Patent Application
20150360279
The present invention relates to a compression relief apparatus for applying shaped or textured features to the neck or shoulder region of a metal container. More specifically, the present invention contemplates an apparatus and method for forming predetermined shapes into the shoulder or neck of drawn and ironed aluminum bottles and cans.
It is generally known in metal container manufacturing processes to provide features on metallic containers such as raised forms and indicia using opposing, offset inside and outside shaped tooling dies. Outer dies frequently comprise inward protrusions, and inner dies comprise outward protruding features. These devices are typically applied to open ended straight wall containers before necking the container. However, these processes generally do not allow for features to be formed in the neck and/or shoulder area, and existing tools and methods of manufacturing fail to provide for large radius shoulders with common necking technology.
Surface features are generally known to be provided on metal containers using opposing, offset inside and outside shape dies, outer dies with inward protrusions, or inner dies with outward protruding features. Such known devices are typically applied to open ended straight wall containers prior to necking the container. Such known processes do not contemplate or allow for features to be provided in a neck or shoulder region of a container, and require more complexity in tool designs which typically cannot be run at commercially required speeds.
Conventional drawn and ironed aluminum and steel containers are drawn into cups, redrawn into a smaller diameter cup and ironed for increased length and to provide closed cylindrical shapes on bottle shaped containers. After coating applications and curing, the opening size is reduced by various necking methods, die necking, or some combination of die necking and spin necking or spin flow necking to be prepared for application of a closure of various styles such as conventional beverage end closures. Ropp (roll on pilfer proof) closures, or bottle crown caps. In the process of creating the necks of such containers, a shoulder is created where the cylindrical wall of the can body meets the neck. Shoulder configurations are generally arcuate in shape with radii in the range from 0.10 inches to about 2.0 inches.
Conventional die necking reduces the diameter of the container by contact of the cut edge of the container with an axi-symmetric forming die which forces the metal inward to effect a slight reduction in the diameter of the opening. A plurality of necking operations are performed to produce the desired opening size depending on the starting diameter and opening size. An axi-symmetric pilot die is generally used with the necking on the inside of the container to control the metal flow and reduce wrinkling. The forming die radii have generally been in the range of 0.10 inches to 0.50 inches for lightweight metal beverage containers. Conventional drawn and ironed metal containers are then finished with a flange to be able to be closed with a container end closure. Metallic bottle shaped containers are typically finished with either a crown curl or a threaded finish which can receive an aluminum or steel closure.
Some shaping and embossing processes to modify the cylindrical shapes are known in the art such as blow molding inside a die, spin flowing forming, and progressive die necking deep into the body of the container followed by expansion operations to create generally axi-symmetric shapes. However, many of these processes are time consuming, expensive, and not conducive to forming unique outward or inwardly shaped geometries in the shoulder or neck region of the bottle shaped container.
A method and apparatus for reshaping at least one of a shoulder and a neck of a container is provided. In one embodiment, a method of reshaping a shoulder of a container is provided wherein a bottle shaped container is provided and reshaped or altered to modify either the shape or dimension of the shoulder/neck region. A further step of the method comprises forming one or more raised surface features. This process provides for better control of feature relief forming and reduces “puckling”, and other irregularities in the surface features as will be described herein.
Embodiments of the present invention contemplate reshaping bottle shaped metal containers to provide either concentric or non-concentric shapes onto the neck, shoulder and wall portion of the container by use of one or more tools which have unique relief features which allow the metal to flow into recessed portions of the die when a compressive force is applied to the bottle shaped containers. Embodiments of the present invention may apply to impact extruded aerosol containers, and drawn and ironed cans and drawn and ironed metal bottles made from aluminum or steel.
Adding ornamental features to the shoulder and/or neck portion of bottle shaped containers is achieved by utilizing a shaping die with a generally larger radius than that on the manufactured bottle and if features are desired, such features are provided in the inner surface of the die between the tangent points of the larger radius. This process of reshaping and forming ornamental features in the shoulder is often done in the later stages of necking operations, after the initial shoulder and neck region has been formed.
Changing the shoulder radius can reduce the total surface area of the shoulder radius, therereby causing the metal to compress. As metal compression ensues the container generally is extended in height as permitted by the die and there is excess material available for flowing into recesses in the die without the necessity of an opposing die or mandrel. This flow of metal into the recess area of the die can be utilized to create unique ornamental features on predetermined portions of the shoulder and neck region of the metal container.
In certain embodiments, the shoulder radius of a container is increased and features are added to the shoulder area by making a die with a larger radius than on the manufactured bottle. In certain other embodiments the shoulder radius of the container may be decreased. Desired features are added with relief into the inner surface of the die, preferably between the tangent points of the larger radius. Reshaping and surfaces are formed when the smaller radius shoulder is pressed with force directly into a larger radius die, which may include features and ornamental shapes which are intended to be formed on the shoulder of the container.
The present invention contemplates altering the shape and/or geometry of the shoulder and/or neck region of a bottle shaped metallic container. This may include but is not limited to modifying the shoulder radius of a metallic bottle or can, thereby reducing the total area of the shoulder and causing the metal to compress. As the metal compresses and thickens, the container grows in height and excess metal material becomes available for flowing into recesses in the die with no inner opposing die or mandrel. Increasing the shoulder radius may be done with one or more dies, depending on the final desired ornamental shape. In certain embodiments of the present invention, a container is initially provided with a first shoulder radius. The container is then put into compression as contact is made with the forming tool, wherein the shoulder and/or neck region is reshaped to a larger or smaller radius.
In various embodiments, a device and method of use of the present invention comprises a substantially annular-shaped tool comprising inwardly or outwardly-oriented relief features. Corresponding features are provided in a shoulder portion of the metallic container by shaping the shoulder by an axial movement of the tool which is positioned over the outer circumference of the metallic container. Preferably, the axial movement of the tool on the container is a linear movement wherein the tool and container to be shaped are positioned substantially coaxially, and without the necessity of using any form of internal mandrel or rotating tool. Thus, a shoulder relief shaping process is performed in certain embodiments through the application of a compressive force between an interior of the tool and an exterior of the container. In various embodiments of the present invention the tool remains stationary while the bottle shaped can is moved towards the tool in a substantially linear direction aligned with the longitudinal axis of the container.
Prior art devices provide for inwardly extending features (i.e. indentations) on a metallic container body, and such features are typically formed on a fixed-radius container. In contrast, the present invention provides systems and devices of providing raised features on the shoulder and/or neck region of the bottle shaped container in either a symmetric or asymmetric orientation. Certain embodiments of the present invention comprise die members having surface features that protrude into the die and thus form outwardly protruding features on the shoulder or neck portion of the containers during reshaping. Such features of the present invention may be formed by incrementally increasing the shoulder radius of the container to promote metal movement and outward metal flow in a container-forming operation wherein metal flows outwardly with respect to the container and allows for the creation of outwardly-extending features during a process step that involves placing the container in a state of compression.
Examples of processes and various tools currently used in prior art metal manufacturing processes may be found in U.S. Pat. No. 4,481,163 to Negishi et al., U.S. Pat. No. 5,713,235 to Diekhoff, U.S. Pat. No. 5,718,352 to Diekhoff et al., U.S. Pat. No. 6,094,961 to Aschberger, and U.S. Pat. No. 7,140,223 to Chupak, which are incorporated by reference herein in their entireties.
In various embodiments, a shoulder shaping tool is provided with voids or outwardly oriented relief features for forming desired features on or proximal to a shoulder of a metallic container. The tool is provided as a generally annular device and adapted for substantially parallel movement to the longitudinal axis of the bottle or metal container. The tool may be provided for either symmetric or asymmetric shaping of the container.
In certain embodiments, the present invention comprises a method and apparatus wherein a shoulder forming or shaping tool is devoid of outwardly projecting relief features in a shaping die. For example, in one embodiment, a shaping tool or die is provided without distinct relief features and an internal surface of the tool comprises the shape of an outer surface of a shoulder profile to be formed. The tool is adapted to conduct a forming operation by axial compression of the tool and the container, without rotation of the container or tool and without internal supports or punches provided in the container. Methods and tools of such embodiments provide a fast and efficient method of shaping and reshaping shoulder portions of metal containers.
A method of certain embodiments of the present invention contemplates shaping the shoulder of a container to form various relief features in the shoulder by axial movement of a shaping tool subsequent to the forming of a final shoulder radius. Notably, a shoulder relief shaping process is performed in certain embodiments by utilizing only exterior tool contact or force application. Wherein various prior art methods and devices contemplate blow molding, rotational molding, and/or knockout features for forming, shaping, and reforming a container, the present invention provides for shaping a shoulder portion with a shoulder relief forming tool and in the absence of a mandrel or other similar tools provided on an interior portion of the container. In certain embodiments, an internal static pressure is provided within the container while a shoulder relief forming tool is actuated to form outwardly oriented relief features (i.e. with respect to the container).
In one embodiment of the present invention, a method of reshaping a neck or shoulder portion of a metallic container is providing and comprising reshaping a neck or a shoulder portion of a metallic container, providing a drawn and ironed bottle shaped metallic container with an open upper end, a neck portion, a shoulder portion, a sidewall, and a dome interconnected to a lower end of the sidewall to define a first shape, providing a forming tool having an annular portion sized to engage a portion of at least one of the neck and the shoulder, and wherein an inner surface of the annular portion includes a relief feature, engaging an exterior surface of at least one of the neck portion and the shoulder portion with said forming tool by moving at least one of said forming tool and said bottle shaped metallic container in a substantially linear motion in a direction aligned with the longitudinal axis of said bottle shaped metallic container, and reshaping the metallic container such that at least one of the neck and the shoulder is altered in shape and or dimension and wherein during the reshaping step, a portion of the metallic container moves outwardly away from a common axis of the metallic container and into one or more recesses in the forming tool to modify the first shape of the bottle shaped metallic container.
In another embodiment of the present invention an apparatus for reshaping at least one of a neck and a shoulder portion of a drawn and ironed metallic bottle is provided, comprising an apparatus for reshaping at least one of a neck and a shoulder portion of a drawn and ironed bottle shaped metallic container, the apparatus comprising a forming tool which is oriented in a substantially linear direction with respect to the longitudinal axis of the bottle shaped metallic container, and adapted to engage an exterior surface of at least one of the neck and shoulder portion of the bottle shaped metallic bottle, a central void in said forming tool comprising an inner surface with at least one recess having a predetermined shape, wherein when said forming tool applies a compressive force to at least one of the neck and the shoulder portion, an outwardly-oriented relief feature is formed in the bottle shaped metallic container.
The accompanying drawings, which are incorporated in and constitute part of the specification, illustrate embodiments of the present disclosure and together with the general description given above and the detailed description of the drawings given below, serve to explain the principle of the present disclosure.
It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted from these drawings. It should be understood, of course, that the present disclosure is not limited to the particular embodiments illustrated in the drawings.
Various embodiments of the present disclosure are described herein with reference to the drawings. It is expressly understood that although
Referring now to
Embodiments of the present invention comprise providing a metallic container with a large shoulder radius, and a correspondingly larger total area of the shoulder. As the metallic container is necked, metal is compressed and moves outwardly. Upon such movement, the container may be extended in height and excess material flows into recesses or outward protruding features in the die without the necessity of an inner opposing die or mandrel.
The compression of the metal during the reshaping operation provides an area of reduction 18 corresponding to the change in shape of the shoulder. Containers having a shoulder radius of up to 2 or 3 inches may be formed using the various methods, tools, and systems of the present invention. In some tests certain containers 12 formed large “puckles” 22 (a buckled pucker) as shown in
As shown in
While various embodiments of the present disclosure have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present disclosure. Further, the invention(s) described herein are capable of other embodiments and of being practiced or of being carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purposes of description and should not be regarded as limiting. The use of “including,” “comprising,” or “adding” and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof, as well as additional items.
