Container assemblies with paper-based end closures

Abstract

The present disclosure is directed to recyclable, composite container assemblies with improved characteristics resulting from a combination of raw materials, structural design, systems, and methods for sealing a paper-based closure to a paper-based container body. The container assemblies demonstrate superior performance and seal properties, such as very low oxygen transmission rates and high resistance to bulging and/or damage due to high pressure differentials. The disclosed container assemblies, manufactured at high speeds, have been optimized by increasing the shelf-life of food products stored therein, while minimizing any non-paper materials such that the container assemblies qualify as recyclable mono-material.

What is claimed is: 
     
         1 . A container assembly comprising:
 a paper-based rigid container body comprising:   at least one sidewall defining a container interior,   a top rim circumscribing a top end of the at least one sidewall, and   a bottom peripheral edge circumscribing a bottom end of the at least one sidewall;   a top closure attached to the top rim; and   a paper-based bottom closure recessed into the bottom end and forming a seal with an interior surface of the container body; and   wherein the container assembly has an oxygen transmission rate of about 0.5 cm 3 /m 2 /day or less, a water vapor transmission rate of about 0.5 g/m 2 /day or less, and can withstand at least 10 inHG for at least 10 minutes.   
     
     
         2 . The container assembly of  claim 1 , wherein the oxygen transmission rate of the container assembly is about 0.05 cm 3 /m 2 /day or less. 
     
     
         3 . The container assembly of  claim 1 , wherein the water vapor transmission rate of the container assembly is about 0.05 g/m 2 /day or less. 
     
     
         4 . The container assembly of  claim 1 , wherein at least one of the container body and bottom closure comprise a plurality of paper-based layers and one or more barrier layers. 
     
     
         5 . The container assembly of  claim 4 , wherein:
 the plurality of layers includes one or more ionomer layers within at least one of the container body and the bottom closure; and   the one or more ionomer layers are of the same grade and, when heated, form a seal between the bottom closure and the interior surface of the container body.   
     
     
         6 . The container assembly of  claim 1 , wherein each of the container body, top closure, and bottom closure comprise a plurality of layers including one or more barrier layers and one or more paper-based layers. 
     
     
         7 . The container assembly of  claim 6 , wherein the one or more paper-based layers of the container body, top closure, and bottom closure comprise at least about 95% by mass of the container assembly. 
     
     
         8 . The container assembly of  claim 6 , wherein the one or more barrier layers of at least one of the container body, top closure, and bottom closure comprise metalized polyethylene terephthalate (MPET). 
     
     
         9 . The container assembly of  claim 6 , wherein the one or more barrier layers of at least one of the container body, top closure, and bottom closure comprise aluminum. 
     
     
         10 . The container assembly of  claim 6 , wherein the one or more barrier layers of at least one of the container body, top closure, and bottom closure comprise metalized polybutylene terephthalate (MPBT). 
     
     
         11 . The container assembly of  claim 6 , wherein the one or more barrier layers of at least one of the container body, top closure, and bottom closure comprise aluminum oxide (AlOx) coated polyethylene terephthalate (PET). 
     
     
         12 . The container assembly of  claim 4 , wherein the plurality of layers includes one or more tie layers. 
     
     
         13 . The container assembly of  claim 1 , wherein the bottom closure is recessed into the bottom end of the container body at a recessed distance within a range of about 0.2-2 cm. 
     
     
         14 . The container assembly of  claim 1 , wherein the seal between the interior surface of the container body and the bottom closure is hermetic. 
     
     
         15 . The container assembly of  claim 1 , wherein the container body is cylindrical. 
     
     
         16 . The container assembly of  claim 1 , wherein the top closure comprises a peelable membrane sealed to the top rim. 
     
     
         17 . A container assembly comprising:
 a paper-based rigid container body comprising:   at least one sidewall defining a container interior,   a top rim circumscribing a top end of the at least one sidewall, and   a bottom peripheral edge circumscribing a bottom end of the at least one sidewall;   a top closure removably attached to the top rim; and   a paper-based bottom closure recessed into the bottom end and forming a seal with an interior surface of the container body; and   wherein the container assembly has an oxygen transmission rate of about 0.5 cm 3 /m 2 /day or less, a water vapor transmission rate of about 0.5 g/m 2 /day or less, and can withstand at least 10 inHG for at least 10 minutes.   
     
     
         18 . A container assembly comprising:
 a paper-based rigid container body comprising:   at least one sidewall defining a container interior, a top rim circumscribing a top end of the at least one sidewall, and a bottom peripheral edge circumscribing a bottom end of the at least one sidewall;   a top closure removably attached to the top rim; and   a paper-based bottom closure recessed into the bottom end and forming a seal with an interior surface of the container body; and   wherein the container assembly has an oxygen transmission rate of about 0.5 cm 3 /m 2 /day or less, a water vapor transmission rate of about 0.5 g/m 2 /day or less, and can withstand at least 10 inHG for at least 10 minutes in an environmental humidity of between 0% humidity and 90% relative humidity.   
     
     
         19 . The container assembly of  claim 1 , wherein the container assembly has an oxygen transmission rate of about 0.5 cm 3 /m 2 /day or less, a water vapor transmission rate of about 0.5 g/m 2 /day or less, and can withstand at least 10 inHG for at least 10 minutes in any environmental humidity which is less than or equal to 90% relative humidity.