lifting the closure includes using a timing mechanism to lift the closure at an axial rate that prevents deformation and unwanted height variation of the closure. In a further example, using the timing mechanism includes lifting the closure at an axial rate of 1-2 mm / s.

[0010] The disclosure also provides a spin core for thermoforming a closure for a container, comprising, a threaded portion having a helical thread configured to form an outer cylindrical wall of the closure, the outer cylindrical wall including a closure thread; and a lurality ofAttorney Docket No.: 00229-014W01 / OM0189.PCTgap forming features disposed along the helical thread, the plurality of gap forming features configured to interrupt the closure thread such that gaps are formed between closure thread segments reducing contact at gaps and a container thread.

[0011] The disclosure also provides a method of forming a spin core for thermoforming a closure for a container, comprising, providing a threaded portion having a helical thread configured to form an outer cylindrical wall of the closure, the outer cylindrical wall including a closure thread; and disposing a plurality of gap forming features along the helical thread, the plurality of gap forming features configured to intermpt the closure thread such that gaps are formed between closure thread segments.

[0012] The disclosure also provides a mold for thermoforming a closure for a container, comprising a first portion configured to form a plug seal of the closure, wherein the plug seal seats against an inner surface of the container; 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 a threaded portion configured to form an outer cylindrical wall of the closure that comprises threads having annularly spaced gaps, 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.

[0013] The disclosure also provides a system for thermoforming a closure for a container, the system comprising a mold as described herein; a thermoplastic material; and a controlled rotation system that comprises a servo, a belt, a chain drive system, or a combination thereof.

[0014] The disclosure also provides for a closure formed using the spin core of the disclosure.

[0015] The disclosure also provides a recyclable closure comprising a cover wall that seats within the opening of a finish of a container when the closure is mounted onto the finish of the container, an annular wall configured to seat against a top surface of a rim of the finish, an outer cylindrical wall extending downward from a first edge of the annular wall, a plurality of helical thread segments in the outer cy lindrical wall that engage with external threads of the neck of the finish, and a plurality of interruption gaps dispersed between helical thread segments, the interruption gaps defining the ends of each of the plurality of helical thread segments, and wherein each of the interruption gaps comprises a taper angle relative to a radial line extending from an outer diameter of the outer cylindrical wall to a center of the closure. In one example, the recycle closure is formed from a polyester resin. In still a further example, the polyester resin is selected from the group consisting of polyethylene terephthalate, polyethylene furandicarboxylate, or a copolymer of polyethylene terephthalateAttorney Docket No.: 00229-014W01 / OM0189.PCTand polyethylene furandicarboxylate. In still another example, the closure further comprises a plug seal. In yet another example, each helical thread segment is defined by at least an outer radius from the center of the closure and an inner radius from the center of the closure, wherein the taper comprises an angle that connects the outer radius and inner radius. In a further example, the angle is between 10° and 80° (e.g., 45°). In another example, the cover wall is planar. In another example, the cover wall is domed. In certain examples, the closure further comprises a tamper evident (TE) feature connected to the outer cylindrical wall. In a further example, the TE comprises a plurality of foldable flaps. In another example herein, the TE is attached to the outer cylindrical wall by one or more breakable bridges. In yet another example, the closure further comprsies a plurality of knurls on the outer cylindrical wall. In still another example, the TE feature comprises a plurality of knurls. In still another example, each of the interruption gaps comprises a reduced-thickness thread segment having an interruption gap radial thickness less than a thread segment radial thickness. In another example herein, at least a portion of each of the interruption gaps is flush with the outer cylindrical wall. In a further example, the taper extends from the thread segment to the at least a portion of each of the interruption gaps that is flush with the outer cylindrical wall.

[0016] The disclosure also provides a sealed container system comprising a closure as described herein.

[0017] 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

[0018] The draw ings refer to embodiments of the present disclosure in w hich:

[0019] FIG. 1A-D illustrates (A) a line drawing perspective view of an exemplary embodiment of a thermoformed PET container closure including a helical thread segments about a circumference of the closure, according to the disclosure; and (B) a shaded view of the same figure as (A); (C) provides a line drawing perspective view of an exemplary embodiment of a PET container closure depicting additional helical thread segments about the circumference; (D) provides a shaded view of the same figure as (C).

[0020] FIG. 2A-B illustrates (A) a line drawing top view of an exemplary embodiment of a thermoformed PET container closure including a thread about a circumference, and interruption gaps and transitions of the closure; and (B) a shaded view of the figure of (A).

[0021] FIG.3A-B illustrates (A) a partial perspective line drawing view- of an embodiment of a closure of the disclosure comprising a domed closure depicting threads about theAttorney Docket No.: 00229-014W01 / OM0189.PCTcircumference as well as interruption gaps and helical thread segments; (B) provides a shaded view of the same depiction as (A).

[0022] FIG.4A-B illustrate additional views of a closure described herein. (A) provides a bottom line drawing perspective of a closure; (B) illustrates a line drawing of a side view of an embodiment of a closure described herein.

[0023] FIG.5A-B illustrates (A) a side view with a partial diametrical cross-section of an example of a closure mounted to an example of a finish of a container; and (B) a diametrical cross-sectional view of another example of a closure including an external seal for sealing to another example of a finish of a container.

[0024] FIG.6 illustrates an exemplary embodiment of a thermoforming process whereby consistent threads can be formed on a thermoformed PET container closure, in accordance with the disclosure.

[0025] FIG. 7A-B illustrate an embodiment of a mold for thermoforming PET container closures.

[0026] FIG. 8A-B illustrate perspective and cross-sectional views, respectively, of an exemplary embodiment of a thermoforming mold including a thread about a circumference of the mold, according to the present disclosure.

[0027] FIG.9A-B illustrate side views of an exemplary' embodiment of a thermoforming mold including a thread about a circumference of the thermoforming mold in accordance with the present disclosure.

[0028] 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

[0029] The following description is merely exemplary in nature and is not intended to limit the disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0030] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary' skill in the art. In case of conflict, the present document, including definitions, will control. Preferred methods and materials are described below, although methods and materials similar or equivalent to those described herein can be used in practice or testing of the present invention. All publications,Attorney Docket No.: 00229-014W01 / OM0189.PCTpatent applications, patents and other references mentioned herein are incorporated by reference in their entirety. The materials, methods, and examples disclosed herein are illustrative only and not intended to be limiting. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0031] The terms "comprise(s)," "include(s)," "having," "has," "can," "contain(s)," "may" and variants thereof, as used herein, are intended to be open-ended transitional phrases, terms, or words that do not preclude the possibility of additional acts or structures.

[0032] The singular forms "a," "an" and "the" include plural references unless the context clearly dictates otherwise.

[0033] The present disclosure also contemplates other embodiments "comprising," "consisting of and "consisting essentially of," the embodiments or elements presented herein, whether explicitly set forth or not.

[0034] The modifier "about" used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (for example, it includes at least the degree of error associated with the measurement of the particular quantity). The modifier "about" should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression "from about 2 to about 4" also discloses the range "from 2 to 4." The term "about" may refer to plus or minus 10% of the indicated number. For example, "about 10%" may indicate a range of 9% to 11%, and "about 1" may mean from 0.9- 1.1. Other meanings of " about" may be apparent from the context, such as rounding off. so, for example "about 1 " may also mean from 0.5 to 1.4.

[0035] For the recitation of numeric ranges herein, each intervening number there between with the same degree of precision is explicitly contemplated. For example, for the range of 6-9, the numbers 7 and 8 are contemplated in addition to 6 and 9, and for the range 6.0-7.0, the number 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, and 7.0 are explicitly contemplated.

[0036] One skilled in the art will also readily recognize that where members are grouped together in a common manner, such as in a Markush group, the disclosure encompasses not only the entire group listed as a whole, but each member of the group individually and all possible subgroups of the main group. Additionally, for all purposes, the disclosure encompasses not only the main group, but also the main group absent one or more of the group members. The disclosure therefore envisages the explicit exclusion of any one or more of members of a recited group. Accordingly, provisos may apply to any of the disclosed categories or examples whereby any one or more of the recited elements, species, orAttorney Docket No.: 00229-014W01 / OM0189.PCTexamples may be excluded from such categories or examples, for example, for use in an explicit negative limitation.

[0037] In describing elements of the disclosure, the terms “1st,” “2nd,” “first,” “second,” “A,” “B,” “(a),” “(b),” and the like may be used herein. These terms are only used to distinguish one element from another element, but do not limit the corresponding elements irrespective of the nature or order of the corresponding elements.

[0038] As used herein, directional and spatial terms such as “up,” “down,” “upper,” “lower,” “above,” “below,” “top,” “bottom,” “vertical,” “horizontal,” “inward,” “outward,” “proximal,” “distal,” “forward,” “rearward,” “axial,” “radial,” “circumferential,” and the like are used solely for convenience in describing the relative positions, orientations, and relationships of elements as illustrated in the figures and described in connection with exemplary embodiments. These terms are not intended to limit the orientation of the device or any component thereof with respect to gravity, the Earth, or any external frame of reference. Unless otherwise expressly indicated, such terms refer only to relative positions and orientations between components of the device in a reference configuration depicted in the drawings. Accordingly, the device and its components may be oriented in any suitable direction during manufacture, assembly, storage, transport, or use without departing from the scope of the disclosure.

[0039] For example, the terms “down,” “downward,” and “downwardly” generally refer to a direction extending toward a portion of the device identified as being lower in the reference configuration shown in the figures, while “up,” “upward,” and “upwardly” refer to the opposite direction. Similarly, “inward” and “outward” generally refer to directions toward and away from a reference interior region or axis of the device, respectively, while “axial,” “radial.” and “circumferential” refer to directions relative to a reference axis. Such terminology is intended to describe relative spatial relationships between elements and should not be interpreted as requiring any particular absolute orientation.

[0040] Unless otherwise defined, all terms used herein, including technical or scientific terms, have the same meanings as those generally understood by those skilled in the art to which the disclosure pertains. Such terms as those defined in a generally used dictionary are to be interpreted as having meanings equal to the contextual meanings in the relevant field of art.

[0041] The primary problem with the conventional methods for forming threads is that standard part removal by stripping from the mold fails when it comes to PET caps. This is because PET tends to crack or deform under the heat and pressure applied during theAttorney Docket No.: 00229-014W01 / OM0189.PCTthermoforming process. Attempts to form the threads from the outside of the mold result in less consistent threads, while alternatives like injection molding and compression molding have their own challenges. Furthermore, the timing of lifting the closure when the thread forming component is moving is crucial to prevent deformation and unwanted height variation, which is difficult to achieve with the conventional methods.

[0042] Therefore, a need exists for methods or processes to effectively form consistent threads on thermoformed PET caps without damaging the cap during removal from the mold. 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. The disclosure provides processes for forming threads 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 threads when formed from the outside of the mold, and 3) the difficulty7in timing the lifting of the closure when the thread forming component is moving to prevent deformation and unwanted height variation.

[0043] Figures 1A-3B illustrate an exemplary embodiment of a thermoformed PET container closure 100 that is particularly well suited for including one or more threads formed by w ay of the thermoforming processes described herein. In general, the closure 100 may be a monolithic portion of thermoplastic material and produced by thermoforming. The thermoplastic material may comprise a polystyrene such as styrene acrylonitrile (SAN) or acrylonitrile butadiene styrene (ABS), or a polyolefin such as polypropylene (PP) or polyethylene (PE), or a polycarbonate or, in particular, a polyester such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT) or polyethylene furanoate (PEF). Further, in some embodiments, the closure 100 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 100 comprises PET, and the container, which is to be closed with the closure 100, is also made of PET. Further details regarding techniques for forming the closure 100 may be found in PCT Application, entitled “Polyester Resin Closures For Containers,” filed on April 20, 2023, and having application serial number PCT / US2023 / 066008, the entirety of said application being incorporated herein by reference.

[0044] Figures 1A-3B show embodiments of a closure of the disclosure. Referring to FIG. 1A and IB there are shown a line drawing (FIG. 1A) and a corresponding shaded drawing (FIG. IB) of an embodiment of the disclosure. The closure 100 has a cover wall 104 and a side wall 108. Cover wall 104 may be flat or domed (see, e.g., FIG. 3A). The sideAttorney Docket No.: 00229-014W01 / OM0189.PCTwall 108 is integrally connected to the cover wall 104 and oriented transversely to the cover wall 104. The side wall 108 is circumferentially closed. The closure 100 has an interior configured to receive a finish portion of the container to be closed with the closure 100. The interior is partially bounded by the cover wall 104 and the side wall 108.

[0045] The closure 100 includes an annular wall 120 and a cy lindrical wall 124 that extends downwardly from the annular all 120 and surrounds the cover wall 104. Interior surfaces of the annular w all 120 and the cylindrical wall 124 typically comprise a plug seal (not shown) for sealing against an inner surface of a finish portion of the container to be closed with the closure 100. An interior surface of the annular wall 120 may be configured to scale against a top surface of a rim of the finish, w hile an outwardly facing radial surface of the cylindrical wall 124 may be dimensioned for an interference fit with a corresponding inw ardly facing surface of a rim of the finish for sealing. As the closure 100 is threaded onto the finish, the plug seal is forced into or onto a mouth of the finish and into a compressed state in w hich the outw ardly facing radial surface of the cylindrical wall 124 pushes against the inwardly facing surface of finish, thereby forming a seal.

[0046] The closure 100 includes a helical segment arrangement comprising one or more helical thread segments 128 and one or more interruption gaps 110 formed into the side wall 108 for engaging w ith external threads of the finish portion of the container to be closed with the closure 100. For the example, each helical thread segment 128 is separated from an adjacent helical thread segment by an interruption gap 110. The helical thread segments 128 are configured to engage an external thread or external thread segments of a neck finish to secure the closure to the neck and seal the bottle after filling w here the helical thread segments 128 extend into the internal portion of the closure 100. The closure 100 includes one or more helical thread segments 128 formed into the side wall 108 for engaging with external threads of the finish portion of the container to be closed with the closure 100. The closure 100 including helical thread segments 128 for engaging an external thread or external thread segments of a neck finish to secure the closure to the neck and seal the bottle after filling, the helical thread segments 128 extending into the internal portion of the closure 100.Each helical thread segment 128 is defined by at least an outer radius A (see, FIG. 2A), an inner radius B and taper 122 extending to the adjacent interruption gap 110. Each interruption gap 110 is defined by an intermption gap radius that is greater than the inner radius B. For the examples herein, the interruption gap radius is the same as the outer radius A. In such examples, helical thread segments 128 are separated by portions of the side wall 108 that have no threads and are flush with the cylindrical wall 108. In some situations, however, theAttorney Docket No.: 00229-014W01 / OM0189.PCThelical thread segments 128 are separated by raised interruption gaps that have an interruption radius less than the outer radius A but greater than radius B and, therefore, protrude less toward the center of the closure than the helical thread segments 128. In other words, each of the interruption gaps 110 comprises a reduced-thickness thread segment having an interruption gap radial thickness less than a helical thread segment radial thickness of the adjacent thread segment.

[0047] Each taper 122 extends from the outer radius A to the inner radius B at an angle 6 to a radial line extending from the interface between thread segment 128 and the adjacent interruption gap 110, at the outer radius A, to the center of the closure. In some embodiments the angle 0 of the taper 122 is between 10° and 80° (e.g., 15°, 20°, 25°, 30°, 35°, 40°, 45°, 50°, 55°, 60°, 65°, 70°, 75°, 80° or any number between any of the foregoing angles values).

[0048] In one example, the helical thread segments 128 are internally rounded versus pointed. The helical thread segment(s) 128 comprise interruption gaps 110 in helical thread segment(s) 128 such that a helical thread segment(s) 128 has at least one interruption gap 110, for example, as shown in FIG. 1. interruption gaps 110 in the helical thread segments 128 are depicted. Each helical thread segment 128 is defined by at least an outer radius A (see, FIG. 2A), an inner radius B and taper 122. In some embodiments, interruption gap 110 is at a depth sufficient to reduce contact with threads on a container finish and need not extend from the inner radius B to outer radius A. but rather may be of any distance between the radius values of A and B.

[0049] In the illustrated embodiment, the closure 100 includes at least one helical thread segment 128, with one helical thread segment start 132 at the beginning of the helical thread segment 128. In some embodiments, however, the closure 100 may include a plurality of helical thread segments 128, such as, for example, two, three, four, five, six, seven or more helical thread segments distributed uniformly around the side wall 108 of closure 100. As such, each of the plurality of helical thread segments 128 includes one of a corresponding plurality of helical thread starts 132 and a plurality7of interruption gaps 110. In one embodiment, where more than one helical thread segment 128 is present about the circumference of the side wall 108, the plurality of interruption gaps 110 extend downward from the top of the closure such that each helical thread segment 128 is of equal length. In still another embodiment, The transition between the helical thread segment 128 and interruption gap 110 can be by an optional taper 122 such that the taper 122 gradually reduces a helical thread segments 128 indentation to be flush with side wall 108. In some embodiments, taper 122 is not present and the indentation can be an abrupt end to thread 128.Attorney Docket No.: 00229-014W01 / OM0189.PCTIn some instances, the taper 122 may be considered to be part of the interruption gap 110 while, in other circumstances, the taper 122 may be considered to be part of a thread segment 128. The interface between a helical thread segment 128 and an interruption gap 110 may be considered to be at an edge of a thread segment at the radius B where the taper 122 begins and the thread segment 128 has a minimum radius in some situations. In other situations, the interface between a helical thread segment 128 and an interruption gap 110 may be considered to be at the radius A where the thread segment 128 has a maximum radius and the taper 122 ends. Accordingly, the positions of the start and end of the taper 122 may depend on the context and on whether the taper 122 is part of the thread segment 128 or part of the interruption gap 110.

[0050] With continuing reference to Figs. 1A-3B. the closure 100 may be viewed as broadly comprising a threaded portion 136 and a tamper evidence feature 140. As the closure 100 is threaded onto a finish portion of a container, the tamper evidence feature 140 rides over a ledge of the finish portion, clears the ledge, and fits into place beneath ledge. The tamper evidence feature 140 may include a plurality of spaced-apart bridges (not shown) that connect the tamper evidence feature 140 to the threaded portion 136 of the closure 100. In the event that the closure 100 is unthreaded from the finish portion, tamper evidence feature 140 will be retained in position on the container by the ledge of the finish portion. The upward force from unthreading of the closure 100 w ill eventually cause sufficient stress on the bridges that they will break, providing evidence that the closure 100 has been tampered with.

[0051] As shown in Figs. 1A-3B, the closure 100 can includes a plurality of external knurls (not shown) distributed around the circumference of the threaded portion 136. The external knurls serve in particular to improve the grip of the threaded portion 136 of the closure 100. Further, the closure 100 includes a plurality of knurls 144 distributed around the circumference of the tamper evidence feature 140. In addition, the tamper evidence feature 140 can comprise a plurality of foldable flaps 142.

[0052] Referring to FIGs. 2A-2B a top view of closure 100 is provided. FIG. 2A is a line drawing of the top view depicting cover wall 104 (which may be flat or domed), helical thread segment(s) 128, interruption gaps 110 and taper 122. FIG. 2B is a shaded view providing a similar perspective to FIG. 2A. Also show n in FIG. 2A is a first radius A which is the distance from the center of the closure 100 to the external w all 108. The distance between the center of the closure 100 and an internal edge of the helical thread segment is identified by a second radius B.Attorney Docket No.: 00229-014W01 / OM0189.PCT

[0053] FIGs. 3A and 3B provided a partial side view of a domed embodiment of the closure 100. The closure 100 has a cover wall 104 (depicted as domed) and a side wall 108.The side wall 108 is integrally connected to the cover wall 104 and oriented transversely to the cover wall 104. The side wall 108 is circumferentially closed. The closure 100 has an interior configured to receive a finish portion of the container to be closed with the closure 100. The interior is partially bounded by the cover wall 104 and the side wall 108. The closure 100 includes an annular wall 120 and a cylindrical wall 124 that extends downwardly from the annular wall 120 and surrounds the cover wall 104. Interior surfaces of the annular wall 120 and the cylindrical wall 124 typically comprise a plug seal (not shown) for scaling against an inner surface of a finish portion of the container to be closed with the closure 100.An interior surface of the annular wall 120 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 124 may be dimensioned for an interference fit with a corresponding inwardly facing surface of rim of finish for scaling. As the closure 100 is threaded onto the finish, the plug seal is forced into or onto a mouth of the finish and into a compressed state in which the outwardly facing radial surface of the cylindrical w all 124 pushes against the inwardly facing surface of finish, thereby forming a seal. The closure 100 includes one or more internal threads 128 formed into the side wall 108 for engaging with external threads of the finish portion of the container to be closed with the closure 100. The threads 128 comprise interruption gaps 110 in thread(s) 128 such that a thread 128 has at least one gap 110. Where more than one thread 128 is present, each of a plurality of threads 128 includes a plurality of interruption gaps 110.The transition betw een the threads 128 and interruption gaps 110 can be by an optional taper 122 such that the taper 122 gradually reduces a thread 128 indentation to be flush with side wall 108. In some embodiments, taper 122 is not present and the indentation can be an abrupt end to thread 128. Closure 100 may be viewed as broadly comprising a threaded portion 136 and a tamper evidence feature 140. As the closure 100 is threaded onto a finish portion of a container, the tamper evidence feature 140 rides over a ledge of the finish portion, clears the ledge, and fits into place beneath ledge. The tamper evidence feature 140 may include a plurality of spaced-apart bridges that connect the tamper evidence feature 140 to the threaded portion 136 of the closure 100. In the event that the closure 100 is unthreaded from the finish portion, tamper evidence feature 140 will be retained in position on the container by the ledge of the finish portion. The upward force from unthreading of the closure 100 will eventually cause sufficient stress on the bridges that they will break, providing evidence that the closure 100 has been tampered with. The closure 100 canAttorney Docket No.: 00229-014W01 / OM0189.PCTincludes a plurality of external knurls (not shown) distributed around the circumference of the threaded portion 136. The external knurls serve in particular to improve the grip of the threaded portion 136 of the closure 100. Further, the closure 100 includes a plurality of knurls 144 distributed around the circumference of the tamper evidence feature 140.

[0054] As show n in FIG. 4A-B, the closure 100 has a vertical axis 116. The side wall 108 extends along this vertical axis 116. The vertical axis 116 is transverse and in particular perpendicular to the cover wall 104. In some embodiments, the vertical axis 116 comprises an axis of rotational symmetry of the closure 100. In some embodiments, wherein the closure 100 serves as a closure cap for a bottle, the closure 100 is at least approximately cylindrical with the side wall 108 disposed symmetrically around the vertical axis 116. As mentioned above, the tamper evidence feature 140 may include a plurality of spaced-apart bridges 102 that connect the tamper evidence feature 140 to the threaded portion 136 of the closure 100.In the event that the closure 100 is unthreaded from the finish portion, the bridges 102 will break and tamper evidence feature 140 will be retained in position on the container by the ledge of the finish portion. The upward force from unthreading of the closure 100 will eventually cause sufficient stress on the bridges 102 that they will break, providing evidence that the closure 100 has been tampered with. In some embodiments, the closures described herein may require from 10 N to 20 N of force for removal.

[0055] Referring to FIG. 5, a side view with partial diametrical cross section of an example of a thermoformed polyester resin closure 100 mounted to an example of a finish 200 of a container typically used for storing liquid contents, such as still or carbonated drinks, is illustrated. Closure 100 may be made of any of the polyester resins described herein.Closure 100 includes helical thread segments 128 formed into outer cylindrical w all 108 (also referred to herein as a "‘side wall”) of closure 100 for engaging with helical container threads 206 of finish 200. The helical container threads 206 may be continuous threads or may be interrupted threads. Other examples may be configured for snap-on engagement with finish 200. Outer cylindrical wall 124 extends downwardly from annular wall 120.

[0056] Closure 100 includes plug seal 208 (also referred to herein as a ’ hub") for sealing against inner surface 204 of finish 200. Plug seal 208 is depicted. Annular wall 120 may be configured to seal against top surface 210 of finish 200. In some embodiments, an interference fit maybe 0.05 millimeters for a wall thickness of 0.5 millimeters. As closure 100 is threaded onto finish 200, plug seal 208 is forced into the mouth of finish 200 into a compressed state such that plug seal 208 pushes against inwardly facing surface 204 of finish 200, forming a seal, the mouth being the open volume between diametrically opposingAttorney Docket No.: 00229-014W01 / OM0189.PCTinwardly facing surfaces 204 of rim 208 of finish 200. The degree of interference fit and dimensions of plug seal 208 and finish 200 determine the sealing force and thus, these parameters may be adjusted to adjust the degree of sealing force for a given application. The interference fit between plug seal 208 and finish 200 may serve as a sealing feature for sealing closure 100 to finish 200. Plug seal 208 may include chamfer 222 for guiding plug seal 208 past lip 212 of the mouth of finish 200 as closure 100 is capped onto the container.

[0057] Plug seal 208 may be configured to have a relatively wide sealing interface with finish 200, the sealing interface being the contact area between outwardly facing radial surface 214 and inwardly facing surface 204 of finish 200, the sealing interface being designed to bridge defects (for example, scratches) that may be present in finish 200. An example width for the contact area between outwardly facing radial surface 214 and inwardly facing surface of the finish for finish 200 with an inner diameter of 26 millimeters may be 0.7 millimeters, and for finish 200 with an inner diameter of 48 millimeters may be 1.5 millimeters.

[0058] To enable closure 100 to elastically deform in the region of plug seal 208, closure 100 may be designed for a clearance between outer skirt 226 of outer cylindrical wall 204 of closure 100 and corresponding outer surface 214 of rim 208 of finish 200. The amount of clearance may be at least as much as the amount of interference of plug seal 208 with finish 200. For example, the amount of clearance may be 0.05 millimeters or more for an interference of 0.05 millimeters.

[0059] An interference fit 250 may be provided for helical container threads 206 to ensure that closure 100 is tightly fitted to finish 200. An exemplary7interference fit is 0.05 millimeters. Interference fit 250 of threads 206 may also serve as a sealing feature for sealing closure 100 to finish 200. The interference may increase with reduction of the modulus of the material of closure 100.

[0060] Closure 100 includes tamper evidence feature 140, which in FIG. 1 is illustrated in the form of unfolded flaps 142 that engages w ith a tamper evidence ledge 205 of finish 200. As closure 100 is threaded onto finish 200, folded flap 142 rides over ledge 205, and once folded band 142 has cleared ledge 205, fits into place beneath ledge 205. Tamper evidence feature 140 may include a plurality7of spaced-apart bridges 102 that connect tamper evidence feature 140 to main body of closure 100. In the event that closure 100 is unthreaded from finish 200, folded band 142 will be retained in position by ledge 205. The upward force from unthreading of closure 100 will eventually cause sufficient stress on bridges 102 that they will break, providing evidence that closure 100 has been tampered with.Attorney Docket No.: 00229-014W01 / OM0189.PCT

[0061] Optionally, one or more of bridges 102 may be dimensioned such that the breaking stress is greater than the breaking stress of remaining bridges 102 such that the one or more bridges 102 will remain intact to provide a tether to keep closure 100 attached to the bottle upon removal.

[0062] In some embodiments of closure 100, a pull tab may be included in place of folded flap 142 as tamper evidence feature 140. The pull tab may be configured such that the pull tab must be at least partially removed in order to disengage closure 100 from finish 200.

[0063] Closure 100 may be thermoformed with a sheet of PET (or any of the materials described herein) with a thickness of 0.22 millimeters to 1.0 millimeters, preferably about 0.5 millimeters.

[0064] In some embodiments, the interface between annular wall 120 and top surface 210 of rim 208 of finish 200 may serve as a secondary seal. In some embodiments, the secondary seal may be formed and / or enhanced by welding the two surfaces together, such as ultrasonically or via direct application of heat.

[0065] Thermoformed polyester resin closures may be configured with an external seal instead of or in addition to a plug seal. External seals may be easier to thermoform than plug seals, and may provide sufficient sealing for at least some beverages. Optionally, a heat shrinking step may be used to solidify the external seal of the closure.

[0066] Referring to FIG. 5B, a diametrical cross-sectional view of another example of a thermoformed resin closure 300 that includes external seal 380 for sealing to finish 350 of a container is illustrated. Closure 300 may be made of any of the polyester resins described herein. External seal 380 may be provided by an interference fit between an inner surface 302 of the top end of closure 300 and outer surface 354 of mouth 352 of finish 350. An exemplary interference fit may be 0.05 milliliters.

[0067] Similar to closure 100 illustrated in FIG. 5A, closure 300 may be configured for threaded engagement with finish 350 or may be configured for a snap-on pressure fit engagement with finish 350. Closure 300 may also include a tamper evidence feature such as folded band 304 like folded band 142 in closure 100.

[0068] The "caps ’ of the disclosure comprising the interruption gaps 110 reduce the amount of contact between the closure 100 and a container (e g., a bottle) neck. For example, a continuous thread (i.e., lacking interruption gaps 110) provide a substantially continuous contact with a bottle neck thread such that there is an increase in resistance when the cap / closure is turned. The interruption gaps of the disclosure reduce the amount of contactAttorney Docket No.: 00229-014W01 / OM0189.PCTbetween the container thread and closure threads thereby reducing resistance and “binding” of the cap during use.

[0069] The disclosure also provides tooling and methods for making the closure as described herein. For example, FIGs. 7A and 7B provide a mold for forming a closure described herein. The instant mold 700 can include a multitude of features to be molded into the finished closure, including threads 750. For example, the mold can include a thread 750 which can be referred to as a discontinuous thread or helical thread segments. The thread 750 can include a multitude of gap forming features 752 that are arranged about the central axis of the mold 200. In an embodiment, three or more (e.g., 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12) gap forming features 752 can be disposed along the helical thread length of the mold 700 to create a discontinuous helical threads (i.e., helical thread segments) on a closure 100. Gap forming features 752 are depicted to extend continuously transecting the helical threads, however, in certain embodiments the gap forming feature 752 need not be continuous, but rather may be located in each thread. Moreover, gap forming features are depicted as being rectangular / square. it will be understood that gap forming features may be of any geometry’ so long as they create a frictionless thread gap in closure 100. In some embodiments, the gap forming features 752 can be arranged at regular intervals, e.g., every 30 in the case of 12 gap forming features to 120 degrees in the case of three gap forming features. In some embodiments, the gap forming features 752 can have a height that is equal to, or less than, the pitch of the threads 750, such that the mold can be unthreaded from the closure and the gap forming features 752 slide within the formed threads. The gap forming features 752 can be disposed about the mold such that any vents on the mold are not obscured. Alternatively, any number of gap forming features 752 can be used. Further, in some embodiments, the gap forming features 752 may not be arranged in regular intervals about the central axis of the mold.

[0070] In some embodiments, the gap forming features 752 can be formed from the same material as the mold 700. Alternatively, the gap forming features 752 can be formed from an alternative material. The gap forming features 752 may have an outer dimension that is equal to the outer dimension of the threads 750. Alternatively, the gap forming features 752 can be smaller or larger than the outer dimension of the threads. In some embodiments, the gap forming features 752 can be added to a preexisting mold, or can be an integral part of the mold 700. While the gap forming features 752 are shown as rectangular, it is contemplated that they can be any shape and in some embodiments are triangular in shape such that the resulting gap has a desired taper.Attorney Docket No.: 00229-014W01 / OM0189.PCT

[0071] It is contemplated that in some embodiments, the heated HDPE or PET material may, alternatively, be injection molded or compression molded. The mold 700 can be designed with precision to create the desired features on the inside of a closure as described herein, 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 170°C (e.g., 80°, 90°, 100°, 110°, 120°, 130°, 140°. 150°, 160° or 170°, or any value between any of the two foregoing values). Experimental observations have demonstrated that these conditions are optimal for forming threads in container closures.

[0072] In some embodiments, as shown in FIGS. 8A and 8B, the mold 800 can include a first mold 801. or spin core, that is substantially the same as mold 700 of FIGS. 7A and 7B, and a second mold 802. The first mold 801 can include a number of gap forming features 833 shown schematically as black diamonds in the figures. For the sake of brevity, the gap forming features 833 will not be discussed in reference to FIGS. 8A, 8B, 9A, 9B, however it is understood to be within the scope of this disclosure.

[0073] 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 threads 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 threads when formed from the outside of the mold, and 3) the difficulty in timing the lifting of the closure when the thread forming component is moving to prevent deformation and unwanted height variation.

[0074] FIGS 8A-8B illustrate perspective and cross-sectional views, respectively, of an exemplary embodiment of a mold 800 for use in thermoforming closure from a sheet made from a thermoforming material. The mold 800 is particularly well suited for including one or more threads formed by way of the thermoforming processes described herein. In general, the mold is designed with precision to create the desired features on the inside of the closure, including the threads and other internal components. Upon thermoforming of the closure, the mold 800 rotates to unthread from the molded part.

[0075] In some embodiments, as shown in FIGS. 8A-8B, the mold 800 comprises at least a primary portion 801. In some embodiments, the mold 800 comprises a stack of portions, including at least a secondary portion 802 that does not rotate but rather demolds vertically.Attorney Docket No.: 00229-014W01 / OM0189.PCTIn some embodiments, the secondary' portion 802 can be removed from the primary' portion 801 by applying torque to the secondary portion 802. In some embodiments, the secondary portion 802 can be slipped out from the primary portion 801. In some embodiments, the mold 800 is monolithic. In some embodiments, the mold comprises one or more vents 803. The vents 803 allow air that would otherwise be trapped to escape from underneath the sheet that is forming on the mold 800, thereby improving formation of the sheet to the mold 800.

[0076] In some embodiments, the mold 800 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 170°C (e.g., 80°, 90°, 100°, 110°, 120°, 130°, 140°, 150°, 160° or 170°, or any value between any of the two foregoing values). In some embodiments, the mold is made of aluminum, steel, stainless steel, brass, copper, bronze, or various grades, alloys, a tool steel, or combinations thereof. In some embodiments, the aluminum comprises Aluminum T-300, Aluminum 6061-T6, Aluminum 2024-T4, Aluminum 7075-T6, or the like or a combination thereof. In some embodiments, the steel comprises P20 / 30 / 40, H-13, 4140 prehard steel, or the like. In some embodiments, the stainless steel comprises 420 Stainless Steel, Stainless Steel 400 series. HH Stainless Steel or the like. In some embodiments, the copper comprises C-18, high copper alloys 83, 940, 88, 972, 95 or the like. In some embodiments, the bronze comprises SAE660 or the like. In some embodiments, the mold is made of Aluminum Bronze Alloy s 18, 25, 21, 45 or the like. In some embodiments, the tool steel comprises O-l, A-2, A-6, A-8. D-2, D-3, S-7, W-l series, DC-53. Vanadis 4 / 6 / 10, Ml. M2, M3, T-3, T-16, or the like. In some embodiments, the mold comprises a coating for improving resistance to wear or corrosion. In some embodiments, the coating comprises anodized aluminum, PTFE-anodized aluminum, electroless nickel plating, ferrous metals (e.g., NiB, TiN, Ni-PTFE, diamond chrome plating), or the like.

[0077] In some embodiments, as shown in FIGS. 8A-8B, the mold 800 comprises at least a first portion configured to form a plug seal of the resulting closure, such that the plug seal seats against an inner surface of the container. In some embodiments, the first portion comprises a cover wall 804, an annular yvall 820 and a cylindrical wall 824 that extends doyvnwardly from the annular wall 820 and surrounds the cover wall 804.

[0078] In some embodiments, as shown in FIGS. 8A-8B, the mold 800 comprises a second portion configured to form an annular wall of the resulting closure, such that the annular yvall seats against a top surface of a rim of the container. The second portion may include a side wall 808. The side wall 808 is integrally connected to the cover wall 804 and oriented transversely to the cover wall 804. The side wall 808 may be circumferentially closed.Attorney Docket No.: 00229-014W01 / OM0189.PCT

[0079] In some embodiments, as shown in FIGS. 8A-8B, the mold 800 comprises a threaded portion configured to form an outer cylindrical wall of the closure that comprises threads, wherein the outer cylindrical wall extends downward from the annular wall, and wherein the threads of the outer cylindrical wall engage with external threads of the container. In some embodiments, the threaded portion includes one or more external threads 828 formed into the side wall 808 for forming internal threads in the closure. In some embodiments, the external threads 828 are confined to the primary portion 801. The resulting internal threads are configured to engage with external threads of the finish portion of the container to be closed with the closure. The threads 828 may be continuous threads or may be interrupted threads by gap forming features 833. In the illustrated embodiment, the mold 800 includes one thread 828. with one thread start 832 at the beginning of the thread 828. In some embodiments, however, the mold 800 may include a plurality of threads 828, such as, for example, three threads distributed uniformly around the side wall 808 of mold 800. As such, each of the plurality7of threads 828 includes one of a corresponding plurality of thread starts 832.

[0080] In some embodiments, the threaded portion of the 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 a slight draft of a few minutes to -30 degrees. With -10 degrees being relatively easy to release. Alternatively, hinges can be molded with even a positive 190 degree angle, with respect to a base of the mold, which also requires an undercut that must be released.

[0081] In some embodiments, as shown in FIGS. 8A-8B, the mold 800 further includes a knurled portion configured to form a plurality of knurls onto an exterior of the closure. In some embodiments, the knurled portion includes a plurality of knurls 848 distributed around the circumference of the mold 800. In some embodiments, a size and / or a shape of each of the plurality of knurls may be adjusted as needed. In some embodiments, the external knurls 848 are confined to the secondary7portion 802. In some embodiments, the mold 800 may further include a tamper evidence feature 840 distributed around the circumference of the mold 800. In some embodiments, tamper evidence feature 840 is confined to the secondary portion 802.

[0082] In some embodiments, a plurality' of external knurls (not show n) are distributed around the circumference of the external threads 828. The external knurls may serve in particular to improve the grip of the external threads 828 of the resulting closure.Attorney Docket No.: 00229-014W01 / OM0189.PCT

[0083] In some embodiments, the external threads 828 may form partial threads (not shown). In some embodiments, the partial threads can be removed if the thread is interrupted. A partial twist may be an option to slip the closure out through gaps (i. e. , vents) between the threads.

[0084] In some embodiments, the mold 800 comprises a female mold (not shown). Such a female mold would comprise inverting the mold such that the thermoforming material would be inserted into the female mold to impart features from the female mold, rather than the thermoforming material being placed onto the mold to impart features from the mold 800.

[0085] FIGS. 9A-9B illustrate side views of the mold 800. As shown in FIGS. 9A-9B, the mold 800 has a vertical axis 816. The side wall 808 extends along this vertical axis 816.The vertical axis 816 is transverse and in particular perpendicular to the cover wall 804. In some embodiments, the vertical axis 816 comprises an axis of rotational symmetry of the mold 800. Arrows for indicate controlled rotation of the mold 800 and lifting of the mold along vertical axis 816. The controlled rotation allows for precise timing of lifting the thermoformed closure away from the mold 800 when the thread forming component is rotating. In some embodiments, the controlled rotation is performed by applying a torque to the mold 800. In some embodiments, torque on the closure may be distributed throughout the closure. In some embodiments, the closure may be held in place by a clamp on the sheet. In some embodiments, closure may be held in place by neighboring cavities. In some embodiments, applying torque can push the secondary portion 802 of the mold stack out of the sheet. In some embodiments, the secondary portion 802 can be pulled out independently.

[0086] The closures or “caps” of the disclosure can comprise a thermoformed polyester resin. As described above with reference to FIGs. 1A-3B, a closure includes an annular wall that seals against a top surface of a rim of a finish of a container (e.g., a bottle, jar, or tube). The closure further includes an outer cylindrical wall that extends downwardly from the annular wall, the outer cylindrical w all including an outer skirt configured to be spaced outw ardly from an outer surface of the rim of the finish to provide a clearance betw een the closure and the outer surface of the finish. The closure further includes an inner cylindrical wall that extends downwardly from the annular wall, the inner cylindrical wall configured such that an outwardly facing surface of the inner cylindrical w al I has an interference fit with an inw ardly facing surface of the finish of the container for sealing against the inw ardly lacing surface of the finish. The closure further includes a low er wall that extends across a bottom of the inner cylindrical wall.Attorney Docket No.: 00229-014W01 / OM0189.PCT

[0087] The disclosure further provides a closure for a container or a pre-product for such a closure, comprising a closure body, which is of thermoplastic material and produced by thermoforming, having a lid wall and a side wall, wherein the side wall facing away from the lid wall has a front face, and wherein the side wall surrounds an opening of the closure body at the front face.

[0088] The disclosure further provides a method for producing a closure for a container or a pre-product for a closure for a container, in which a starting material in plate form or film form made of thermoplastic material is provided and a closure body is produced by thermoforming the starting material, which has a lid wall and a side wall, wherein the side wall surrounds an opening.

[0089] An example of such a closure is a closure cap for a bottle (for liquid intake) as a container. The disclosure is based on the object of providing a closure or pre-product of the initially mentioned type that can be easily produced by thermoforming with advantageous properties.

[0090] In some embodiments, the disclosure provides a thermoformed resin closure for closing a container including a polyester. The closure includes a top wall (also referred to herein as a “lid wall’’ or “cover wall” (e.g., 104 of FIG. 1A)) having an annular wall 120 that seats against a top surface of a rim of a finish of the container. The closure further includes a cylindrical wall (also referred to herein as a “side wall” (e.g., 108 of FIG. 1A)) extending downwardly from the top wall (in some embodiments, the annular wall) and configured such that an inwardly facing surface of the cylindrical wall has an interference fit with an outwardly facing surface of the rim for sealing against the outw ardly facing surface of the rim.

[0091] In some embodiments, the present disclosure provides an injection molded polyester resin closure for closing a container including a polyester, wherein the polyester resin includes polyethylene furandicarboxylate (“PEF”).

[0092] In some embodiments, the disclosure provides a thermoformed polyester resin closure for closing a container made of a polyester. To provide further a further description of the disclosure with reference to the foregoing figure descriptions, the closure includes an outer layer and an inner layer. The outer layer includes an outer layer annular wall. The outer layer further includes an outer layer outer cylindrical wall that extends downwardly from the outer layer annular wall. The outer layer further includes an outer layer inner depression wall that extends downwardly from the outer layer annual wall. The outer layer further includes an outer layer lower wall that extends across a bottom of the outer layer inner depression wall.Attorney Docket No.: 00229-014W01 / OM0189.PCTthe outer layer lower wall including a first shaped downward depression (e g., a dome). The inner layer includes an inner layer annular wall. The inner layer includes an inner layer outer cylindrical wall that extends downwardly from the inner layer annular wall. The inner layer includes an inner layer inner depression wall that extends downwardly from the inner layer annular wall, the inner layer depression wall configured such that an outwardly facing surface of the inner layer inner depression wail has an interference fit with an outwardly facing surface of the finish for sealing against the outwardly facing surface of the finish. The inner layer includes an inner layer lower wall that extends across a bottom of the inner layer inner depression wall, the inner layer lower wall including a second shaped downward depression that receives the first shaped downward depression. A low er surface of the first shaped downward depression is configured to confront and lock against an upper surface of the second shaped downward depression.

[0093] Moreover, the disclosure relates to a closure element (closure) for a container or a precursor for such a closure element, comprising a closure body which is made of thermoplastic material and is formed by thermoforming, with a lid wall (e.g., an annular wall having an inner cylindrical) and a side wall (e.g., an outer cylindrical wall), wherein the side w all has an end face facing aw ay from the lid wall, and w herein the side wall surrounds an opening of the closure body at the end face.

[0094] The disclosure also relates to a method for producing a closure element for a container or a preliminary product for a closure element for a container, in which a starting material is provided in sheet form or film form from thermoplastic material and a closure body is produced by thermoforming the starting material, which closure body has a lid wall and a side wall, the side wall surrounding an opening. An example of such a closure element is a cap for a bottle (for holding liquids) as a container. WO 2023 / 205730A1, incorporated herein in its entirety, discloses poly-ester resin closure elements for containers produced by thermoforming.

[0095] By thermoforming from a thermoplastic material, closure elements may be produced which have a relatively low wall thickness. This means that the amount of material used may be kept low and the mass of a of such a closure element may be kept relatively low. This also makes it possible to produce closure elements from PET for PET bottles, for example. This makes it easy to recycle the entire system of closure element and bottle.

[0096] In some embodiments, the thermoplastic material of the closure body comprises PET. PET is a common material for containers and in particular for bottles. In the case of a closure element made of PET (optionally with at least one securing element), a standardizedAttorney Docket No.: 00229-014W01 / OM0189.PCTmaterial may be used for the system of bottle and closure element. This allows for high recyclability and, in particular, no plastic separation required during recycling. Furthermore, the closure element may be produced with relatively little material input, low mass and low wall thicknesses.

[0097] In some embodiments, the thermoplastic material comprises a polystyrene, a polyolefin, a polycarbonate, a polyester or a thermoplastic elastomer (such as TPE. TPE-O, TPE-S, TPE-U). In some embodiments, the closure element is used as a cap and in particular a screwable closure cap for a container and in particular a bottle is designed as a container. The corresponding closure element may be effectively produced in large quantities by thermoforming. In some embodiments, the closure element according to the present disclosure is used for a container which is made of the same thermoplastic material as the closure body, such as, for example, PET. This may allow for in high recyclability.

[0098] In some embodiments, the disclosure provides closures formed from a polymer that may be recycled in the same recycling stream as the containers closed by the closures. Examples of suitable polymers from which the closures described herein may be formed may include polyester resins, including bio-modified polyesters, such as co-polymers of PET and polyethylene furandicarboxylate (“PEF,” also referred to as “polyethylene 2.5-furandi carboxylate,” polyethylene 2.5 -furanoate,” or “polyethylene furanoate”), which may include from 0 to 100 mole percent of each of PET and PET (for example, 100 mole percent or less of PET. with the remainder, if any. being PEF), and co-polymers modified by isophthalic acid (“IPA”) or other additives or co monomers. In some embodiments, closures may be made of a polyester resin that includes PEF of up to 90 mole percent (0.90 mole fraction) of the polyester resin. In some embodiments, the PEF may be derived from a reaction of furandicarboxylate (“FDCA”) with ethylene glycol polyethylene glycol (“PEG”) and / or di ethylene glycol (“DEG”). In some embodiments, closures may be made from a polyester resin having a total comonomer content of the reaction product of FDCA with ethylene glycol, PEG, and / or DEG of up to 50 mole percent (0.5 mole fraction) of the polyester resin. The polyester resin may be prepared by a process including melt blending PEE with PET, or by a process that includes reacting ethylene glycol with FDCA. In some embodiments, closures may be made by injection molding or compression molding a polyester resin including a total comonomer content of the reaction product of FDCA with ethylene glycol, PEG, and / or DEG of up to 90 mole percent (0.90 mole fraction) of the polyester resin), or up to 50 mole percent (0.50 mole fraction) of the polyester resin, or from 5 to 25 mole percent (from 0.05 to 0.25 mole fraction) of the polyester resin, or from 12 to 15Attorney Docket No.: 00229-014W01 / OM0189.PCTmole percent (0.12 to 0.15 mole fraction) of the polyester resin. In some embodiments, closures may be made by thermoforming a polyester resin having a total comonomer content of the reaction product of FDCA with ethylene glycol, PEG. and / or DEG of up to 50 mole percent (0.50 mole percent) of the polyester resin, or from 0.5 to 20 mole percent (from 0.05 to 0.20 mole fraction) of the polyester resin, or from 1 to 8 mole percent (from 0.01 to 0.08 mole fraction) of the polyester resin. In some embodiments, a container may be made of a polyester or polyester resin described herein. A closure comprising a polyester or polyester resin described herein may be shrunk to a finish or thermally or ultrasonically bonded to a finish of a container comprising a polyester or polyester resin described herein. Alternatively, a closure may be heat shrunk to a finish.

[0099] In some embodiments, a closure may include a plurality of layers of polyester resins. In some embodiments, an inner layer of a plurality of layers may be more compliant than an outer layer of the plurality of layers to more readily deform to the finish, and provide a better seal. Additionally, or alternatively, an outer layer may provide more aesthetic appeal than an inner layer, which may be more functional than an outer layer. Examples of techniques for preparing a closure including a plurality of layers of polyester resins may include thermoforming, compression molding, and injection molding.

[0100] As described herein, examples of closures made from polyester resin, such as PET and / or PEF, may have a number of advantages over closures made from conventional materials, such as HDPE and / or PP. For example, the polyester resin closures described herein may help to avoid contaminating a recycle stream and may be made from a high fraction of recycled polyester resin, such as recycled PET (“rPET”). The rPET supply may be cleaner and more readily accessible than HDPE supplies. In some embodiments, the polyester resins may be supplemented with bio-based PET (“bio-PET”) or virgin-PET.

[0101] In some embodiments, the polyester resin closures may increase the oxygen and carbon dioxide barrier compared to HDPE and PP, thereby increasing the resulting shelf-life of beverages due to the improvement barrier. In some embodiments, an oxygen barrier of closures including PET may be at least 10 times greater than an oxygen barrier of closures made from HDPE. In some embodiments, the oxygen barrier of closures may even further increase if the closures also include FDCA. In some embodiments, the polyester resin closures may not float (e.g., may have a reduction in buoyancy), and may reduce the tendency of closures to contaminate the environment.

[0102] In some embodiments, the polyester resin closures may provide for lighter container finishes, which may reduce the cost of materials and the amount of material wasted.Attorney Docket No.: 00229-014W01 / OM0189.PCTFurther, because the coefficient of thermal expansion of a polyester resin closure described may closely match the coefficient of thermal expansion of a PET finish of a container, the ability to successfully seal a lighter finish may improve. In some embodiments, during a deformation caused by an external force, such as during storage or transportation, a closure and a finish may deform similarly due to the material of the closure and the finish being similar, resulting in a sealing between the closure and finish remaining intact.

[0103] In some embodiments, because the polyester resin closures are made from a material similar to, or the same as, the container, such as, for example, PET, the closures may be thermally or ultrasonically welded to the finish of the container. In some examples, a polyester resin closure described herein may be welded to a PET finish at one or more locations. In some embodiments, a closure may be welded to a top rim of a finish to provide an additional seal between the closure and the finish. In some embodiments, one or more spot welds may be included so as to provide evidence of lack of tampering. The ability to weld a closure to a PET container may also offer a unique way to meet the tethering requirements of the European Union and considered for the United States. In some embodiments, a polyester resin closure described herein may include a tamper-evident (“TE”) band, a spiral tether, or another feature such as a hinge that is spot welded at one or more terminal points to the container, providing a tether with controlled strength.

[0104] In some embodiments, polyester resin closures described herein may be made via a thermoforming process. Thermoformed closures may be designed to balance wall thickness and tuning for an interference fit with container finishes within the elastic limit of PET or any of the other polymers described herein, such as by, for example, including a plug seal (also referred to herein as a ‘‘hub’') or an external seal (e.g., an olive seal). Because of the relatively higher stiffness of polyester resins, such as PET, compared to HDPE and PP (for example, on the order of two times higher), the seal designs for conventional HDPE and PP closures may be ineffective for thermoformed polyester resin disclosures described herein, because the seal designs for conventional HDPE and PP closures rely upon a relatively high level of elastic deformation that is generally not achievable with thermoformed polyester resin closures described herein. Accordingly, In some embodiments, the seal configurations of thermoformed polyester resin closures may be tailored to provide sufficient sealing with less material strain.

[0105] In some embodiments, the thermoforming is done using a thermoforming machine, which shapes the material into the desired size and shape. A thermoforming machine may include a mold, which may be a male mold or a female mold. The male moldAttorney Docket No.: 00229-014W01 / OM0189.PCTmay matches a shape of a desired interference with the finish while accounting for shrinkage. The features of the closure that may provide the interference and clearance with the finish may be in contact with the mold. A suitable mold can be designed using the foregoing descriptions of the closures and is within the skill of one of skill in the art.

[0106] In some embodiments, a mold in a thermoforming machine comprises a female mold. Such a female mold would comprise inverting the mold such that the thermoforming material would be inserted into the female mold to impart features from the female mold, rather than the thermoforming material being placed onto the mold to impart features from the mold. In some embodiments, a mold comprises a female mold, which is then penetrated with a male mold to compress a formation of features, e.g., threads, intermption gaps, knurls etc. into place. Subsequently, the female portion of the mold may be unscrewed from the male mold. In some embodiments, the closure is trimmed from the multilayer structure as a final part or an intermediate part with features on the periphery designed for forming tamper evidence. In some embodiments, a closure of the present disclosure is cooled within a thermoforming machine.

[0107] In some embodiments, a thermoforming machine comprises a rotary thermoforming machine. Rotary thermoforming machines may serve as an alternative to thermoforming closures in a previously formed sheet that is subsequently heated, such that parts may be formed from a thermoplastic material out of the molten state, as a result, parts may be extruded like a sheet that is quenched onto a chilled mold. Rather than forming only a sheet, the chilled mold, typically in the form of a roller or wheel, may also include any number of intricate parts (e.g., threads) for forming closures as segments on the roller. This works particularly well for positive molded parts, also known generally as male mold components. Similar to forming on a flat mold, individual closures with threads may be rotationally removed from a sheet after it is cooled. Such removal may be driven by rotation of a cam or gear w ithin a roller. This method may allow for high fidelity formation of the part and any engravings on the part. In some embodiments, the thermoforming machine comprises multiple rotary thermoforming machines in series

[0108] In some embodiments, a diameter of a roller or wheel may is matched to an extrusion rate and the part thickness. For example, as a thickness of an extruded sheet decreases (e.g., from 1 mm to 0.5 mm), the parts may need to be removed by rotating off at a faster rate to accommodate the larger material. In some embodiments, the removal may be timed with a cooling rate of the thermoplastic material and a rotational step of the parts. In some embodiments, the formation of knurls (also referred to herein as ‘’corrugation”) on theAttorney Docket No.: 00229-014W01 / OM0189.PCTformed parts may be performed with another roller mated and timed to coin knurls on outer portions of the parts. If not trimmed in place, trimming of the parts from the sheet may be performed in a second station. In some embodiments, design of the mold, roller, and part may allow room for cooling the roller, which, for example, may be performed using chilled water. With advances in additive manufacturing of steels or other alloys, some mold components may be generated by additive manufacturing to get around standard machining limitations that otherwise may cause excessive skeleton scrap.

[0109] In some embodiments, a rotary thermoforming machine comprises a hinged wheel or roller 2601 for receiving an extrusion die or sheet, a screen changer / vacuum pump, and a press. In some embodiments, the rotary thermoforming machine comprises a rotary mold system. In some embodiments, the rotary thermoforming machine rotates at a desired speed, such as, for example, a speed less than 1 RPM, or a speed ranging between about 1 and about 5 RPM, between about 5 and about 10 RPM, between about 10 and about 20 RPM, between about 20 and about 30 RPM, between about 30 and about 40 RPM, between about 40 and about 50 RPM. between about 50 and about 60 RPM, between about 60 and about 70 RPM, between about 70 and about 80 RPM, or greater than 80 RPM.

[0110] In some embodiments, closures described herein may be made by vacuum forming. In some embodiments, closures described herein may be made via pressure-assisted vacuum forming at pressures up to 4 bar, preferably up to 24 bar, and more preferably up to 40 bar. In some embodiments, a thermoformed polyester resin closure with a plug seal may include a relatively wide sealing surface that may be designed to bridge defects (for example, scratches) that may be present in the finish of a container. By contrast, plug seals of conventional HDPE and PP closures take advantage of the relative softness of the HDPE and PP material and are designed with relatively high levels of elastic deformation that result in relatively smaller areas of sealing contact with the finish. In some embodiments, a polyester resin closure described herein, such as a thermoformed polyester resin disclosure, may include a sealing surface of a plug seal w ith a width of 0.7 millimeters that may be configured for a finish with an inner diameter of 26 millimeters, and a width of 1.5 millimeters that may be configured for a finish with an inner diameter of 48 millimeters.

[0111] In some embodiments, a plug seal (also referred to herein as a “hub’’) of a closure described herein may be configured for providing an interference fit with a finish, such that a sealing surface of the closure may provide sufficient pressure against a mating surface of the finish and provide sufficient sealing, including for containing pressurized contents, such as carbonated liquids. An amount of interference may refer to a difference between a radius of aAttorney Docket No.: 00229-014W01 / OM0189.PCTsealing surface of a closure and a corresponding sealing surface of a finish. The amount of interference may vary depending on a diameter of a finish and a wall thickness of a closure. In some embodiments, an amount of interference may range from 0.02 millimeters to 0.2 millimeters for material thicknesses in a range of from 0.2 millimeters to 0.5 millimeters. In some embodiments, an amount of interference for a closure thermoformed from a sheet of PET having a thickness of 0.5 millimeters may be 0.05 millimeters. An amount of interference may be adjusted, for example by changing a behavior of the polyester resin such as by including FDCA and / or DEG, such that a softer polymer may result in a larger interference fit and / or a larger thickness. The values for interference disclosed herein are nominal interference values provided as examples, and variations from the disclosed values may occur due to manufacturing variability.

[0112] In some embodiments, a polyester resin closure described herein may be thermoformed from a sheet of polyester resin described herein having a thickness of from 0.20 millimeters to 2.00 millimeters. In some embodiments, a sheet of polyester resin may have a thickness of from 0.20 millimeters to 1.95 millimeters, or to 1.90 millimeters, or to 1.85 millimeters, or to 1.80 millimeters, or to 1.75 millimeters, or to 1.70 millimeters, or to 1.65 millimeters, or to 1.60 millimeters, or to 1.55 millimeters, or to 1.50 millimeters, or to 1.45 millimeters, or to 1.40 millimeters, or to 1.35 millimeters, or to 1.30 millimeters, or to 1.25 millimeters, or to 1.20 millimeters, or to 1.15 millimeters, or to 1.10 millimeters, or to 1.05 millimeters, or to 1.00 millimeters, or to 0.95 millimeters, or to 0.90 millimeters, or to 0.85 millimeters, or to 0.80 millimeters, or to 0.75 millimeters, or to 0.70 millimeters, or to 0.65 millimeters, or to 0.60 millimeters, or to 0.55 millimeters, or to 0.50 millimeters, or to 0.45 millimeters, or to 0.40 millimeters, or to 0.35 millimeters, or to 0.30 millimeters, or 0.25 millimeters; or from 0.25 millimeters, or from 0.30 millimeters, or from 0.35 millimeters, or from 0.40 millimeters, or from 0.45 millimeters, or from 0.50 millimeters, or from 0.55 millimeters, or from 0.60 millimeters, or from 0.65 millimeters, or from 0.70 millimeters, or from 0.75 millimeters, or from 0.80 millimeters, or from 0.85 millimeters, or from 0.90 millimeters, or from 0.95 millimeters, or from 1.00 millimeters, or from 1.05 millimeters, or from 1.10 millimeters, or from 1.15 millimeters, or from 1.20 millimeters, or from 1.25 millimeters, or from 1.30 millimeters, or from 1.35 millimeters, or from 1.40 millimeters, or from 1.45 millimeters, or from 1.50 millimeters, or from 1.55 millimeters, or from 1.60 millimeters, or from 1.65 millimeters, or from 1.70 millimeters, or from 1.75 millimeters, or from 1.80 millimeters, or from 1.85 millimeters, or from 1.90 millimeters, or from 1.95 millimeters to 2.00 millimeters; or any range that may be formed from any two of theAttorney Docket No.: 00229-014W01 / OM0189.PCTforegoing numbers, including any subranges therebetween. Preferably, a sheet of polyester resin may have a thickness of from 0.50 millimeters to 0.90 millimeters, including any of 0.50 millimeters. 0.55 millimeters, 0.60 millimeters, 0.65 millimeters. 0.70 millimeters, 0.75 millimeters, 080 millimeters, 0.85 millimeters, or 0.90 millimeters, including any ranges or subranges therebetween. In some embodiments, a desirable or preferable thickness of a sheet of a polyester resin described herein used to prepare a polyester resin closure described herein may be a determinable function of a diameter of a polyester resin closure.

[0113] In some embodiments, so as to allow a plug seal of a closure described herein to deform when engaging a finish, a thermoformed polyester resin closure may be configured with sufficient radial clearance between an outer surface of the finish and an outer wall of the closure, which encloses the outer surface of the finish. Without a radial clearance, a plug seal of a closure may not be able to fully insert within a finish, or stress on a closure may be high enough to cause failure.

[0114] In some embodiments, a thermoformed polyester resin closure described herein may be configured with an external seal that seals with an outer surface of a mouth of a finish. The external seal may be achieved with an interference fit with the finish. An amount of interference may depend on the application. Examples of interferences and wall thicknesses disclosed above for the plug seal may be used for the external seal. In some embodiments, a sealing of the external seal may be enhanced by taking advantage of an ability of a polyester resin to heat shrink by heat shrinking a closure after capping.

[0115] To achieve a suitable interference of a seal, such as a plug seal and / or an external seal, with the finish and, in some embodiments, a suitable clearance between an outer wall of a closure and a finish, the dimensions of the interference and the clearance may be well controlled during manufacture by thermoforming a closure using a male mold that matches a shape of a desired interference with the finish while accounting for shrinkage. The features of the closure that may provide the interference and clearance with the finish may be in contact with the mold.

[0116] Because thermoformed polyester resins are relatively stiff, a sealing surface of a polyester resin closure may have a relatively low surface roughness. In some embodiments, a low surface roughness may be achieved by polishing regions of a thermoforming mold that form the sealing surfaces. In some embodiments, portions of a thermoforming mold that do not form the sealing surfaces of the closure are not polished, or are not polished to the same degree as portions that do form the sealing surface so as to avoid a closure sticking to theAttorney Docket No.: 00229-014W01 / OM0189.PCTmold and being difficult to release. Examples of a roughness of sealing surface(s) of a closure may include about 0.2 microns (an Ra value of 0.2 or an N4 finish).

[0117] In some embodiments, a seal, a thread-engagement, and / or a TE band of a polyester resin disclosure described herein may be configured to provide an opening torque in a range of from 0.45 N-m to 1.24 N m, and preferably 1.02 N-m. In some embodiments, a closure may be configured to provide a pressure retention of less than or equal to 2 bar, and preferably less than or equal to 10 bar.

[0118] In some embodiments, a polyester resin used in thermoformed closures described herein may include some amount of FDCA and / or DEG, which may provide numerous advantages. For example, FDCA and DEG may interfere with cry stal formation, so resulting material may have a longer processing window in which to form features on the closure. Additionally, including FDCA and / or DEG may make material of a closure sufficiently different from material of a finish such that the closure docs not fuse to the container during storage. Additionally, including FDCA and / or DEG may lower a modulus of material of a closure, which may allow for higher material strains, and higher material strains may be useful for increasing a seal between a closure and a finish.

[0119] In some embodiments, a closure may be made by injection molding or compression molding a polymer resin. In some embodiments, the polyester resin may include some amount of FDCA and / or DEG. The FDCA and / or DEG content may sufficiently reduce the modulus of the material such that a closure may easily eject from various cavities of a mold. For example, a modulus of the amorphous phase of the material may be in the range of 1 to 3 GPa. An increased FDCA content may increase the processing window such that ejection of a closure is easier, because the polyester resin may remain soft for a longer period of time. The amount of FDCA and / or DEG in a polyester resin that is submitted to injection molding or compression molding may be relatively higher than an amount of FDCA and / or DEG in a thermoformed closure because of a need for greater compliance in injection molding or compression molding. In some embodiments, an ability of a material to flow during injection molding or compression molding may be increased by limiting an intrinsic viscosity of the material. Examples of methods of limiting an intrinsic viscosity of the material may include limiting the duration of solid-state polymerization of the polyester resin after synthesizing the polyester resin. In some embodiments, an intrinsic viscosity may be in a range of from 0.4 dL / g to 0.7 dL / g. A higher intrinsic viscosity may lead to more toughness in the final closure. In some embodiments, an intrinsic viscosity in the range of Irom 0.8 dL / g to 1.2 dL / g may be beneficial for toughness. A bimodal resin may provide benefits from bothAttorney Docket No.: 00229-014W01 / OM0189.PCTof a low viscosi polyester and a high viscosity polyester to impart both beneficial flow and toughness characteristics. Similar to thermoformed closures, by including FDCA and / or DEG in a polyester resin closure described herein, the closure material may be made sufficiently different from a finish material such that the closure may not fuse to the container during storage. Further, by including FDCA and / or DEG in a polyester resin closure described herein, the modulus of the closure material may be lowered, which may allow for higher material strains, and which may increase the seal between the closure and the finish. Further, by including FDCA and / or DEG in a polyester resin closure described herein, the comonomers may also lower the melting point, allowing reduced energy for bonding or intentional sealing using heat as is used with inductive seals on metalized film.

[0120] In some embodiments, a movable core component may be used in injection molding or compression molding in order to reduce the need of warm threads so as to strip stiff PET, which is conventionally performed with injection molded HDPE. In some embodiments, an FDCA-. PEG-, and / or DEG-modified polyester resin may be used in combination with a movable core.

[0121] In some embodiments, closures may be colored using dye or dyeing processes that are compatible with recycling. For example, a dye used to color a closure may be compatible with recycling. In some embodiments, a dye or an ink may be removable via washing. In some embodiments, a nanocoating may be deposited on a surface of a closure.

[0122] Closures may be configured to fit custom or industry standard finishes. Examples of industry standard thread finishes may include 26 / 22, 29 / 25, 29 / 21, 28PCO1881, 30 / 25, 38 / 33, and 48 mm.

[0123] 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 IP A. 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.Attorney Docket No.: 00229-014W01 / OM0189.PCT

[0124] 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 than 10 mole % FDCA, or less than 9 mole % FDCA, or less than 8 mole % FDCA, or less than 7 mole % FDCA, or less than 6 mole % FDCA, or less than 5 mole % FDCA, or less than 4 mole % FDCA, or less than 3 mole % FDCA. or less than 2 mole %, or less than 1 mole % FDCA, or an amount in a range formed from any two of the foregoing numbers, including all ranges and subranges therebetween. In 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.

[0125] In some embodiments, the copolymers provided herein may include repeating units (L), (M), and (N), or any salts thereof:

[0126] 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 toAttorney Docket No.: 00229-014W01 / OM0189.PCT50.0 mol %, or to 45.0 mol %, or to 40.0 mol % or to 35.0 mol %, or to 30.0 mol %, or to 25.0 mol %, or to 20.0 mol %, or to 15.0 mol %, or to 10.0 mol %, or to 9.5 mol %, or to 9.0 mol %, or to 8.5 mol %, or to 8.0 mol %, or to 7.5 mol %, or to 7.0 mol %, or to 6.5 mol %, or to 6.0 mol % of the copolymer; or from 6.5 mol %, or from 7.0 mol %, or from 7.5 mol %, or from 8.0 mol %, or from 8.5 mol %, or from 9.0 mol %, or from 9.5 mol %, or from 10.0 mol %, or from 15.0 mol %, or from 20.0 mol %, or from 25.0 mol %, or from 30.0 mol %, or from 35.0 mol %, or from 40.0 mol %, or from 45.0 mol %, or from 50.0 mol %, or from 55.0 mol %, or from 60.0 mol %, or from 65.0 mol %, or from 70.0 mol %, or from 75.0 mol %, or from 80.0 mol %, or from 85.0 mol % to 90.0 mol % of the copolymer; or any range made from any two of the foregoing numbers, including any subranges therebetween. In 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.

[0127] Repealing unit (M) is may be based on terephthalic acid (“PT A” 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 fromAttorney Docket No.: 00229-014W01 / OM0189.PCT94 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.

[0128] 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.

[0129] 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 by-products and may improve 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 ty pical, 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.

[0130] 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 cry stallization additives such as graphene.

[0131] In some embodiments, a PEF component may have less entanglement density than PET. In some embodiments, the PETF provided herein may have low PEF yellowing due to low FDCA fractions used. In some embodiments, pellet blending for PETF concentration may be another route to PET with a low mole percent of FDCA.

[0132] 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 some embodiments 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.Attorney Docket No.: 00229-014W01 / OM0189.PCT

[0133] 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.

[0134] 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.

[0135] 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. Further, because the reaction temperature of the SSP process is lower than melt polymerization, thermal degradation of the polymer may be minimal.

[0136] 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.

[0137] The main reaction in SSP is polyesterification, a result of the dehydration reaction between carboxyl and hydroxy l 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.

[0138] 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 dependentAttorney Docket No.: 00229-014W01 / OM0189.PCTupon a size of a polymer chip and there may be a molecular weight gradient from a surface to a center of a polymer chip.

[0139] In some embodiments, toners may be used to adjust a color of the resulting PETF. 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.

[0140] The present disclosure additionally provides methods of sterilizing closures and containers described herein. In some embodiments, a method of sterilizing a closure and a container described herein may include exposing the closure to a source of electromagnetic radiation capable of inactivating pathogens. Exposure of the closure to the source of electromagnetic radiation may be enhanced by the transparency of the closure. The closure may be exposed to the source of electromagnetic radiation before or after the closure is applied to the container. Electromagnetic radiation may be capable of inactivating pathogens. For example, electromagnetic radiation may be of a wavelength of from 200 to 300 nanometers. In some embodiments, the exposing may be for a duration from 1 minute, or from 2 minutes, or from 5 minutes, or from 10 minutes, or from 15 minutes, or from 20 minutes, or from 25 minutes to 30 minutes or more; or from 2 minutes to 5 minutes, or to 10 minutes, or to 15 minutes, or to 20 minutes, or to 25 minutes, or to 30 minutes or more; or any range made from any two of the foregoing numbers, including any subranges therebetween. In some embodiments, the source of electromagnetic radiation may be of a wavelength of 253 nanometers to 254 nanometers. In some embodiments, the source of electromagnetic radiation may be of a wavelength of from 255 nanometers to 280 nanometers. In some embodiments, the source of electromagnetic radiation may be of a wavelength of about 230 nanometers. In some embodiments, the source of electromagnetic radiation may be of a wavelength of less than 10'7meters. In some embodiments, the source of electromagnetic radiation may be of a wavelength of less than 10'11meters. In some embodiments, the source of electromagnetic radiation may be of a wavelength of up to 10’6m. The source of electromagnetic radiation may also be of a wavelength within a range formed by any two foregoing wavelengths, including any subranges therebetween. In some embodiments, the exposure may be to bursts of electromagnetic radiation of the same or varying wavelengths in a series. Examples of sources of electromagnetic radiation may include a low-pressure mercury lamp, ultraviolet light-emitting diodes, and a pulsed-xenonAttorney Docket No.: 00229-014W01 / OM0189.PCTlamp. In some embodiments, the closure may include an antimicrobial coating on an outer surface or on an inner surface.

[0141] In some embodiments, a method of sterilizing the closure may include: exposing the closure to a source of electromagnetic radiation capable of inactivating pathogens. In some embodiments, the method may further include applying the closure to the container before the exposing. In some embodiments, the method may further include applying the closure to the container after the exposing. In some embodiments, the source of electromagnetic radiation may be of a wavelength of from 200 to 300 nanometers. In some embodiments, the closure may include an antimicrobial coating on an outer surface and / or an inner surface.

[0142] In some embodiments, a method of sterilizing the closure may include: exposing the closure to a source of electromagnetic radiation capable of inactivating pathogens. In some embodiments, the method may further include applying the closure to the container before the exposing. In some embodiments, the method may further include applying the closure to the container after the exposing. In some embodiments, wherein the source of electromagnetic radiation may be of a wavelength of from 200 to 300 nanometers. In some embodiments, wherein the closure may include an antimicrobial coating on an outer surface and / or an inner surface.EXAMPLES

[0143] The present disclosure may be better understood in connection with the following Examples. In addition, the non-limiting examples are an illustration. The person skilled in the art will appreciate that it may be necessary to vary the procedures for any given example of the present disclosure, e.g., vary the order or steps and / or the chemical reagents used.EXAMPLE 1Thermoforming of PET Closures

[0144] Herein is described the development of a replacement of injection molded HDPE / PP-based PCO 1881 plastic bottle caps with a PET closure thermoformed from sheets of PET.

[0145] A design for the mold for thermoforming the closure was developed in order to allow for demolding of dissimilar geometry without entrapment. A CAD program. Solid Works, was utilized to develop a mold that could be three-dimensionally printed and communicated to stakeholders. Three-dimensional printing of initial prototy pe molds allowed for the trial of several concepts, economically, with rapid turn-around of mold revisions. Rough surfaces that would translate to the finished thermoformed closure, and cause issuesAttorney Docket No.: 00229-014W01 / OM0189.PCTwith seal integrity, were polished out using a multi-step polishing process starting at 800 Grit and ending at an 80,000 Grit jewelry polishing compound. The final thermoformed product was cut-out utilizing a cutting die and tested for performance against industry standards.

[0146] Engineering considerations included temperature control, an aluminum mold, an external pressure apparatus, and seal testing.

[0147] Temperature Control: PET is a crystalline plastic that has unique properties while being healed. PET enters its glass transition range, becoming malleable and clear, from 67-80°C (153-76°F). With time, PET crystallizes, becoming white in color and brittle, between 80-260°C (176-500°F). PET melts al 260°C (500°F). Thus, PET is versatile in usage but may have limitations. The molding machine has a maximum temperature of 457°C (855°F) and may heat the plastic loo fast. Therefore, a variable resistor was inserted onto the molding machine to manage the temperature control to have more accurate temperatures and to be able to control molding of the PET easier.

[0148] Aluminum Mold: High Thermal Conductivity, or quick heat transfer, causes heat from PET during molding to be whisked away very quickly for fast cooling of the PET closure and fast cooling of the mold.

[0149] External Pressure Apparatus: Vacuum within the machine was needed to draw hot plastic into the crevices of the mold. Maximum vacuum that may be achieved is 1 bar (14 psi). Due to working in the glass range of the PET, more pressure w as used to form sharp angles found on the mold. An external pressure apparatus may allow for a range of external pressures, wherein diminishing returns in the formation of the plastic around the mold were encountered after reaching 4.1 bar (60 psi). With the addition of the 4.1 bar (60 psi) external pressure along with the 1 bar (14 psi) internally, the plastic may form easily around the mold. Higher external pressures may further improve the definition of part features.

[0150] Testing for a Seal: Testing for a leak in the seal requires a way to generate pressure within the caps. A pressure testing apparatus was created to create the pressure on the cap and, then using w ater, look for air bubbles leaking from the caps.

[0151] The testing performed on the closures included torque testing, weights and measures (for example, based on thread depth, and cap weight), and seal testing. Testing was performed to determine the crystallization point of the material. Excess heat can create a rapid crystallization transition phase that was difficult to control. A resistive control to the JT-018 was added to control the heat for repeated trials.

[0152] Table 1 provides crystallization data (Cycle Time for Forming PET Plastic). The temperature of the heater was at the heater’s maximum temperature for all trials, which wasAttorney Docket No.: 00229-014W01 / OM0189.PCTapproximately 468.3° C (875° F). The level from heater was mid-way between the mold and the heater.TABLE 1Vacuum TimeFormation of Part Time Under Heat Crystallized While Forming10% 24 sec 3 sec 100% 15% 22 sec 3 sec 100% 20% 21 sec 5 sec 85%90% 18 sec 5 sec 0%50% 12 sec 5 sec 0%30% 18 sec 18 sec 0%70% 19 sec 19 sec 0%90% 19 sec 1 sec 10%90% 16 sec 1 sec 0%90% 20 sec 1 sec 5%

[0153] A device was constructed to allow7for the application of external pressure during the forming process. Vacuum processing was limited to 1 atm (1.01 bar) of differential pressure under seal conditions. The modified system allowed for the application of up to an additional 10 bar of differential pressure to force greater forming detail. Trials showed 4 bar to be sufficient. Table 2 summarizes the testing data.Attorney Docket No.: 00229-014W01 / OM0189.PCTTABLE 2Final Testing Torque and Seal Data (Heater at 288° C for 21 sec)ThermoSeal Closing Depth offormingPressure Torque ThreadWeight (g) Bell Comments Achieved Achieved FormationPressure(bar) (Nm) (mm)(bar)0.414 1,018 0.485 0.79 4.151.241 1.356 0.6 0.82 4.151.379 0.946 0.43 0.86 4.152.413 2.599 0.69 0.8 4.150.000 0.847 0.49 0.8 4.150.138 0.508 0.375 0.81 4.152.413 0.000 0.00 0.8 4.15 Catastrophic Rupture 0.517 0.226 0.44 0.83 4.151.724 1.164 0.7 0.8 4.151.793 1.977 0.415 0.8 4.150.000 0.701 0.1 0.8 4.15 Visual Malformation 0.000 0.655 0.1 0.74 4.15 Visual Malformation 0.000 0.169 0.1 0.72 4.15 Visual Malformation 0.000 0.260 0.1 0.69 4.15 VisualMalformations

[0154] A correlation was observed between closing torque and seal pressures. As closing torque increases or decreases the ability to hold a seal has a proportional relationship.

[0155] Improvements to thread detail were realized in the seal when external pressure was applied during the thermoforming process. A correlation may be seen between increased seal pressure and produced thread torque.

[0156] Finished thermoformed caps were reviewed under a polarized film to reveal lines of stress and material deformation from the thermoforming process.

[0157] Other films were analyzed to validate the thermoforming process. These materials failed to develop a torque or ability to hold pressure, but the analysis showed nearly fully developed thread detail. Thus, modifications to increase pressure on thermoforming machine could lead to an increased performance with the thicker and stiffer PET material.EXAMPLE 2Injection Molded PET Closure

[0158] In some embodiments, closures may be injection-molded polyester resins, such as polyester resins having an FDCA and / or DEG content that sufficiently increases aAttorney Docket No.: 00229-014W01 / OM0189.PCTcompliance of the polyester resin material relative to PET to enable the material to be injection-molded. In some embodiments, a closure is of a standard injection-molded configuration (in other words, a closure has a similar shape to injection-molded HDPE and PP closures).

[0159] In some embodiments, an injection-molded closure is configured similarly to a standard injection-molded HDPE or PP closure but with lower wall thicknesses to reduce the relative stiffness of the closure. In addition to wall thickness, an interference fit may be reduced as discussed for the range used for thermoformed PET closures in order to accommodate the relatively higher stiffness of PET or co-monomer-modified polyester.EXAMPLE 3Copolymer for Closures Produced Via Synthesis of 2% FDCA in PET

[0160] In some embodiments, a copolymer suitable for closures was produced via polymerization of 2% FDCA in PET and SSP. The process of synthesizing the copolymer PET with 2% FDCA from PTA (or TP A) and EG was divided into two stages. The transesterification stage went on until the temperature of the top of the distillation was below 90°C, and the mixture was clear. Esterification was followed by polycondensation. During the course of synthesis, the reaction was monitored based on the amount of water produced and collected in a buffer tank. About 369 milliliters of water was recovered. The material was extracted from the reactor when the intrinsic viscosity reached approximately 0.55 dL / g based on torque calibration. The intrinsic viscosity may be increased using solid state polymerization, which further improves the performance of the prepared material for injection molding applications. Tables 3 and 4 below provide the reaction conditions in the esterification reactor and polycondensation reactor, respectively.TABLE 3EsterificationEsterification ReactorMaterials Amount TPA 1696g FDCA 33 g EG 970 g Triethylamine ("TEA") 0.10 mL (50 ppm)Final PropertiesTime 5 h Water collected 369 mLTemperature of the process 260° CAttorney Docket No.: 00229-014W01 / OM0189.PCTTABLE 4PolycondensationPolycondensation ReactorMaterials Amount Antimony dioxide 0.84 g (350 ppm) Phosphoric Acid 0.16 mL (50 ppm) Cobalt acetate tetrahydrate 0.42 g (50 ppm)Final PropertiesTime 3 hTemperature of the process 280° CEXAMPLE 4Impact of FDCA Fraction on Cry stallization

[0161] An impact of the amount of FDCA present in a copolymer on crystallization in a polyester resin copolymer suitable for closures was demonstrated. Specifically, as the FDCA fraction was increased, the rate and degree of crystallization in PET was observed to decrease.

[0162] Table 5 provides DSC results that demonstrate (1) an increase in Tg with FDCA fraction, (2) an increase in Tm. and (3) a reduction in % crystallinity.TABLE 5DSC ResultsFDCA Tg (° C) Tc(° C) Tm (° C) % Crystallinity (Weight %)0 74.01 122.58 250.12 12 0.50 73.25 127.51 239.10 6 1.00 75.96 131.52 247.10 16 2.00 74.77 116.74 243.25 5.85 3.00 71.93 125.38 242.54 104.00 76.54 129.92 241.35 3

[0163] Varying the amount of FDCA also changed other physical and chemical properties of the resulting copolymer, including, for example, the modulus of elasticity, and gas diffusion (barrier) properties. Both % crystallinity of the copolymer and the mobility of the furan dicarboxylate component of the copolymer impact the modulus of elasticity and gas diffusion properties, such that the same % crystallinity in PET without FDCA had lower diffusion or mechanical properties than PET with FDCA.EXAMPLE 5Thread Depth and Pressure RetentionAttorney Docket No.: 00229-014W01 / OM0189.PCT

[0164] Thread depth is both a function of the design of a mold and the forming process. With a given mold, thread depth may be adjusted through process control, which leads to a change in performance of the closure. When the threads are fully formed, the interaction between the finish and the closure is maximized for a certain mold design, so that the torque to strip the closure by jumping the closure threads over the finish threads increases. The thread depth may also be a function of thickness and material stiffness, for example from increased crystallinity, so that multiple methods of increasing strip torque may be possible in one design. Once the fully formed thread performance is understood, it may be useful to perform a modification to the mold to deepen the possible thread formation limit. Another reason to adjust thread depth and contact surface may be to avoid increasing the application or removal torque beyond a limit that is comfortable for consumer use.

[0165] Using a standard laboratory-sized torque tester, a preform was placed in clamps and zeroed. Applying consistent torque in a clockwise manner, a closure was applied until snug, or until roughly 580 degrees. A positive value will be an Application Torque. Once a closure is applied, the closure was removed by applying force in a counterclockwise direction. A negative value will be a Removal Torque. Applying consistent torque in a clockwise manner, a closure was applied past snug or 580 degrees until failure. A positive value will be a Strip Torque. A closure will be deformed after a Strip Torque test. After several tests are performed a preform is exchanged with a new unused preform as a neck finish may be damaged after repeated tests, which may skew data. Torque may also be tested with a blown bottle filled with water.

[0166] A pressure retention test uses a standard battery bike / ball air pump to generate air pressure used to blow off a closure. The pump is connected to an additional pressure gauge to provide two readings on the pressure being applied. Pressurized air is routed into an 1881 neck. An 1881 closure was placed on a neck finish and secured with standard application procedures. The 1881 neck finish may be exchanged for other neck finishes and further 1881 necks. Air pressure rises until the 1881 closure reaches failure. Failure may be a slow leak with a steady decrease in air pressure inside a neck finish, or dramatic failure, which involves rapid loss of pressure.TABLE 6Pressure Retention Thread Depth (mm)Closure # (psi)Test 1 Test 2 Test 3 Average Peak Sustained 1 0.83 0.92 0.9 0.88 27.5 222 0.95 1 0.98 0.98 23 15Attorney Docket No.: 00229-014W01 / OM0189.PCTPressure Retention Thread Depth (mm)Closure # (psi)Test 1 Test 2 Test 3 Average Peak Sustained 3 0.87 1.06 0.83 0.92 22 14.5 4 0.87 0.89 1.08 0.95 20.5 17 5 0.75 0.94 0.78 0.82 25 18.5 6 0.75 0.78 0.72 0.75 22 12.5 7 0.84 0.91 0.82 0.86 24 19 8 1.01 0.97 1.03 1.00 23 20 9 0.95 1.08 1.05 1.03 23.5 15.5 10 1.04 1.07 0.9 1.00 21 15 11 0.82 0.86 0.78 0.82 20 15.5 12 0.8 0.99 0.9 0.90 22 15.5 13 0.89 0.95 0.94 0.93 20 15.5 14 0.93 0.85 1 0.93 17.5 14.5 15 0.89 0.78 0.9 0.86 22 13 16 0.86 0.85 0.75 0.82 18.5 15.5 17 0.81 0.89 0.73 0.81 21 16 18 0.81 0.98 1.01 0.93 18 15.5 19 1.45 1.4 1.31 1.39 17 14 20 0.88 0.85 0.82 0.85 18 14.5 21 1.2 1.13 1.12 1.15 19.5 15 22 0.89 0.89 0.77 0.85 14 12.5 23 1.21 1.02 1.21 1.15 18 13.5 24 1.01 0.98 1.02 1.00 15 13.525 1.35 1.43 1.22 1.33 20.5 19EXAMPLE 6Exemplary Rotary Thermoforming Machine

[0167] Rotary thermoforming sen es as an alternative form of thermoforming.Specifically, rather than thermoforming PET caps in a previously formed sheet that is subsequently heated, parts can be formed from a polymer out of the molten state which is extruded like a sheet that is quenched onto a chilled mold. Rather than forming only a sheet, the chilled mold, typically in the form of a roller, also contains the intricate parts such as the threads for forming the cap as segments on the roller. This allows for positive molded parts (i.e., male mold components). Similar to forming on a flat mold, the individual threaded parts are rotationally removed from the sheet after it is cooled. This can be cam or gear driven rotation within the roller. This method allows for high fidelity’ formation of the part and any engravings on the part.

[0168] Mold, roller, and part design may allow room for cooling the roller, typically done using chilled water. With advances in additive manufacturing of steels or other alloys, someAttorney Docket No.: 00229-014W01 / OM0189.PCTmold components can be generated by additive manufacturing to get around standard machining limitations that otherwise cause excessive skeleton scrap.

[0169] Figure 6 illustrates an exemplary embodiment of a thermoforming process 160 whereby consistent threads can be formed on a thermoformed PET container closure, such as the closure 100 shown in FIGs. 1-5. The process 660 begins at step 664, 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.

[0170] In step 668, the heated HDPE or PET material is placed into a thermoforming machine comprising 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 170°C (e.g., 80°, 90°, 100°, 110°, 120°, 130°, 140°. 150°, 160° or 170°, or any value between any of the two foregoing values). Experimental observations have demonstrated that these conditions are optimal for forming threads in container closures.

[0171] After the thermoforming process is complete, the process 660 advances to step 672, wherein the molded closure is cooled to between room temperature and the glass transition temperature of the thermoplastic material 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.

[0172] In step 676, the closure is removed from the mold by using a controlled rotation system. In some embodiments, the controlled rotation system comprises a servo, a belt, or a chain drive system that is configured to ensure consistent and accurate rotation of the threads.Attorney Docket No.: 00229-014W01 / OM0189.PCTIn some embodiments, the controlled rotation system operates at a speed ranging between about 10 RPM and about 20 RPM, which has been found to be optimal for removing closures without causing damage. In step 680, a clearance mechanism is used as the closure is removed from the mold, as described in connection with step 676. The clearance mechanism is configured to ensure the thread path follows the contour of the rotation while the closure is being removed. Along the threads, a clearance may be provided to allow for smooth removal of the closure from the mold. This clearance could allow for vents or other interruptions, which may be provided through a vertically moving part that slips from the closure after formation before step 676. This clearance allows for smooth removal of the closure from the mold and prevents damage to the threads.

[0173] In step 684. a timing mechanism is used to lift the closure at an axial rate that is correctly timed with the rotation of the thread component. Timing of lifting the closure when the thread forming component is moving 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 be optimal for preventing deformation and unwanted height variation.

[0174] It should be understood that the controlled rotation system, the clearance mechanism, and the timing mechanism, described in steps 676-684, cooperate to prevent damage to the closure during removal from the mold. As such, the process 660 advantageously enables removing HDPE, PET, PHA. PLA or any type of polymer closures from molds without causing damage.

[0175] Compared with conventional methods, the beneficial effects of the thermoforming process 160 provided herein are as follows:

[0176] 1. Improved Consistency: The thermoforming process 660 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.

[0177] 2. Reduced Damage: The thermoforming process 660 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 attempts using 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.Attorney Docket No.: 00229-014W01 / OM0189.PCT

[0178] 3. Enhanced Control: The thermoforming process 660 disclosed herein introduces a controlled rotation technology that allows for precise timing of lifting the closure when the thread forming component is rotating. 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.

[0179] 4. Versatility: The thermoforming process 660 is not limited to a specific type of mold or plastic material. The process 660 can be applied to any mold and any plastic material that is suitable for thermoforming. Similarly, it is contemplated that the process 660 can be applied to injection or compression molding for ejecting PET closures. This makes the thermoforming process 660 a versatile solution that can be used in a wide range of applications, without limitation.

[0180] 5. Efficiency: The thermoforming process 660 includes the use of a servo, belt, or chain drive system to rotate the threads 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.

[0181] 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.

[0182] 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.

[0183] In an alternative method, a closure 100 can be formed having discontinuous, or broken, threads (e.g., “interruption gaps” 110; see FIG. 1A). By way of this method, a closure 100 can be formed having spaces, or gaps, along a helical thread to generate helical thread segments. These gaps can reduce the overall surface area for the threads of the finish to ride along, thereby reducing the frictional forces that can occur between the closure 100 and the finish. In an embodiment, a closure 100 having threads with gaps can facilitate lower torque to open or close the bottle by a user which can be advantageous. Further, the reduced friction can result in a lower needed torque during the capping process. This can beAttorney Docket No.: 00229-014W01 / OM0189.PCTadvantageous to reduce damage to the closure and the closure threads during the capping process.

[0184] In an alternative step 668, the heated HDPE or PET material is placed into a thermoforming machine comprising the mold 200. As illustrated in FIGs. 7A and 7B, the mold can be a spin core, for example. The instant mold 200 can include a multitude of features to be molded into the finished closure, including threads. For example, the mold can include a thread 250 which can be referred to as a discontinuous thread or helical thread segments. The thread 250 can include a multitude of gap forming features 252 that are arranged about the central axis of the mold 200. In an embodiment, three or more gap forming features 252 can be disposed along the length of the mold 200 to create a discontinuous helical threads (i.e.. helical thread segments) on a closure 100. In some embodiments, the gap forming features 252 can be arranged at regular intervals, e.g., every 120 degrees in the case of three gap forming features. In some embodiments, the gap forming features 252 can have a height that is equal to, or less than, the pitch of the threads 250, such that the mold can be unthreaded from the closure and the gap forming features 252 slide within the formed threads. The gap forming features 252 can be disposed about the mold such that any vents on the mold are not obscured. Alternatively, any number of gap forming features can be used. Further, in some embodiments, the gap forming features may not be arranged in regular intervals about the central axis of the mold.

[0185] In some embodiments, the gap forming features 252 can be formed from the same material as the mold 200. Alternatively, the gap forming features 252 can be formed from an alternative material. The gap forming features 252 may have an outer dimension that is equal to the outer dimension of the threads 250. Alternatively, the gap forming features 252 can be smaller or larger than the outer dimension of the threads. In some embodiments, the gap forming features 252 can be added to a preexisting mold, or can be an integral part of the mold 200. While the gap forming features 252 are shown as rectangular, it is contemplated that they can be any shape.

[0186] It is contemplated that in some embodiments, the heated HDPE or PET material may, alternatively, be injection molded or compression molded. The mold 200 can be designed with precision to create the desired features on the inside of the closure, including the threads and other internal components. The thermoforming mold 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 I20°C. Experimental observations have demonstrated that these conditions are optimal for forming threads in container closures.Attorney Docket No.: 00229-014W01 / OM0189.PCT

[0187] After the thermoforming process is complete, the process 660 may advance to step 672, wherein the molded closure is cooled to between room temperature and the glass transition temperature of the thermoplastic material in the thermoforming machine. This cooling step can help to set the shape of the closure and solidify the threads. In some embodiments, water cooling channels can be provided in the mold to cool the closure. In order to reduce the pitch or distance between individual forming portions of the mold, a 3D network of cooling channels can be provided, as discussed above.

[0188] In step 676, the closure can be removed from the mold by using a controlled rotation system. In some embodiments, the controlled rotation system comprises a servo, a belt, or a chain drive system that is configured to ensure consistent and accurate rotation of the threads. In some embodiments, the controlled rotation system operates at a speed ranging between about 10 RPM and about 20 RPM, which has been found to be optimal for removing closures without causing damage. In step 680, a clearance mechanism is used as the closure is removed from the mold, as described in connection with step 676. The clearance mechanism is configured to ensure the thread path follows the contour of the rotation while the closure is being removed. Along the threads, a clearance may be provided to allow for smooth removal of the closure from the mold. This clearance could allow for vents or other interruptions, which may be provided through a vertically moving part that slips from the closure after formation before step 676. This clearance allows for smooth removal of the closure from the mold and prevents damage to the threads. Alternatively, the closure can be removed from the mold via additional means, for example, while the closure is still warm and partially set.

[0189] The resulting closure 200 can have gaps along the length of the thread in those locations where the gap forming features were located during the formation process. These gaps can reduce the overall surface area for the threads of the finish to ride along, thereby reducing the frictional forces that can occur between the closure 100 and the finish. In an embodiment, a closure 100 having threads with gaps can facilitate lower torque to open or close the bottle by a user which can be advantageous. Further, the reduced friction can result in a lower needed torque during the capping process. This can be advantageous to reduce damage to the closure and the closure threads during the capping process.

[0190] In some embodiments, the mold can include a first mold, or spin core, that is substantially the same as mold 200 of FIGS. 7A and 7B, and a second mold. The first mold can include a number of gap forming features. In general, there is a need for processes for effectively forming consistent threads on thermoformed PET caps without damaging the capsAttorney Docket No.: 00229-014W01 / OM0189.PCTduring removal from the mold. Embodiments provided in the present disclosure provide processes for forming threads 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 threads when formed from the outside of the mold, and 3) the difficulty in timing the lifting of the closure when the thread forming component is moving to prevent deformation and unwanted height variation. The mold is particularly well suited for including one or more threads formed by way of the thermoforming processes described herein. In general, the mold is designed with precision to create the desired features on the inside of the closure, including the threads and other internal components. Upon thermoforming of the closure, the mold rotates to unthread from the molded part.

[0191] In some embodiments, the mold comprises at least a primary portion that rotates, at least a secondary' portion that does not rotate, but rather demolds vertically. In some embodiments, the secondary portion can be removed from the primary portion by applying torque to the secondary portion. In some embodiments, the secondary portion can be slipped out from the primary portion. In some embodiments, the mold is monolithic. In some embodiments, the mold comprises one or more vents. The vents allow air that would otherwise be trapped to escape from underneath the sheet that is forming on the mold, thereby improving formation of the sheet to the mold.

[0192] In some embodiments, the 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 170°C (e.g., 80°, 90°, 100°, 110°, 120°, 130°, 140°, 150°, 160° or 170°, or any value between any of the two foregoing values). In some embodiments, the mold is made of aluminum, steel, stainless steel, brass, copper, bronze, or various grades, alloys, a tool steel, or combinations thereof. In some embodiments, the aluminum comprises Aluminum T-300, Aluminum 6061-T6, Aluminum 2024-T4, Aluminum 7075-T6, or the like or a combination thereof. In some embodiments, the steel comprises P20 / 30 / 40, H-13, 4140 prehard steel, or the like. In some embodiments, the stainless steel comprises 420 Stainless Steel, Stainless Steel 400 series, HH Stainless Steel or the like. In some embodiments, the copper comprises C-18, high copper alloys 83, 940, 88, 972, 95 or the like. In some embodiments, the bronze comprises SAE660 or the like. In some embodiments, the mold is made of Aluminum Bronze Alloys 18, 25, 21, 45 or the like. In some embodiments, the tool steel comprises O-l, A-2, A-6, A-8, D-2, D-3, S-7, W-l series, DC-53. Vanadis 4 / 6 / 10, Ml. M2, M3, T-3, T-16, or the like. In some embodiments, the mold comprises a coating for improving resistance to wear orAttorney Docket No.: 00229-014W01 / OM0189.PCTcorrosion. In some embodiments, the coating comprises anodized aluminum, PTFE-anodized aluminum, electroless nickel plating, ferrous metals (e.g., NiB, TiN, Ni-PTFE, diamond chrome plating), or the like.

[0193] In some embodiments, the mold comprises a threaded portion configured to form an outer cylindrical wall of the closure that comprises threads, wherein the outer cylindrical wall extends downward from the annular wall, and wherein the threads of the outer cylindrical wall engage with external threads of the container. In some embodiments, the threaded portion includes one or more external threads formed into the side wall for forming internal threads in the closure. In some embodiments, the external threads are confined to the primary portion. The resulting internal threads are configured to engage with external threads of the finish portion of the container to be closed with the closure.

[0194] In some embodiments, the threaded portion of the 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 a slight draft of a few minutes to -30 degrees. With -10 degrees being relatively easy to release. Alternatively, hinges can be molded with even a positive 190 degree angle, with respect to a base of the mold, which also requires an undercut that must be released.

[0195] In some embodiments, the mold comprises a female mold. Such a female mold would comprise inverting the mold such that the thermoforming material would be inserted into the female mold to impart features from the female mold, rather than the thermoforming material being placed onto the mold to impart features from the mold.

[0196] While the thermoforming process has been described in terms of particular variations and illustrative figures, those of ordinary skill in the art will recognize that the process is not limited to the variations or figures described. In addition, where methods and steps described above indicate certain events occurring in certain order, those of ordinary skill in the art will recognize that the ordering of certain steps may be modified.Additionally, certain of the steps may be performed concurrently in a parallel process, when possible, as well as performed sequentially as described above. To the extent there are variations of the thermoforming process, which are within the spirit of the disclosure or equivalent to the process found in the claims, it is the intent that this patent will cover those variations as well. Therefore, the present disclosure is to be understood as not limited by the specific embodiments described herein, but only by scope of the appended claims.

Claims

Attorney Docket No.: 00229-014W01 / OM0189.PCTCLAIMSWhat is claimed is:

1. A process for forming threads inside a thermoformed PET container closure, comprising:heating a thermoplastic material in a thermoforming machine; thermoforming the thermoplastic material with a mold into a closure having at least one thread, the at least one thread having a plurality of interruption gaps therein; andcooling the closure in the thermoforming machine.

2. The process of claim 1, wherein heating the thermoplastic material includes providing any of HDPE, PET, PHA, PL A or any type of polymer that is suitable for forming closures.

3. The process of claim 1, wherein heating the thermoplastic material includes heating the thermoplastic material to a temperature that allows the thermoplastic material to become more flexible and easier to shape.

4. The process of claim 1, wherein heating the thermoplastic material includes heating the thermoplastic material to a temperature ranging between about 80°C and about 170°C.

5. The process of claim 1, wherein thermoforming includes injection molding or compression molding a HDPE or PET material.

6. The process of claim 1, wherein thermoforming the thermoplastic material includes configuring the mold to create desired features on the inside of the closure.

7. The process of claim 1, wherein thermoforming the thermoplastic material includes configuring the mold to accommodate the formation of threads on the inside of the closure.

8. The process of claim 1, wherein thermoforming the thermoplastic material includes applying pressure to the thermoplastic material using the thermoforming machine.Attorney Docket No.: 00229-014W01 / OM0189.PCT9. The process of claim 1, wherein thermoforming the thermoplastic material includes applying a pressure that is sufficient to shape the thermoplastic material into the closure but not so high as to cause damage to the PET material.

10. The process of claim 1, wherein cooling the closure includes allowing the closure to cool to between room temperature and the glass transition temperature of the thermoplastic material in the thermoforming machine.

11. The process of claim 1, wherein cooling the closure includes providing water cooling channels in the mold to cool the closure.

12. The process of claim 11, wherein providing water cooling channels includes forming a 3D network of cooling channels to reduce the pitch between individual forming portions of the mold.

13. The process of claim 1, further comprising removing the closure comprising using a controlled rotation system to ensure consistent and accurate rotation of the threads.

14. The process of claim 13. wherein using the controlled rotation system includes using any one or more of a servo, a belt, a chain drive system, or any combination thereof.

15. The process of claim 14, wherein using the controlled rotation system includes operating the controlled rotation system at a speed ranging between about 10 RPM and about 20 RPM.

16. The process of claim 1, further comprising applying clearance by using a clearance mechanism to ensure a thread path follows the contour of the rotation as the closure is removed from the mold.

17. The process of claim 16, wherein using the clearance mechanism includes providing clearance along the threads to enable smooth removal of the closure from the mold.Attorney Docket No.: 00229-014W01 / OM0189.PCT18. The process of claim 16, wherein using the clearance mechanism includes allowing for vents or other interruptions in the closure.

19. The process of claim 1, further comprising lifting the closure by using a timing mechanism to lift the closure at an axial rate that prevents deformation and unwanted height variation of the closure.

20. The process of claim 19, wherein using the timing mechanism includes lifting the closure at an axial rate of 1-2 mm / s.

21. A spin core for thermoforming a closure for a container, comprising,(a) a threaded portion having a helical thread configured to form an outer cylindrical wall of the closure, the outer cylindrical wall including a closure thread; and(b) a plurality’ of gap forming features disposed along the helical thread, the plurality of gap forming features configured to interrupt the closure thread such that gaps are formed between closure thread segments.

22. A method of forming a spin core for thermoforming a closure for a container, comprising,(a) providing a threaded portion having a helical thread configured to form an outer cylindrical wall of the closure, the outer cylindrical wall including a closure thread; and(b) disposing a plurality of gap forming features along the helical thread, the plurality of gap forming features configured to interrupt the closure thread such that gaps are formed between closure thread segments.

23. A mold for thermoforming a closure for a container, comprising:(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 having annularly spaced gaps, wherein the outerAttorney Docket No.: 00229-014W01 / OM0189.PCTcylindrical wall extends downward from the annular wall, and wherein the threads of the outer cylindrical wall engage with external threads of the container.

24. A system for thermoforming a closure for a container, the system comprising:(a) the mold of claim 23;(b) a thermoplastic material; and(c) a controlled rotation system that comprises a servo, a belt, a chain drive system, or a combination thereof.

25. The system of claim 24, further comprising a thermoforming machine.

26. A closure formed using the spin core of claim 21.

27. A recyclable closure comprising:(a) a cover wall that seats within the opening of a finish of a container when the closure is mounted onto the finish of the container,(b) an annular wall configured to seat against a top surface of a rim of the finish, (c) an outer cylindrical wall extending downward from a first edge of the annular wall. (d) a plurality of helical thread segments in the outer cylindrical wall that engage with external threads of the neck of the finish, and(e) a plurality of interruption gaps dispersed between helical thread segments, the interruption gaps defining the ends of each of the plurality’ of helical thread segments, and wherein each of the interruption gaps comprises a taper angle relative to a radial line extending from an outer diameter of the outer cylindrical wall to a center of the closure.

28. The recyclable closure of claim 27, wherein the recycle closure is formed from a polyester resin.

29. The recyclable closure of claim 28, wherein the polyester resin is selected from the group consisting of polyethylene terephthalate, polyethylene furandi carboxylate, or a copolymer of polyethylene terephthalate and polyethylene furandicarboxylate.

30. The recyclable closure of claim 27, further comprising a plug seal.Attorney Docket No.: 00229-014W01 / OM0189.PCT31. The recyclable closure of claim 27, wherein each helical thread segment is defined by at least an outer radius from the center of the closure and an inner radius from the center of the closure, wherein the taper comprises an angle that connects the outer radius and inner radius.

32. The recyclable closure of claim 31, wherein the angle is between 10° and 80°.

33. The recyclable closure of claim 32, wherein the angle is 45°.

34. The recyclable closure of claim 27, wherein the cover wall is planar.

35. The recyclable closure of claim 27, wherein the cover wall is domed.

36. The recyclable closure of claim 27, further comprising a tamper evident (TE) feature connected to the outer cylindrical wall.

37. The recyclable closure of claim 36, wherein the TE comprises a plurality of foldable flaps.

38. The recyclable closure of claim 36, wherein the TE is attached to the outer cylindrical wall by one or more breakable bridges.

39. The recyclable closure of claim 27, further comprising a plurality of knurls on the outer cylindrical wall.

40. The recyclable closure of claim 36, wherein the TE feature comprises a plurality of knurls.

41. The recyclable closure of claim 27, wherein each of the interruption gaps comprises a reduced-thickness thread segment having an interruption gap radial thickness less than a thread segment radial thickness.

42. The recyclable closure of claim 27, wherein at least a portion of each of the interruption gaps is flush with the outer cylindrical wall.Attorney Docket No.: 00229-014W01 / OM0189.PCT43. The recyclable closure of claim 42, wherein the taper extends from the thread segment to the at least a portion of each of the interruption gaps that is flush with the outer cylindrical wall.

44. A sealed container, comprising,(a) a container; and(b) a closure according to claim 26 or 27.

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