The present invention relates to a manufacturing process for forming metallic containers and container end closures, and more specifically a method and apparatus for forming high strength geometries while maintaining necessary chuck wall and seaming panel characteristics.
Metallic beverage can end closures have historically been designed and manufactured to provide a stiffening bead referred to as countersink. This feature may include vertical walls attached by a full radius bottom forming a channel, and in some embodiments may incorporate arcuate shapes or other geometric profiles. Absolute vertical walls may not exist, but generally the more vertical they become the greater the resistance to deformations resulting from internal pressure.
Beverage can bodies and end closures must be durable to withstand high internal pressures, yet manufactured with extremely thin and durable materials such as aluminum to decrease the overall cost of the manufacturing process and the weight of the finished product. Accordingly, there exists a significant need for a durable beverage can end closure which can withstand the high internal pressures created by carbonated beverages, and the external forces applied during shipping, yet which are made from durable, lightweight and extremely thin metallic materials with geometric configurations which reduce material requirements. To obtain these characteristics, can end closures require aggressive material working to achieve the various forms and geometries, which is generally accomplished utilizing a male/female tool combination. Unfortunately, this process may lead to inconsistencies within a given contour or geometry. Formation inconsistencies also apply to strength performance. The aggressive forming within the countersink may alter other characteristics within the body of the entire structure. Thus, there is a significant need to provide an apparatus and material forming technique which provides improved end closure on container geometries which have improved strength and buckle resistance. These features are obtained in one embodiment by placing the end closure material in compression during forming to avoid thinning and unwanted material deformation, while simultaneously supporting certain portions of the end closure chuck wall and seaming crown geometry during forming while not supporting other portions to create a predetermined shape.
One patent related to a method and apparatus for producing a container end closure countersink is described in U.S. Pat. No. 5,685,189, (the “'189 patent”) which is incorporated herein by reference in its entirety. In the '189 patent, a portion of the countersink is formed when the countersink is unsupported by tooling while the countersink is placed in compression. Unfortunately, with lighter gage stock materials this process has been found to allow unwanted deformation in the chuck wall and seaming crown, and thus inconsistencies in the end closure geometry.
The present invention relates to an apparatus and method for forming a preferred geometric shape in containers and end closures utilizing thin walled materials (0.0084 or less gauge) which have improved strength characteristics and material properties. Thus, in one aspect of the present invention a “free forming” process is used in the manufacturing of a metallic container end closure, wherein at least a portion of the material is placed in compression during forming, and is thus less likely to become “coined” or thinned, and ultimately weakened. It is a further aspect of the present invention to provide a method and apparatus for forming a predetermined shape from a metallic material wherein a portion of the metallic material is unsupported by a tool during formation. Thus, a portion of the metallic material is allowed to “free form” into a desired shape without being substantially supported on both the entire upper or lower surface of the material.
It is a further aspect of the present invention to provide a forming press to form a preferred geometry in a metallic end closure with existing high speed forming processes currently known in the industry and having improved reliability. Thus, in one aspect of the present invention an inner pressure sleeve is utilized in combination with critical forming parameters to assure that the end closure achieves a predetermined geometry, and is extracted efficiently from the forming process at speeds of 1800-11,000 end closures/minute.
It is a further aspect of the present invention to provide an inner pressure sleeve which is driven with pins extending between itself and either a pneumatic piston, spring plate or individual springs to apply a sufficient force to support a portion of an end closure chuck wall to form a preferred geometry during manufacturing.
It is another aspect of the present invention to provide an apparatus and method for forming a preferred geometric shape in container end closures where other portions of the end closure are supported on both an interior and exterior surface to prevent movement and unwanted deformation, while another portion is allowed to “free form”. Thus, in one embodiment of the present invention a “pressure sleeve” is used to support an end closure chuck wall and/or the seaming panel radius against a die core ring during forming, while at least a portion of the countersink is placed in compression to form a preferred geometry. Thus, in one aspect of the present invention an apparatus for forming a preferred shape in a metallic blank to create a beverage container end closure with a preferred geometry. It is another aspect of the present invention to provide a method and apparatus for forming improved end closure geometries by generally utilizing tooling equipment which is well known in a container end closure manufacturing plant, and thus requires only minor modifications to implement. Thus, in one embodiment of the invention, an apparatus is provided to form a metallic end closure which generally comprises:
a first tool in opposing relationship to a second tool which is adapted to provide a clamping force on a portion of a seaming panel of the metallic material;
a third tool in opposing relationship to a fourth tool which is adapted to providing a clamping force on a central panel portion of the metallic material;
a fifth tool positioned between said first tool and said third tool, which is adapted to support at least a portion of a chuck wall portion of said metallic material; and
providing a reciprocating motion between at least said fifth tool and said first and second tools while a portion of a countersink in the container end closure remains unsupported, wherein a preferred geometry is created in the countersink producing a material thickening, thus avoiding a reduction of material thickness of the countersink.
In another aspect of the present invention, a method for forming a predetermined shape in a metallic container end closure is provided herein, the end closure generally comprising a seaming panel interconnected to a downwardly extending chuckwall, a central panel having a substantially vertical center axis, and a countersink integrally interconnected to a lower portion of the chuck wall and the central panel, comprising:
positioning an end closure blank in a forming press;
providing a clamping force on at least a portion of the seaming panel between a first tool and a second tool;
providing a clamping force on at least a portion of the central panel between a third tool and a fourth tool to substantially prevent movement of the central panel;
supporting at least a portion of the chuckwall on both an interior surface and an exterior surface to substantially prevent movement of at least a portion of the chuckwall;
supporting a first portion of the countersink with at least one of said third tool and said fourth tool while allowing another portion of the countersink to remain unsupported; and
providing a compressive force on the countersink while retaining the chuck wall in a preferred position, wherein the end closure is formed into a predetermined shape.
While an effort has been made to describe various alternatives to the preferred embodiment, other alternatives will readily come to mind to those skilled in the art. Therefore, it should be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. Present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not intended to be limited to the details given herein.
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a) capable of producing end closures with aggressive geometries while maintaining total control of the chuck wall and seaming panel;
b) allows the forming of difficult chuck wall and countersink geometries without metal thickness reductions;
c) allows the formation of end closure countersinks with material thickening, wherein the prior art may create thinning or coining in the metal in various locations;
d) the added control of the present invention allows tooling designs which more accurately define closure contours than previous apparatus with aggressive forms;
e) capable of producing closure with higher strength materials without the metal fatigue normally associated with tight forms and radii;
f) the greater control and latitude provided by the present invention allow higher strength end closures with lower material gauge; and
g) improved operating efficiency during manufacturing and removal of the container end closures from the forming press.
While an effort has been made to describe various alternatives to the preferred embodiment, other alternatives will readily come to mind to those skilled in the art. Therefore, it should be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. Present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not intended to be limited to the details given herein.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/592,784, filed Jul. 29, 2004, which is incorporated by reference in its entirety herein.
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