This application relates to systems and methods of forming shaped containers, and, more specifically, to systems and methods for forming shaped metal containers from metal such as aluminum or aluminum alloys.
Many containers such as food and drink cans, tire extinguishers, gas cans, oil filter casings, damper casings, and many other types of articles are made from metal materials such as aluminum, aluminum alloys, stainless steel, brass, low-carbon steel, and various other suitable materials. The process of forming the container from the metal material generally includes a number of processes such as a drawing and wall ironing process, a shaping process such as a sequence of full-body necking steps or other mechanical shaping, and other processes as desired to shape a metal blank into a container having a shape as desired. Oftentimes, metal containers that are adapted to hold contents under pressure (e.g., carbonated beverages) are provided with an upwardly extending dome in a bottom wall of the container to resist deformation under pressure. However, existing dome geometries have a lower limit for a metal gauge of the wall of the container, or, stated differently, domes having a metal gauge below a lower limit will fail and/or deform under pressure.
Embodiments covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.
According to certain embodiments, a domer assembly for a bottom forming system includes a first domer and a second domer. The first domer includes a first surface that may engage a bottom of a metal container during a bottom forming process. The second domer includes a second surface that may engage the bottom of the metal container during the bottom forming process. The second domer is movable relative to the first domer.
According to some embodiments, a bottom forming system for forming a metal container includes a domer assembly that forms a double dome in a bottom of the metal container during a bottom forming process. The double dome formed in the bottom of the metal container may include a first dome having a first dome profile and a second dome having a second dome profile.
According to various embodiments, a method of forming a bottom of a metal container includes forming a first dome profile in the bottom of the metal container using a first domer and a second domer of a domer assembly. The method includes forming a second dome profile in the bottom of the metal container by moving the second domer relative to the first domer.
Various implementations described herein may include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.
The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.
The subject matter of embodiments is described herein with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “front,” and “back,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing. While the systems and methods described herein can be used with any metal, they may be especially useful with aluminum or aluminum alloys.
Described herein are systems and methods for forming a bottom of a metal container. In various embodiments, the systems and methods provided herein may form a metal container with a double dome. In certain embodiments, a domer assembly includes a first domer and a second domer that is selectively movable relative to the first domer. During a first stage of a bottom forming process, the first domer and the second domer may together create a dome profile and engage a bottom of a metal container for forming a first dome profile. During a second stage of the bottom forming process, the second domer may move relative to the first domer to further engage the bottom of the metal container, which may change the geometry of the first dome profile and create a second dome profile such that the metal container includes a double dome.
The geometry of the double dome may withstand and improve dome reversal pressure compared to traditional domes, and the double dome may allow for containers to be formed from a metal having a lower metal gauge compared to traditional containers with a dome while still withstanding dome reversal pressure. The ability to use a metal having a lower metal gauge may in turn allow for cans to have a reduced weight (e.g., due to less material), which may provide cost reductions for can makers in certain aspects, the systems and methods described herein may increase a dome depth/height compared to traditional domes, change the geometry of the dome profile compared to traditional domes, increase work hardening and residual stress, and/or improve the dome reversal pressure for the container. Various other advantages and benefits may be realized with the systems and methods described herein, and the aforementioned benefits should not be considered limiting
The domer assembly 102 includes at least a first domer 110 and a second domer 112. In some embodiments, and as best illustrated in
As best illustrated in
In various embodiments, the second domer 112 is selectively movable relative to the first domer 110. In certain aspects, the second domer 112 is axially movable relative to the first domer 110, although the second domer 112 may include additional movement relative to the first domer 110 in other embodiments. In embodiments where the second domer 112 is positionable within the central aperture 114 of the first domer 110, the second domer 112 may be movable within the central aperture 114. Various mechanisms, devices, or features may be utilized such that the second domer 112 is movable relative to the first domer, including but not limited to various mechanical systems, pneumatic systems, hydraulic systems, magnetic systems, combinations thereof, and/or other devices or systems as desired.
Referring to
As mentioned, in addition to the domer assembly 102, the bottom forming system 100 may optionally include the retainer 106 and the punch 108. In certain embodiments, the retainer 106 includes a receiving area 122, and the domer assembly 102 may be positionable and movable within the receiving area 122 during the bottom forming process. The punch 108 and retainer 106 may be used to further shape the bottom 104 of the metal container during the bottom forming process. However, the particular punch 108 and retainer 106 illustrated should not be considered limiting, and in other embodiments punches and/or retainers with other shapes, profiles, features, etc. may be used as desired. In further embodiments, the bottom forming system 100 may include fewer or additional features as desired.
A bottom forming process using the bottom forming system 100 is described in detail below. Referring to
Referring to
Referring to
A collection of exemplary embodiments are provided below, including at least some explicitly enumerated as “Illustrations” providing additional description of a variety of example embodiments in accordance with the concepts described herein. These illustrations are not meant to be mutually exclusive, exhaustive, or restrictive; and the disclosure not limited to these example illustrations but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.
Illustration 1. A domer assembly for a bottom forming system, the domer assembly comprising: a first domer comprising a first surface configured to engage a bottom of a metal container during a bottom forming process; and a second domer comprising a second surface configured to engage the bottom of the metal container during the bottom forming process, wherein the second domer is movable relative to the first domer.
Illustration 2. The domer assembly of any preceding or subsequent illustrations or combination of illustrations, wherein the second domer is movable within the first domer.
Illustration 3. The domer assembly of any preceding or subsequent illustrations or combination of illustrations, wherein the first domer is a sleeve and the second domer is an insert movable within the sleeve.
Illustration 4. The domer assembly of any preceding or subsequent illustrations or combination of illustrations, wherein the second domer is axially movable relative to the first domer.
Illustration 5. The domer assembly of any preceding or subsequent illustrations or combination of illustrations, wherein the domer assembly is positionable in a first configuration and a second configuration, wherein, in the first configuration, the first surface is continuous with the second surface and together forms a first dome profile, and wherein, in the second configuration, the second surface is offset from the first surface and the second surface forms a second dome profile
Illustration 6. The domer assembly of any preceding or subsequent illustrations or combination of illustrations, wherein the first domer and the second domer are configured to together form a first dome in a bottom of a metal container during a first stage of a bottom forming process, and wherein the second domer is configured to form a second dome in the bottom of the metal container during a second stage of the bottom forming process.
Illustration 7. A bottom forming system for forming a metal container, the bottom forming system comprising a domer assembly configured to form a double dome in a bottom of the metal container during a bottom forming process comprising a first dome having a first dome profile and a second dome having a second dome profile.
Illustration 8. The bottom forming system of any preceding or subsequent illustrations or combination of illustrations, wherein the domer assembly comprises a first domer and a second domer, wherein the second domer is selectively movable relative to the first domer
Illustration 9. The bottom forming system of any preceding or subsequent illustrations or combination of illustrations, wherein the domer assembly comprises a first configuration and a second configuration, wherein, in the first configuration, the second domer is at a first position relative to the first domer such that the first domer and the second domer are configured to together form the first dome, and wherein, in the second configuration, the second domer is at a second position relative to the first domer such that the second domer is configured to form the second dome.
Illustration 10. The bottom forming system of any preceding or subsequent illustrations or combination of illustrations, wherein the first domer is a sleeve, and wherein second domer is an insert movable within the sleeve.
Illustration 11. The bottom forming system of any preceding or subsequent illustrations or combination of illustrations, wherein the second domer is axially movable relative to the first domer.
Illustration 12. The bottom forming system of any preceding or subsequent illustrations or combination of illustrations, wherein the first domer comprises a first surface and the second domer comprises a second surface, wherein the second domer is movable relative to the first domer such that, in a first position of the second domer relative to the first domer, the first surface is continuous with the second surface, and, in a second position of the second domer relative to the first domer, the second surface is offset from the first surface
Illustration 13. The bottom forming system of any preceding or subsequent illustrations or combination of illustrations, further comprising: a punch, and a retainer comprising a receiving area for a metal container, and wherein the domer assembly is movable within the receiving area.
Illustration 14. A method of forming a bottom of a metal container, the method comprising: forming a first dome profile in the bottom of the metal container using a first domer and a second domer of a domer assembly; and forming a second dome profile in the bottom of the metal container by moving the second domer relative to the first domer.
Illustration 15. The method of any preceding or subsequent illustrations or combination of illustrations, wherein forming the second dome profile comprises axially moving the second domer relative to the first domer.
Illustration 16. The method of any preceding or subsequent illustrations or combination of illustrations, wherein forming the first dome profile comprises axially moving the first domer and the second domer together in a first direction to engage the bottom of the metal container, and wherein forming the second dome profile comprises moving the second domer relative to the first domer in the first direction.
Illustration 17. The method of any preceding or subsequent illustrations or combination of illustrations, wherein forming the first dome profile comprises using a punch to further form the first dome profile in the bottom of the metal container.
Illustration 18. The method of any preceding or subsequent illustrations or combination of illustrations, wherein the first domer is a sleeve and the second domer is an insert within the sleeve, and wherein forming the second dome profile comprises moving the second domer while the second domer is at least partially within the sleeve.
Illustration 19. The method of any preceding or subsequent illustrations or combination of illustrations, wherein forming the first dome profile comprises engaging a first surface of the first domer and a second surface of the second domer with the bottom of the metal container.
Illustration 20. The method of any preceding or subsequent illustrations or combination of illustrations, wherein forming the second dome profile comprises moving the second domer relative to the first domer such that at least a portion of the bottom of the metal container does not contact the first surface or the second surface.
Illustration 21. A metal container comprising a bottom formed by the method of any preceding or subsequent illustrations or combination of illustrations.
Illustration 22. The metal container of any preceding or subsequent illustrations or combination of illustrations, wherein the metal container comprises aluminum or an aluminum alloy
Illustration 23. The metal container of any preceding or subsequent illustrations or combination of illustrations, wherein the bottom comprises a reduced metal gauge.
The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described embodiments, nor the claims that follow.
This application claims the benefit of U.S. Provisional Patent Application No. 63/250,806, filed Sep. 30, 2021, which is incorporated by reference herein in its entirety.
Number | Date | Country | |
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63250806 | Sep 2021 | US |