A. Field
The invention relates to apparatus used in the die necking of aluminum beverage cans. More particularly, this invention relates to a flexible arrangement of necking stations for necking the open end of a can body, in which the can body has a diameter greater than 2.8 inches. Such cans are used for holding larger volumes of beverage such as for example 20 or 24 fluid ounces.
B. Related Art
Conventional aluminum beverage cans are made from an aluminum alloy disc which is drawn into a cup and then subject to further drawing and ironing into a can body by a device known as a can body maker. The can body has a sidewall, composed of a mid-wall portion and a top wall portion, and an integral bottom wall. In the drawing and ironing process, the bottom of the can is typically formed into a central inwardly-directed dome configuration and a peripheral, lowermost annular rim (sometimes referred to as a “stand” or “nose radius”) which forms the structure supporting the can when the can is placed upright on a horizontal surface. Can body makers, including punch sleeves and related tooling for forming a can body are known in the art and commercially available, see for example U.S. Pat. No. 6,434,996, the content of which is incorporated by reference herein. See also U.S. Pat. Nos. 4,852,377; 3,735,629; 5,394,727; 5,014,536 and 4,414,836, also incorporated by reference herein.
The can thus formed is then sent to a necking unit having a plurality of stations in which the top wall is subject to a plurality of necking steps, in which the diameter of the open end of the can is progressively reduced. After necking, a flange is formed on the open end for receiving a separate closure member or end.
Necking units use a multitude of individual, progressive necking stations, each one progressively reducing the diameter of the neck a bit more than the diameter produced from the previous necking station. Necking units are commercially available and described in the patent literature, see for example U.S. Pat. Nos. 5,775,161; 4,774,839; 5,775,130 and 6,698,265. The description of the necking units and individual necking modules (stations) of these patents is incorporated by reference herein.
This disclosure relates to a set of necking stations used to neck a relatively large size diameter beverage can (one with a diameter prior to necking of at least 2.8 inches, such as for example 3.0 inches or larger) in which the set of necking stations can be used to neck the can down to a first diameter for receiving a first standard end such as a 202 (2 and 2/16ths inches) end, and in which a subset of the necking stations can be used to neck the can down to receive a second standard diameter end such as a 206 (2 and 6/16ths inches) end or a 209 (2 and 9/16ths) diameter end. This feature provides the flexibility of the can manufacturer to change the necking of the can body to adapt to different end requirements for its customers, without having to invest in creation of separate tooling. For example, where customer A desires to use the larger size can and have a small end (e.g., 202 end), a subset of the necking stations created for manufacturing such an end can also be used if the customer (or a different customer, customer B) wants to use the same basic large size can but have a larger end (e.g., a 209 end). This invention also relates to a punch sleeve for a can body maker which is modified to provide a longer top wall in order to allow such a larger diameter can to be necked to smaller diameter sizes.
In a first aspect, a beverage can manufacturing apparatus is provided in the form of a set of N necking stations S1, S2 . . . SN for progressively necking a beverage can body having a diameter greater than or equal to 2.8 inches to result in an open end designed to receive a first standard end. The necking stations are constructed such that a subset of the necking stations Si . . . Sj, where 1≦i<j<N, progressively neck the beverage can body to result in an open end designed to receive a second standard end for the beverage can. The diameter of the first standard end is less than the diameter of the second standard end. For example, the first standard end is say a 202 standard end and the second standard end is a 209, 204, or a 206 standard end. Alternatively, for example, the first standard end could be a 206 end and the second standard end could be a 209 standard end.
Consider, for example, a set of twenty necking station, S1, S2, . . . S20. Here, in this example N is equal to twenty. The twenty necking stations are used to neck a 3 inch diameter can down to receive a 202 end for customer A. However, a subset of the stations can be used to neck the can body to fit a 209 standard end, for example in the situation where customer B wants to use the same base large diameter can body but with a larger diameter end such as a 209 diameter end. The change to neck the can body down to a new diameter for customer B does not require manufacture of any new necking stations, even though the end diameter is different, since the necking stations were designed in the first place to allow for this possibility. Thus, a subset of the 20 necking stations can be selected and used to make the can body fit a 209 diameter end. The subset of stations to use for the 209 diameter end could be, for example stations, S1 to S10. In this case, i=1 and j=10. Alternatively, for example where Customer B wants a 206 end, the subset of stations which is selected could be some other subset of 20 necking stations, such as stations S1, S2, . . . S15, where i=1 and j=15. The subset of stations need not necessarily be consecutive stations in the original set of N stations. However, in some embodiments, they may be consecutive, such as S1, S2 . . . S10, or S5, S6, . . . S15.
In one arrangement, the stations are consecutive stations Si, Si+. . . Sj in the set S1 to SN, and the diameter reduction D achieved for each of the necking stations Si, Si+1 . . . Sj is defined approximately in accordance with the following relationship:
D=T/N
where T represents the total amount of necking to be performed on the beverage can by the set of N necking stations and N represents the number of necking stations, and wherein the diameter reduction D for at least one of the necking stations in the series of necking stations Si, Si+1, . . . , Sj is adjusted from D by an amount±Δ, where Δ is some small variation from the diameter reduction D.
In one configuration, the subset of stations used to neck down to a second standard diameter end is basically selected roughly in the middle of the sequence of stations from S1 to SN. More precisely, the “middle” station in the subset of stations is represented by S(i+j)/2, and this station is within 2 necking stations of the middle necking station or stations in the progression of necking stations S1, S2, . . . , SN. For example, if N is equal to 20, i=5 and j=15, and the subset consists of stations S5 to S15. The middle station is S10 (i+j divided by 2), and the middle station S10 is also the middle station in the sequence from S1 to S20. In this situation, the tooling from the S1 station is moved and installed in the 5th operation station, S2 is moved to the 6th operation station, etc. Either no tooling is present in the 1st to 4th stations or if tooling is present it is rendered inoperative, by keeping it in the “up” or idle position.
In one embodiment, the beverage can comprises a can designed to hold at least 12 oz. of beverage, such as 20 oz. of beverage. In one specific embodiment, the beverage can comprises a 24 oz. beverage can.
The number of necking stations N can vary. In one embodiment, N is greater than or equal to 20. In one specific example, N is equal to 20 and wherein Si comprises either the 4th, 5th or 6th necking station.
The concept of flexibility of the design of the necking stations can be extended further such that one subset allows the can to be necked down to a second diameter standard end and a third subset allows the can to be necked down to a third diameter standard end. In particular, a necking station Sk is present in the set of necking stations as follows: S1, S2, . . . Sj, Sj+1, . . . Sk, Sk+1 . . . SN, and wherein a second subset of the necking stations including station Sk results in a set of necking stations which progressively neck the beverage can body to result in an open end designed to receive a third standard end for the beverage can body, the third standard end having a smaller diameter than the second standard end. Consider for example a set of 25 necking stations (N=25) for necking down a can body of at least 2.8 inch diameter to a 202 end. S1-S10 neck down to a 209 end (j=10). S1-S20 neck down to a 206 end. K is 20 in this example.
In another aspect of this invention, a can body maker includes a punch sleeve which is modified in order to produce a sufficient top wall length in the can body such that the required amount of necking from the larger diameter body to a relatively small diameter end, such as 209, 202 or 204 can be performed without wrinkling or other problems in the can body. In one particular embodiment, the punch sleeve is designed such the body maker produces a beverage can body having a topwall length of at least 1.00 inches, such as between 1.00 and 1.40 inches. In one particular embodiment, beverage can manufacturing apparatus is provided including a set of necking stations which provides the flexibility as described above, and also a can body maker for forming the beverage can body having a punch sleeve and wherein the punch sleeve is designed such that the beverage can body has a topwall length of at least about 1.00 inch.
In another particular configuration, the can body maker is used in conjunction with the flexible set of necking stations for larger diameter can bodies, N is at least about 20 and wherein the diameter reduction performed by the N necking stations is approximately between 13/16 inches and 1.40 inches, inclusive. In another particular embodiment, the beverage can is designed to hold at least 20 oz. of beverage, the set of necking stations S1 . . . SN neck the beverage can body down to a receive a 202 standard end and wherein the subset of stations necks the can down to receive a 209, 206, or a 204 standard end.
Other aspects of the invention include a beverage can made in accordance with the apparatus of this disclosure. Such as a can made from the stations S1 to SN having the first standard diameter end or from the subset of stations producing a can having the second standard diameter end.
In another aspect, a beverage can is described designed to hold at least 20 oz. of beverage, comprising a can body having a diameter of at least 2.8 inches, and a neck portion, wherein the neck portion of the can body is formed by at least 15 necking operations to have a finished diameter designed to receive a 202 can end to close off the can body.
Referring now to the Figures,
The necking stations are constructed and arranged such a subset of the stations provide a series of necking stations that will neck the same size can body down to a larger diameter to receive a second standard end, such as for example a 209 end or a 206. See
The necking stations of
The diameter reduction D achieved for each of the necking stations Si, Si+1 . . . Sj is defined approximately in accordance with the following relationship D=T/N, where T represents the total amount of necking to be performed on the beverage can by the set of N necking stations and N represents the number of necking stations. For example, T may 14/16 inches, N is 20 and so D is 0.04375 inches ( 14/320). The diameter reduction D for at least one of the necking stations in the series of necking stations Si, Si+1, . . . , Sj is adjusted from D by an amount±Δ. Consider the example of
In another variation, a second subset of the stations are designed to neck the can body down to a receive a third standard end, which has a diameter between that of the first end (e.g., 202) and the second standard end (209). For example, stations S1 . . . S15 are constructed and arranged such that after the 15th station operates on the can body the can has been necked down to receive a 204 diameter end.
The subset of stations which are used to neck down to the second standard diameter end could be installed in a different necking unit with the number of stations matching the number of stations used to neck down to the second standard diameter end. For example, as shown in
As noted previously, to take a large diameter can (diameter greater than 2.8 inches) and neck it down to a small diameter end such as 202 or 204, the tooling in the can body maker is modified in accordance with another feature of this invention to provide a top wall of sufficient length.
Generalizing the foregoing examples, in one aspect of this disclosure a beverage can manufacturing apparatus has been described comprising a set of N necking stations S1, S2 . . . SN for progressively necking a beverage can body having a diameter greater than or equal to 2.8 inches to result in an open end designed to receive a first standard end (e.g., 202, 204, or 206), and wherein a subset of the necking stations Si . . . Sj, where 1≦i<j<N, progressively neck the beverage can body to result in an open end designed to receive a second standard end for the beverage can.
As demonstrated in
In one embodiment, the first standard end comprises a 202 end and the second standard end comprises a 209 end. In another embodiment the first standard end comprises a 202 end and wherein the second standard end comprises a 206 end. In another embodiment, the first standard end comprises a 202 end and wherein the second standard end comprises a 204 end. In preferred embodiments, the beverage can comprises a can designed to hold at least 12 oz. of beverage. For example, the beverage can comprises a 20 oz or 24 oz. beverage can.
The number N of necking stations can vary. In preferred embodiments, N is greater than or equal to 20. In one specific embodiment, N is equal to 20 and wherein Si comprises either the 4th, 5th or 6th necking station. See for example
The flexible necking station arrangements of this disclosure are preferably implemented in a can manufacturing apparatus that includes a can body maker for forming the beverage can body having a punch sleeve (
In a specific embodiment, N is at least about 20 and wherein the diameter reduction performed by the N necking stations is approximately between 13/16 inches and 1.40 inches, inclusive. In such an arrangement the beverage can is designed to hold greater than 12 oz of beverage. In one particular embodiment the beverage can is designed to hold at least 20 oz. of beverage, the set of necking stations S1 . . . SN neck the beverage can body down to a receive a 202 end and wherein the station Sj necks the can down to receive a 209 end. In another embodiment the beverage can is designed to hold at least 20 oz. of beverage, the set of necking stations S1 . . . SN neck the beverage can body down to a receive a 202 end.
Still further aspects include a beverage can made in accordance with any of the beverage can manufacturing apparatus described herein.
In still another aspect, a beverage can is described which is designed to hold at least 20 oz. of beverage, comprising a can body having a diameter of at least 2.8 inches, and a neck portion, wherein the neck portion of the can body is formed by at least 15 necking operations to have a finished diameter designed to receive a 202 can end to close off the can body.
While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize that certain modifications, permutations, additions and sub-combinations thereof are also present in the disclosure. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.