BACKGROUND
Field
The disclosed concept relates generally to containers and more particularly, to ecology tabs and can ends for containers, such as beer and beverage cans. The disclosed concept also relates to tooling and associated methods for the manufacture of ecology tabs and can ends.
Background Information
Metallic containers (e.g., cans) for holding products such as, for example, liquids, beverages, or food products, are typically provided with an easy open can end on which an opening mechanism, such as a pull tab, is attached (e.g., without limitation, riveted) to a tear strip or severable panel. Typically, the tear strip is defined by a scoreline in the exterior surface (e.g., public side) of the can end. The pull tab, commonly referred to simply as the “tab,” is structured to be lifted, pulled, and/or rotated to sever the scoreline and deflect the tear strip, thereby creating an opening for dispensing the contents of the can.
When the can end is made, it originates as a can end shell, which is formed from a sheet metal product (e.g., without limitation, sheet aluminum; sheet steel). The shell is then conveyed to a conversion press, which has a number of successive tool stations. As the shell advances from one tool station to the next, conversion operations such as, for example and without limitation, rivet forming, paneling, scoring, embossing, tab forming, tab securing and tab staking, are performed until the shell is fully converted into the desired can end and is discharged from the press. Typically, tooling for each tool station of the conversion press includes an upper tool member, which is structured to be advanced towards a lower tool member upon actuation of a press ram. The upper and/or lower tool members cooperate to perform a number of the aforementioned conversion operations. Upon completion of a given operation, the press ram retracts the upper tool member and the partially converted shell or tab is moved to the next successive tool station, or the tooling is changed within the same station, to perform the next conversion operation.
In the canmaking industry, there is an ongoing desire to reduce the amount of metal required to be used in the manufacture of the container and components thereof (e.g., can end; tab; can body). In addition to reducing cost, minimizing the amount of metal required has an ecological impact that is good for the environment. Prior proposals for addressing these issues suffer from various disadvantages. Among them, are complexity of design of the tab and/or can end, and strength and operating mechanics considerations of the tab and/or can end. Consequently, some known designs, which have attempted to achieve metal savings, are too costly and/or impractical to produce, or fail to achieve the desired result. Many known designs also require substantial modification or complete redesign of the tab, the can end, or both, which undesirably necessitates completely new tooling and forming methods.
There is, therefore, room for improvement in tabs and can ends for containers, such as beer and beverage cans, and in associated tooling and methods.
BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the disclosed concept can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
FIG. 1 is a top perspective view of a tab in accordance with an embodiment of the disclosed concept;
FIG. 2 is another top perspective view of the tab;
FIG. 3 is a bottom perspective view of the tab;
FIG. 4 is another bottom perspective view of the tab;
FIG. 5 is a top plan view of the tab;
FIG. 6 is a bottom plan view of the tab;
FIG. 7 is a side elevation view of the tab;
FIG. 8 is a section view taken in the direction of line 8-8 shown in FIG. 5;
FIG. 9 is a front end elevation view of the tab;
FIG. 10 is a back end elevation view of the tab;
FIG. 11A is a top perspective view of a can end and tab in accordance with an embodiment of the disclosed concept;
FIG. 11B is a top perspective view of the can end of FIG. 11A, shown without the tab;
FIG. 12A is another top perspective view of the can end and tab of FIG. 11A;
FIG. 12B is another top perspective view of the can end of FIG. 11B,
FIG. 13 is a bottom perspective view of the can end;
FIG. 14 is another bottom perspective view of the can end of FIG. 13;
FIG. 15A is a top plan view of the can end and tab of FIG. 11A;
FIG. 15B is a top plan view of the can end of FIG. 11B;
FIG. 16 is a bottom plan view of the can end;
FIG. 17 is a side elevation view of the can end;
FIG. 18A is a section view taken in the direction of line 18A-18A shown in FIG. 15A;
FIG. 18B is a section view taken in the direction of line 18B-18B shown in FIG. 15B;
FIG. 19 is a simplified section view of tooling in accordance with an embodiment of the disclosed concept;
FIG. 20 is an enlarged section view of a portion of the tooling of FIG. 19;
FIGS. 21 and 22 are top plan views, respectively, showing differences of a new tab in accordance with an embodiment of the disclosed concept compared to a conventional tab;
FIG. 23 is a top plan view showing the public side (i.e., outside or exterior) of a conventional can end and tab;
FIG. 24 is a top plan view showing the public side of a new can end and tab in accordance with an embodiment of the disclosed concept;
FIG. 25 is a bottom plan view showing the product side (i.e., inside or interior) of the conventional can end and tab of FIG. 23;
FIG. 26 is a bottom plan view of the new can end and tab of FIG. 24;
FIG. 27 is a top plan view of a portion of a conventional conversion press system forming the conventional can end and tab of FIGS. 23 and 25, with a portion of the conversion press shown in simplified form in phantom line drawing; and
FIG. 28 is a top plan view of a portion of a conversion press forming the new can end and tab of FIGS. 24 and 26, with a portion of the conversion press shown in simplified form in phantom line drawing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For purposes of illustration, embodiments of the disclosed concept will be described as applied to tabs and can ends for beverage/beer cans, although it will become apparent that they could also be employed to other contains such as, for example and without limitation, cans for liquids other than beer and beverages, and food cans.
It will be appreciated that the specific elements illustrated in the figures herein and described in the following specification are simply exemplary embodiments of the disclosed concept, which are provided as non-limiting examples solely for the purpose of illustration. Therefore, specific dimensions, orientations and other physical characteristics related to the embodiments disclosed herein are not to be considered limiting on the scope of the disclosed concept.
Directional phrases used herein, such as, for example, left, right, front, back, top, bottom, upper, lower and derivatives thereof, relate to the orientation of the elements shown in the drawings and are not limiting upon the claims unless expressly recited therein.
As employed herein, the terms “can” and “container” are used substantially interchangeably to refer to any known or suitable container, which is structured to contain a substance (e.g., without limitation, liquid; food; any other suitable substance), and expressly includes, but is not limited to, food cans, as well as beverage cans, such as beer and soda cans.
As employed herein, the term “can end” refers to the lid or closure that is structured to be coupled to a can, in order to seal the can.
As employed herein, the term “can end shell” is used substantially interchangeably with the term “can end.” The “can end shell” or simply the “shell” is the member that is acted upon (e.g., without limitation, formed) and is converted by the disclosed tooling to provide the desired can end.
As employed herein, the statement that two or more parts are “coupled” together shall mean that the parts are joined together either directly or joined through one or more intermediate parts.
As employed herein, the term “number” shall mean one or an integer greater than one (i.e., a plurality).
FIGS. 1-10 and 21 show a tab 2 in accordance with one non-limiting embodiment of the disclosed concept. The tab 2 includes a body 4 having opposing first and second ends 6,8. A nose portion 10 is located at or about the first end 6 (i.e., front) of the tab 2, and a lift portion 12 is located at or about the second end 8 (i.e., back) of the tab 2. As shown in FIGS. 1-6 and 21, a rivet receiving portion 14 is disposed proximate the nose portion 10, and includes a rivet hole 16.
The tab 2 in the non-limiting example shown and described herein is a reduced length ecology tab for use on an easy open beer/beverage can end 200 (see, e.g., without limitation, FIGS. 11A-18, 24; see also tab 200′ in FIG. 26). By way of one non-limiting example, it will be appreciated that a conventional tab 102 (see, for example, FIG. 22) has a length 150 of about 0.985 inch, whereas a reduced length ecology tab 2 in accordance with the disclosed concept (see, for example, FIG. 21) has a length 50 of between 0.810-0.950 inch, and preferably only about 0.860 inch. Continuing to refer to FIGS. 21 and 22, it will be appreciated the width 52 of the reduced length ecology tab 2, measured at the widest portion of the tab 2 as shown in FIG. 21, is generally similar to the width 152 of the conventional tab 150, also measured at the widest portion of the tab 102 as shown in FIG. 22. By way of one non-limiting example embodiment, the conventional tab 150 may have a width 152 of about 0.620 inch, and the reduced length ecology tab 2 may have a width 52 of about 0.616 inch. It will be appreciated, however, that in other embodiments (not shown), the tabs (e.g., 2, 102) could have the same width (e.g., 52, 152), without departing from the scope of the invention. The thickness of the reduced length ecology tab 2 is also preferably substantially the same as the thickness of conventional tabs (e.g., without limitation, tab 102 of FIG. 22).
The aspect ratio (i.e., length divided by width) of the tab 2 is also unique. That is, the aspect ratio is preferably between 1.5:1 to 1.30:1 and, more preferably, is about 1.396:1. By comparison, the aspect ratio of the conventional tab 102 of FIG. 22 is 1.589:1. It will therefore be appreciated that the length 50 of tab 2 is preferably between 0.035-0.175 inch shorter than a conventional tab, and more preferably is about 0.125 inch shorter than a conventional tab (see and compare, for example, new reduced length ecology tab 2 compared to conventional tab 102, shown side-by-side in FIGS. 27 and 28).
In accordance with one aspect of the disclosed concept, the tab 2 was strategically designed around a progression length 702, which would allow relatively easy retrofit into an existing machine 700 (e.g., without limitation, a 1.1500 inch tab progression Tetrad machine (partially shown in simplified form in FIG. 28)). More specifically, it is generally well known in the art of progressive die stamping that the “progression length” refers to the distance or pitch between die stations. Accordingly, it is generally understood that any change in progression length would necessarily require extensive and costly modification to the associated tooling. Among other unique improvements, the reduced length ecology tab 2 is significantly shorter in length 50 (FIGS. 7, 8 and 21) compared to the length 150 (FIG. 22) of a conventional tab 102 (FIG. 22), and through extensive research and design efforts a unique progression length 702 (FIG. 28) has been discovered and implemented that is different from the progression length 602 (FIG. 27) of the prior art tooling 600 (FIG. 27), yet the new tab 2 can be incorporated or retrofitted into existing machinery (e.g., without limitation, prior art conversion press 600 of FIG. 27). In the example shown and described with respect to FIGS. 27 and 28, the existing tab die progression length 602 of the prior art conversion press 600 is preferably reduced from 1.1500 inch to a tab die progression length 702 of between 1.0857 inch and 0.8857 inch and, more preferably, to a tab die progression length 702 of about 0.9857 inch.
Referring to FIGS. 1-5, for example, in accordance with another aspect of the disclosed concept, the reduced length ecology tab 2 utilizes the same geometry and known technology on the front half or front portion (see segment 60 of tab 2 in FIG. 5) of the tab 2 (i.e., the aforementioned “nose” 10). The aforementioned reduced tab length 50 is therefore achieved exclusively from the back half or back portion (see segment 70 of tab 2 in FIG. 5) of the tab 2 (i.e., the aforementioned “lift portion” 12 or finger hole area 18). That is, a major distinctive feature of the disclosed tab 2 is a smaller finger hole 18 and, thus, a shorter overall tab length 50. It will be appreciated that such a reduction in tab length 50 results in increased opening forces, which provides the largest technical challenge and largest obstacle for customer acceptance.
A significant advantage of the disclosed reduced length ecology tab 2 is metal-savings. That is, there is a significant reduction in the amount of metal (e.g., without limitation, aluminum) required per tab 2. This results in significant tab cost savings over time. Another advantage of the disclosed reduced length ecology tab 2 is the enhanced finger access that is gained on smaller diameter can ends 200 (FIGS. 11A-18B, see also can end 200′ of FIGS. 24 and 26). For example and without limitation, diameter 200 and smaller can ends 200 do not allow enough finger access when employing a conventional tab of standard length (e.g., tab 102 of FIG. 22). As shown in FIG. 15A, for example, this is because there is relatively little available space available on the center panel 202 of the can end 200. That is, the diameter 204 of the center panel 202 of a conventional 200 diameter can end 200 is typically in the range of between about 1.780 inches to about 1.650 inches leaving relatively little remaining space for the tab 2, tear panel 206 and other features.
Accordingly, among other distinct features and benefits, the reduced length (e.g., without limitation, 0.9857 inch) ecology tab 2 has the following distinctive features:
1. Same nose portion 10 (e.g., segment 60 in FIG. 5) and, therefore, same performance advantages as known tabs;
2. Smaller finger hole 18 (FIGS. 1-5) and increased finger access;
3. Reduced overall length 50;
4. Substantially similar tab thickness as previous standard tabs; and/or
5. Improved metal efficiency and economy (e.g., less metal).
It will be appreciated that a reduced length ecology tab 2 in accordance with alternative embodiments (not shown) of the disclosed concept could have different measurements and features (not shown), as well as a different size, shape or geometry (not shown), without departing from the scope of the disclosed concept. For example and without limitation, the tab 2 could be made from material (e.g., without limitation, aluminum) having a reduced gauge (i.e., thinner). Additionally, or alternatively, by way of example and without limitation, the reduced length concept could be employed with a tab that has a solid lift portion (i.e., no finger thru hole), commonly known as a “promotional” or “promo” tab.
As best shown in the section view of FIG. 18A, the rivet hole 16 is structured to receive a rivet 214, which is staked to fasten the rivet receiving portion 14 of the tab 2 to a can end 200, see also, FIG. 15A.
FIGS. 11A, 12A, 15A and 18A show an example of a can end 200 employing the tab 2, in accordance with one non-limiting example embodiment of the disclosed concept. It will be appreciated, however, that a tab 2 in accordance with the disclosed concept could alternatively be employed with can ends having any other known or suitable alternative size (not shown), geometry (not shown), and/or configuration of features (e.g., without limitation, shell type, size and shape; score line and/or tear panel size and/or shape; panel size and/or shape)(not shown), without departing from the scope of the disclosed concept. For example and without limitation, FIGS. 24 and 26 show one non-limiting alternative embodiment of a different type of can end 200′ employing a tab 2 in accordance with the disclosed concept.
FIGS. 11B, 12B, 15B and 18B show the aforementioned example can end 200, without the tab, to better show unique features of the can end 200, in accordance with aspects of one non-limiting example embodiment of the disclosed concept. It will be appreciated with reference to FIGS. 13, 14, 16 and 17, that the product side (i.e., inside, interior or bottom) and side elevation views of the can end 200 appear the same whether or not the tab 2 (FIGS. 1-10, 11A, 12A, 15A, 18A, 21, 24 and 26) is affixed to the can end 200.
Referring to FIG. 15A, for example, among other features, the can end 200 includes an end panel or center panel 202 and a scoreline 205, which defines a tear panel 206. Accordingly, when the tab 2 is actuated (e.g., without limitation, lifted and pivoted or rotated) it will sever the scoreline 205 about the tear panel 206, and depress the tear panel 206 downward, thereby providing an opening in the can end 200 for dispensing the contents of the container or canto which the can end 200 is affixed.
In the example shown and described herein, the can end 200 has several additional distinctive features. As best shown in FIGS. 11B, 12B and 15B, the end panel 202 includes arc-shaped beads 216, 218, see also, arc-shaped beads 216′, 218′ on panel 202′ of can end 200′ in FIG. 26, designed to fit under the reduced length ecology tab 2 to provide stiffness behind the rivet thereby enhancing opening performance. The end panel 202 of the example can end 200 further includes locating beads 220, 222 (see also locating beads 220′, 222′ of can end 200′ of FIG. 26), which function to locate the part as it is being formed by tooling (see tooling 500 in FIGS. 19, 20 and 28) and methods (e.g., without limitation, a progressive die tooling process as best shown in FIGS. 27 and 28) in accordance with aspects of the disclosed concept. Linear beads 224, 226 may also be optionally included, as shown for example and without limitation in the alternative example embodiment of FIGS. 24 and 26. Such linear beads 224, 226 function to further stiffen the end panel 202′ of the can end 200′. It will be appreciated that this unique combination of features is significantly different from the prior art end panel 302, shown in FIG. 25 and, in particular, the bead 304 commonly referred to in the art as a “cent bead.”
Many of the foregoing features can also be seen from the product side (e.g., interior or inside) of the can end 200, 200′, as shown for example in FIGS. 13, 14, 16 and 26.
As noted above, another unique feature and advantage of the disclosed concept is enhanced finger access to facilitate easier access for the finger of a user to lift the tab 2 and thereby open the associated container or can (not shown). More specifically, as best shown with reference to FIGS. 23-26, the reduced length ecology tab 2 results in the second end 8 of the tab body 4, and thus the lift portion 12 and figure hole 18, being disposed a greater distance 208′ (FIG. 24) from the outer edge or perimeter 210′ (FIG. 24) of can end 200′ (FIG. 24) than prior art designs (see and compare the prior art can end 300 and smaller distance 308 between tab 102 and outer edge 310 shown in FIGS. 23 and 25, to the new can end 200′ shown in FIGS. 24 and 26; see also, distance 208 between tab 2 and the outer edger 210 of can end 200 of FIG. 15A). In the non-limiting example embodiments of FIGS. 15A and 24, the improvement in finger access is directly attributed to the distance 208 (FIG. 15A), 208′ (FIG. 24) preferably being between 0.325-0.500 inch and, more preferably being about 0.414 inch compared to the distance 308 (FIG. 23), which is less than 0.300 inch. The embodiments of FIGS. 15A and 24 also include an optional finger well or recess 212 (FIG. 15A) 212′ (FIG. 24) in the end panel 202 (FIG. 15A), 202′ (FIG. 24), which still further improves finger access by a user by allowing the user's finger to reach under the lift portion 12 of the tab 2 to further facilitate operation thereof. The magnitude of this difference will be even further appreciated when recognizing that the prior art can end 300 of FIGS. 23 and 25 is a larger diameter can end (e.g., a 202 diameter can end 300) compared to the smaller 200 diameter can end 200, 200′ (FIGS. 24 and 26) shown and described herein with respect to the reduced length ecology tab 2 of the disclosed concept. Thus, it will be appreciated that a conventional tab 102 having a standard length 150 (FIG. 22) disposed on the smaller diameter can end 200, 200′ would result in even less finger access space than the distance 308, shown in FIG. 23.
As shown, it will be appreciated, that the reduced tab length 50 also allows for the overall size (e.g., diameter 204 (FIG. 15A)) of the associated can end 200 to be reduced, if desired, which would advantageously result in even further metal savings.
FIGS. 19 and 20 show a non-limiting example of tooling 500 for forming a reduced length ecology tab 2 in accordance with aspects of the disclosed concept. The tooling 500 includes an upper tooling assembly 502 and a lower tooling assembly 504 each having a plurality of opposing tools that cooperate in order to form features of the tab 2. In the non-limiting example of FIGS. 19 and 20, the tooling 500 shown is structured to form the tongue wipe down, finger hole precurl, panel and coin pre-curl operations associated with forming the tab 2. It will be appreciated, however, that additional tooling (e.g., without limitation, one or more additional forming stations (not shown)) could be employed to form the reduced length ecology tab 2 in accordance with the disclosed concept.
As previously discussed, FIG. 21 shows a reduced length tab 2 in accordance with a non-limiting example embodiment of the disclosed concept compared to the standard length of a convention tab 102, shown in FIG. 22. The dimensions provided are not intended to restrict the scope of the disclosed concept, but rather are provided merely for purposes of illustration to show a non-limiting example of reduced tab length 50 and other features that can be achieved by the disclosed concept.
Similarly, FIGS. 23-26 provide another non-limiting example, for purposes of comparing a convention can end 300 employing a convention tab 102 to a reduced size can end 200′ employing a reduced length tab 2 in accordance with aspects of one non-limiting embodiment of the disclosed concept. Specifically, FIGS. 23 (prior art) and 24 show the public sides (e.g., outsides or exteriors) of the can ends 200′, 300, and FIGS. 25 (prior art) and 26 show the product sides (e.g., insides or interiors) of the can ends 200′, 300.
FIG. 27 shows a portion of a conversion press system 600 forming the conventional can end 300 and tab 102 of FIGS. 23 and 25, with a portion of the conversion press 600 shown in simplified form in phantom line drawing. Similarly, FIG. 28 shows a portion of a conversion press 700 forming the new can end 200′ and tab 2 of FIGS. 24 and 26, with a portion of the conversion press 700 shown in simplified form in phantom line drawing. It will be appreciated with reference to, and comparison of, FIGS. 27 and 28 that certain dimensions between and among components of the prior art conversion press 600 (FIG. 27) and the conversion press 700 (FIG. 28) for forming the new tab 2 in accordance with the disclosed concept are similar enough to avoid requiring completely new lane dies and feed equipment In more detail, the aforementioned unique tab die progression length 702 of the disclosed concept was researched and developed extensively to achieve a dimension that permits the transfer belt centerline dimension 704 (FIG. 28) to remain substantially unchanged from the transfer belt centerline dimension 604 (FIG. 27). Preferably, the lane die progression length 706 (FIG. 28) also remains substantially unchanged from the prior art lane die progression length 606 (FIG. 27). Accordingly, as previously discussed hereinabove, an additional significant advantage of the disclosed concept is that the reduced length ecology tab 2 can be implemented or retrofitted within existing conversion systems (e.g., 600).
It will be appreciated that features of the disclosed concept can be employed independently, without certain other aspects for features, in accordance with some embodiments of the disclosed concept, whereas in other embodiments all of the aforementioned features can be employed in combination. It will further be appreciated with reference to for example and without limitation, FIGS. 23-26, that the new tab 2 and can end 200′ designs in some instances may remove or eliminate the requirement of features required in prior art designs.
Accordingly, the disclosed concept provides a reduce length tab 2, providing a number of advantages, and further provides for an improved can end 200, 200′, tooling 500, 700 and associated methods, which individually and collectively achieve significant metal savings and ecological benefit.
While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of disclosed concept which is to be given the full breadth of the claims appended and any and all equivalents thereof
Patent Application
20210347526
