CA1163584A

CA1163584A - Lightweight container

Info

Publication number: CA1163584A
Application number: CA000386698A
Authority: CA
Inventors: John Walter; Donald J. Roth; Charles S. Kubis
Original assignee: Continental Group Inc
Current assignee: Continental Group Inc
Priority date: 1980-09-26
Filing date: 1981-09-25
Publication date: 1984-03-13
Also published as: DE3167726D1; EP0048890A1; BR8106173A; GB2084107A; ES510422A0; ES8303228A1; DK425981A; AU542031B2; AU7568681A; GB2084107B; GR75018B; EP0048890B1

Abstract

LIGHTWEIGHT CONTAINER
ABSTRACT OF THE DISCLOSURE

A novel pressure holding container formed of thin sheet metal of the order of between 10 and 4 mils wherein the container has a bottom portion and a top portion, the bottom portion having a body and an integral bottom, and in one embodiment having a necked-in upper end of the body which tightly fits into a lip portion of the lower end of the top portion and is adhesively bonded thereto and where-in the upper portion of the top portion has a toro-conical shape which under pressure wants to expand it into a spherical shape and thus through beam loading on the lip portion imposes compressive stresses thereon and holds in compression the adhesive which is interposed between the lip and the annulus of the necked-in portion of the body which is loaded in tension by the internal-pressure in the container. In another embodiment of the invention, the body has no necking-on at its upper edge and is of uniform diameter from end to end and is tightly fitted into the lip of the upper portion and adhesively bonded thereto. The joint in each embodiment has thin lapped metal sections which deflect and transmit lateral loads imposed on the body and/or lip and thus attenuate the forces without imposing peeling forces on the adhesive. The conical sections are either stepped or smooth for different force loadings particularly in the application of different types of closures thereto.
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Description

li!63s84 LIGHTWEIGHT CONTAINER

B ckground of the Invention Containers of the type under consideration are primarily made of aIuminum and have a cylindrical body with an integral bottom. The top is usually closed by a generally flat end member of different alloy than the body which is usually H19~3004. The present com-mercial aluminum containers including ends weight approximately .04a-.045 pounds each. The single service beverage cans of the 1960'~s included a three-piece steel ~ody, steel bottom and an aluminum top. The most popular can of the 1970's was an all aluminum drawn and wall-ironed can with a double seamed top~ The top was of a different alloy than the can body.
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Description of the Problem ::
Aluminum, because of its light weight and ductility and being able to be easily case, is finding growing uses, most recently in the automotive industry.
Material costs are rapidly escalating and the supply is dwindling. Various structures have been made to shape the bottom of the can to obtain more volume with less strength. Inverted or the champagne bottoms on the 1970 vintage cans have been used to hold the pres-sure, but this design is wasteful of the material in that a taller than necessary can $

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must be provided necessitating additional material to obtain the desired volume. Furthermore, the flat top end requires the use of a strong alloy aluminum material having a magnesium content. The compositions of the body and that of the end of each can, being different, complicates re-cycling of the cans Steel cans on the other hand, because of the thickness of the metal used, require high tonnage presses and tools must be more frequently replaced. When thick metal is used, the costs and carrying weights become exces-sive. In order to obtain an easy opening feature, steel cans invariably use aluminum tops which complicates re-cycling. The aluminum and the steel must be separated which is a time consuming costly process. The attractive-ness of steel for cans is in the lower cost of the metal and its yreater availabilityO
Solution of the Problem A primary object of -the invention is to provide a pressure vessel design to create an optimum container.
The concave bottoms of the principal curren*
designs .014 inch thick are replaced in the can of this inven-tion formed of aluminum by a convex bottom about ~008 inch thick which obtains increased volume with less alumi-num.
The double seam which also consumes aluminum is eliminated by substituting an adhesive telescoped joint.
The top or dome of the new container is about ~ mils thick compared to the double seam flat top of 14 mils. The heavy flange thickness of 7 mils of double seamed cans is not re~uired and is reduced to 4 mils.
A total packaye weight of about 20 pounds per one thousand cans is obtained versus 38-40 pounds for the present lightest weight aluminum cans.
The two pieces of the new can are assembled at the can plant and later filled through the small drink hole using conventional bottle fillers.

3~4 It is postulated that although aluminum cans 4 mils thick are about the thinnest than can be commercially made, steel cans 2 to 2-1/2 mils in wall thickness are feasi-ble. The elimination of a special alloy for the can ends by making the can of one alloy produces a uni-alloy can, therefore making it more valuable as scrap for recycling.
The inventlon particularly relates to a metal can comprising a body, a dome, and a lapped joint including an adhesive layer between the body and the dome, and the rela-tionship between the body and the dome being one whereinwhen the can is filled with a liquid packaged under pressure the dome in the general area of the lapped joint radially inwardly deforms and the body in the general area of the lapped joint radially outwardly deforms with the combined deformation of the dome and the body compressing the adhesive layer.
A dome-shaped top member is used having a novel shape including a cone-like center portion and a peripheral annulus or band portion which is joined to the center por-2Q tion by a toroidal section, the annulus preferably terminat-ing at its lower edge in an outwardly turned flange which not only strengthens the annulus against radial deflection but also provides on its underside a bell-shaped pilot surface for guiding the end member into an interference fit assembly with a necked-in section formed at the upper end of the body portion oE the can, the necked-in section terminating at its lower end in an outwardly extending shoulder which merges into the can body section therebelow, the shoulder providing a stop which the flange at the lower end of the top portion engages as the top is fully entered over the necked-in section which is secured to the top portion by a suitable preferably tnermoplastic or thermo-setting adhesive of well k~nown kind.
Advantage is taken of the shape of the top and of the thinnesss of about .009 inch and short axial length of the top with respect to the body length of the container s~`~
- ~ -to which the top is applied by shaping the top in a manner such that on filling the container with pressurized bever-age internal pressure forces are exerted on the cone sec-tion of the top to cause beamloading of the cone section to exert inward forces on the lip at the base of the cone portion to assist the adhesive by applying compressive forces thereagainst and to the portion of the opposing body portion at the telescoped junction of the body and top.
Peeling forces on the adhesive in the Donded telescoped junction as would ordinarily occur unaer internal pressure loading are thus eliminated. Various configurations of the top portion are shown which obtain specific benefits as hereinafter defined.
In conducting studies with respect to the cans, with particular reference to the adhesive, it has been unexpectedly found that the adhesive, when placed in com-pression, exhibits a marked increase in sheer strength.
In 12 ounce cans, the body has a diameter of

2.60 inches and an axial length of 4 inches whereas in the 20 16 ounce can the body length or height is 4.75 inches.
In order to obtain a beaming action wherein the forces of expansion acting on the conical portion of the top produce compressive forces on the adhesive, the toroid-al section, which provides the transition between the slop-ing conical section and the axial lip section, is arcuate in cross section and has a radius of l/16 to l/4 inch. It has been found that as the material used becomes thinner, the radius must be made larger. If the beaming forces were to be restricted or with a sharp angle at the juncture, the conical portion would buckle and wrin~le adjacent to the lip.
The invention comprehends providing a transition between the cone and the lip such that internal pressure forces tending to expand the conical section as well as the toroidal portion are utilized to produce a compressive force radially inwardly on the adhesive which together with the tensile forces tending to expand the upper end of the body a~ ~

_5_ portion ensures parallelism between opposing body and lip portions and thus precludes developing voids such as would produce leaking joints.
Furthermore, the invention comprehends making an adhesively bonded joint as an extremely narrow axial band on the order of 1/16 to 1/8 of an inch which is now feasible because of the compressive loading on the adhesive.
In steel cans to be comparable to the aluminum cans, the wall thickness of both the top and bottom sec-tions of the can would be on the order of 2 to 2-1/2 mils thick or 0.30mm (.0118 inch) thick which in Europe and particularly in Holland is identified as E5,6/5,6 (.50) Flow Brightened Type and Temper DKK (Type D Killed) T52 BA
(Temper).
Although the can is in no way restricted to formation from aluminum, as indicated by the possibility of utilizing even thinner gauge steel, for the present it would appear that the best commercial aspects are with respect to a can formed of aluminum, and for that reason, there has been established a can deemed most suitable for commercialization and that can, as well as various modifi-cations of the can, have been subjected both to analytical and experimental tests. These tests clearly indicate that a specific relationship of the dome to the body provides for maximum strength with a minimum usage of metal and at the same time assures the formation of a lap bond between the body and the dome which will not be subject to rupture under all expected conditions.
With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, -the appended claims, and the several views illustrated in the accompanying drawings.
IN 1'HE ~RAWINGS:
Figure 1 is a perspective view of one embodiment of the invention.

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Figure 2 is a top plan view thereof.
Figure 3 is a side elevational view thereof shown partly in axial section.
Figure 4 is an enlarged fragmentary sectional view taken substantially on line 4 4 of Figure 3.
Figure 5 is a view similar to Figure 5 showing the container wall portion partly inducted.
Figure 6 illustrates a further embodiment incorporating a modified upper portion of the container.
Figure 7 is a perspective view illustrating a further embodiment of the invention.
Figure 8 is a top plan view thereof.
Figure 9 is a side elevational view thereof partly in axial section.
Figure lQ is an enlarged cross section taken substantially on line 10-10 of Figure 8.
Figures 11-14 illustrate a further embodiment of the invention;
Figure 11 being a perspective view;
Figure 12 being a top plan view;
Fi~ure 13 being a side elevational view partly in vertical section taken substantially on line 13-13 of Figure 12, and Figure 14 is an enlarged portion of a part of Figure 13. ~-Figlre lS is an enlarged fragmentary sectionalview taken through the lap joint area of a preferred em-bodiment of dome and body relationship.
Figure 16 is a schematic view showing the over-all configuration of the dome and upper part of the body of a preferred embodiment.
Figure 17 is a plot comparing the deformation of the dome and body in the lap area under internal pressure with the undeformed can shape.
Figure 18 is a schematic view indicating merid-ional forces considered during analysis.

~ ~;3S~4 '7 Figure 19 is a schematic view showing circum-ferential forces considered during analysis.
Figure 20 is a plot of meridional forces in the dome and body of the can of Figure 17 at the indicated locations.
Figure 21 is a plot of the meridional moments of the can of Figure 17.
Figure 22 is a plot of the circumferential forces of the can of Figure 17.
Figure 23 is a plot of the circumferential moments of the can of Figure 17.
Figure 24 is an enlarged fragmentary plot of the can of Figures 15 and 16 comparing the deformed shape with the original shape when the can is under an 80 pound axial fitment load.
Figure 25 is a plot of the meridional forces of the loaded can of Figure 24.
Figure 26 is a plot of the meridional moments of the loaded can of Figure 24.
Figure 27 is a plot of the circumferential forces of the can of Figure 24.
Figure 28 is a plot of the circumferential moments of the can of Figure 24.
Figure 29 is a schematic sectional view of a modified can geometry having a lowered lap joint.
Figure 30 is a p~ot of the deformed shape of the can of Figure 29 under internal pressure as compared to the undeformed shape.
Figure 31 is a schematic sectional view of an-other modified can shape wherein the body has a straightwall.
Figure 32 is a plot of the can of Figures 15 and 16 with a decreased dome cone angle comparing the deformed shape of the can under internal pressure with the unde-formed shape.
Figure 33 is a plot of the meridional forces i~the can of Fiyure 32 at the indicated locations.
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Figure 34 is a plot of the meridional moments of the can of Figure 32.
Figure 35 is a plot of the circumferential forces on the can of Figure 32.
Figure 36 is a plot of the circumferential moments of the can of Figure 32.
Figure 37 is a plot of the can of Figure 32 showing the deformed shape thereof under an 80 pound axial fitment load as compared to the undeformed shape.
Figure 38 is a plot of the meridional moments of the can of Figure 37.
Figure 39 is a plot of the circumferential forces of the can of Figure 37.
Figure 40 is a plot of the circumferential moments of the can of Figure 37.
Figure 41 is a plot of the meridional forces of a can similar to the can of Figure 16, but wherein the dome toroidal radius has been decreased.
Figure 42 is a plot of the meridional moments of the same can discussed in Figure 41.
Figure 43 is a schematic sectional view taken through the lap joint and shows the arrangement of adhesive segments utilized in obtaining the analysis data oE TABLE II.
Figure 44 is a schematic sectional view through the lap joint showing the use of a si~ segment adhesive arrangement utilized in obtaining a portion of the analysis data of TABLE III.
Figure ~5 is a schematic sectional view through the lap joint showing the use of a nine segment adhesive arrangement utilized in obtaining a portion of the analysis data of TABLE III. , Figure 46 is a plot showing the undeformed shape of the can of Figures 15 and 16 comparing the computer predicted displacement wi-th respect to sensed displace-ments in a tested experimental can having an in-ternal pressuriæed load.

3S~14 g Figure 47 is a plot of the modified can of Figure 29 illustrating the undeformed can shape and a comparison of the computer predicted displacements with actual sensed displacements under an internal pressure load.
Figure ~8 is plots of allowable sheer stresses of different tested adhesives under a range of compres-sive loadings.
Description of Fi~ures 1-5 of the Invention The invention as shown in Figures 1-5 of the drawings comprises a novel container, generally designated 1, preferably entirely formed of one alloy of aluminum such as H19-3004.
The container has a lower or bottom portion 2 and a top portion or dome 3O The lower portion 2 com-prises a bottom 4 and an integral cylindrical body 6 which at its upper end 8 is necked-in to provide a radially in-wardly extending shoulder 10 about 1/32 to 1/16 of an inch wide and about the inner edge of which there is an axially extending annulus or ring 12 of approximately 1/8 of an inch in length.
The annulus or ring 12 preferably has a tight or interference fit into the lower end of an annular band or lip 14 of the dome 3 which is of an axial length corre-sponding to that of the ring 12 while the dome 3 is about.837 inch in total axial height. The upper edge of the lip 14 merges into the lower edge of a toroidal or arcuate transition section 15 which at its upper edge merges into the lower edge of a conical section 16. The section 15 has a radius of between 1/16 inch and 1/4 inch. Prefer-ably the thinner the metal, the greater the radius. The conical section 16 shown in Figures 1 and 5 is preferably of a stepped design and comprises a frustoconical annular band 18 which merges at its lower edge with the upper edge of the toroidal section 15 and the upper edge of the band 1~ merges with the lower edge of a conical segment 20 which at its upper edge, in turn, merges into the lower edge of a second smaller frustoconical band 22. The band 22 has its upper edge merging into the lower edge of a second frustoconical section 2.4 which, at its upper edge, merges into a curl 25 which is turned outwardly over the second section 24.
The lower edge of the lip 14 is provided with an outturned downwardly flaring frustoconical or curled flange 26 which has an outer edge substantially coaxial with an external circular surface 30 of the body portion of the container. A preferably thermoplastic resin or adhesive 32 such as polyvinyl chloride and thermoplastic resin such as polyethylene or polypropylene or alterna-tively thermosetting epoxy resin, or vinyl plastisol is applied to an outer side 34 of the ring 12 and to an inner surface 36 of the lip prior to assembly of the dome to the lower portion so that after assembly the assembled can may be heated to a temperature melting the plastic adhesive during which time the top and bottom portions of the can may be relatively axially or circumferentially moved to eliminate any pinholes or the like formed in the adhesive and to promote good adhesion of ~he adhesive to the metal parts. Upon cooling, the adhesive 32 bonds the telescoped parts together.
In the instant invention, a metal closure 40 is shown in Figures 1-10 for purposes of illustration, it being understood that plastic closures of various kinds such as shown in Figures 11-13 may also be used. The closure comprises a center plug 42 which fits into the pour opening 44. The plug has an axially extending side wall 45 which at its lower end is connected to a bottom wall 46 and at its upper ~nd has a downwardly open outward curl 48 which overlies the convex upper side 49 of the curl 25 and is drawn tightly against a foam gasket sealing material 50 applied thereto by mechanically crimping and expanding the side wall 45 of the plug to form a shoulder 51 under the curl.

~63~8~

The wall 46, side wall ~5 and curl ~8 are scored at 52, 52 and a ring type opener 55 is formed with the closure or cap and bent downwardly to extend generally parallel with the conical section of the upper portion.
The closure is readily opened by lifting the ring 55 thus breaking the scores 52, 52 and thus lifting the closure out of the pour opening.
One of the fea-tures of the invention is that the side wall of the body portion of the can may be made of aluminum having a substantially uniform thickness on the order of 4 mils. The side wall thickness has been main-tained substantially uniform from end to end, there being no necessity for a thick zone about the open end since the double seaming has been eliminated. It is, however, feas-ible to make the entire side wall of the container, exce?t for the extreme top, of a metal thickness of about 4 mils and the bottom of about 4-8 mils. However, if desired, variable thicknesses may be incorporated in various zones of the side wall.
The novel telescoping arrangement of the lip of the top and the necked-in band of the bottom portion and the provision of the outturned flange on the lower edge of the lip has been found to provide exceptional resistance to impact breeching of the connection. The flange 26 materi-ally improves the radial strength of the lip portion of the top and the configuration of the lip and toroidal and conical sections develop a compression loading on the connection which together with the radial shoulder and necked-in band of the lower section resist inward displace-ment and thus do not extend peel stresses to the adhesive.
This feature is amply illustrated in Figure 5wherein the body portion is depressed immediately below the necked-in region. The shoulder 10 stops the body from deflec-ting inwardly and thus prevents peeling of the ad-hesive. Furthermore, the thin metal top, upon being pres-surized, when the can is filled with pressurized beverage, 8~ -becomes a prehensible member and wants to expand its conical section into a sphere. This, in turn, loads the lip portion in compression which resists the expansion of the necked-in portion and holds the adhesive in compres-sion therebetween.

Embodiment of Figure 6 In this embodiment, as well as all others, parts which are ide~tical with the other embodiments are identi-fied by the same reference numerals.
As seen in Figure 6, the top portion of the container is an unstepped conical section. In this embodi-ment the transition from the toroidal section 15 to the curl is a smooth single conical section 60 a design satis-factory depending on the stacking strength required of the container.

Embodiment of Figures~7-10 In this embodiment the necked-in structure at the upper end of the body section is eliminated and the upper end of the body portion 6 is a continuous cylinder which is slightly precompressed and fitted into the lip 14 of the top portion 3. The adhesive is thus held in com-pression between the lip 14 and the upper portion of the body 6.
In this embodiment the bottom and top portions of the container are generally of the same diametrical dimension. The bottom portion is precompressed about its upper edge portion 8 prior to insertion into the top lip 14 of the upper portion and then is released compressing the adhesive 32 between the inner surface of the lip and the outer surface of the upper portion 14. The adhesive is preferably a thermoplastic type such that after the container portion of any of the previous or subsequent embodiments are assembled and they are passed through a heating chamber, the adhesive melts and fuses the top ; and bottom por-tions into a unitary structure. In this embodiment it will be appreciated that the joint is 3S~it9L

flexible because of the wall thicknesses being of the order of 4-9 mils, preferably the former for the body portion 6, and the adhesive is flexible. Thus, when the container is struck with a side blow in the body wall adjacent to the joint, the extremely thin seccion of material, that is the metal and the plastic adhesive, allows the joint to flex inwardly thus attenuating the forces and inhibiting these forces from applying peeling loads on the adhesive and separating the inner portion from the lip.

Embodiment of Figures 11-14 In this embodiment the structure of the bottom portion 2 is the same as in the embodiments of Figures 1-5.
The top, however, is made to accommodate a dif-ferent type of closure 100.
In this embodiment the nec~ 102 at the top of the stepped cone 104 is elongated and has an inturned frustoconical lip 105 which forms a smooth apical annulus 106 against which the bottom side 108 of a radial flange 110 of the plastic closure 100 seats.
The flange 110 is connected to a hollow sleeve 114 which fits into the lip 105 and has external sealing shoulders or rings 115 and 116. Shoulder 115 wedges against the top internal angular surface 117 of the lip 105 and the shoulder 116, which is at the bottom of the sleeve 114, underlaps the lower edge 118 of the lip 105 and tightly engages therewith. At the juncture of the upper end of the sleeve 114 and the flange 110 there ls provided an integral tearable -thin membrane 122 which is also integral with the outer peripheral edge portion 124 of a depressed closure plug 125 which is integrated with a hinge ring 126 connected by hinge 1?.7 to the flange 110 and at the diametrically opposite side to a pull tab 130 which is angled downwardly toward the cone top portion.
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Lifting of the tab rips the membrane 122 and opens the container.
It will be noted that in each container the bottom 4 is convex and has feet 75. The bottom wall -thick-ness is usually the initial thickness of the blank sheetpreparatory to forming of the can, that is 10-6 mils, preferably 8 mils, thick. The body wall is irored to akout 5 mils or less. The top portion is also less than 10 mils thick, preferably ~-9 mils, and the pour opening is less than 30% of the bottom area. The angle of the conical portions is between 10-45 degrees, preferably 22-1/2, in the stepped designs, as well as in the unstepped design of Figure 6. However, to obtain greater axial strength, an angle of 45 degrees would be preferred, but that is dependent upon other desired parameters as will be de-scribed in more detail hereinafter. The stepped design greatly improves the axial strength of the top.
Steps have been taken to develop the can for commercialization utilizing aluminum as the metal. Cans such as that generally illustrated in Figures 1-5 have been developed, but with slight modifications in the wall thick-nesses, radii, axial dimensions and the like. Reference is made to Figure 15 which illustrates on a large scale the specifics of the dome and can body in the vicinity of the lap joint between the dome and the can body with respect to what has been considered to be the most effic-ient construction.
The dome 3 has a wall thickness tl on the order of 9 mils. The can body 8 has a wall thickness t2 of 4 mils, but increases at its extreme upper end to a wall thickness t3 of 6 mils for a distance generally on the order of 0.06 inch. It is also to be noted that the extreme upper end of the body 8 is provided with a radi-ally inwardly directed curl 29. The annulus 12 is radi-ally inwardly offset and has an axial height on the orderof 0.12 inch. The lip 14 has a like axial extent and the 3S~3~

radius 15 has a preferrecl radius Rl of 1.12 inch. The extent of the radius 15 is such that the conical section 16 is disposed at an angle to the horizontal on the order of 22-1/2 degrees.
The necking-in of the upper portion of the can body 8 provides a radially inward offsek on the order of 0.06 inch with the shoulder 10 being joined to the ring 12 by a radius R2 to the remainder of the body 8 by a radius R3 which is also on the order of 0.06 inch. It is to be noted that the shoulder 10 slopes upwardly and radially inwardly between the body 8 and the ring 12.
A decision was made to make both analytical and experimental investigations of the can construction of Figure 15 and modifications thereof. IIT Research Insti-15 tute of 10 West 35th Street, Chicago, Illinois 60616 was selected to carry out the research.
The analytical research was by way of a computerprogram known as BOSOR 4 which is a computer program for the Buckling of Shells of Revolution. The program was developed by Lockheed Missile & Space Company, Sunnyvale, California.
The BOSOR computer program was used because it has been demonstrated extensively in the past that it is a reliable, accurate and efficient code for the elastic analysis of shells of revolu-tion and has been exten-sively employed in the past both by IITRI personnel and personnal of -the assignee of record of this appli-cation.
It was determined in advance that there are four conditions which could place loadings on the can which could be destructure. These are~
1. Internal pressurization loads which may be as high as 100 psi.
2. An axial loading applied to the dome during the application of the closure fi-tment and which may be as high as 80 pounds.

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3. An axial loading which may be applied to the closure fitment during filling of a can.

4. A comhined axial stacking loading and internal pressure loading.
The latter two loadings were found not to be critical, and test results with respect thereto will not be set forth here.
Reference is made to Figure 16 wherein there is illustrated the geometry of the can which corresponds to Figure 15 and was considered as the basic can construction under consideration. In Figure 17 there is illustrated both the original shape in solid lines and the deformed shape in dash lines of the can in the area of the joint between the body and the dome when the can was subjected to 100 psi internal pressure, the deformed can being traced out by the computer in accordance with the BOSOR 4 code.
Forces and moments in the body and in the dome were determined with respect to the meridional direction aa diagrammatically shown in Figure 18 as well as circum-ferential forces and moments as diagrammatically shown in Figure l9. With a permissible yield stress of 45, 800 psi, maximum permissible yield thrust in the body is calculated to be 183 lbs/inch and in the dome to be 412 lbs/inch, and the maximum permissible yield bending moment in the body to be 0.122 "lb/inch and in the dome to be 0.618 "lb/inch.
As is clearly shown in Figure 20, the plotted meridional force at the various points A-H (Figure 17) are well within the permissible range. The same is general-ly true of the meridional moments at the points A-H as plotted in Figure 21. A graph of the circumferential forces at the points A-H is found in Figure 22 wherein the forces are clearly shown to be within the permissible limit. The same is true of the circwnferential moments as plot-ted in Figure 23.
The can of Figures 15 and 16 was also theoreti-cally subjected to an axial fitment load of 80 pounds .

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with the dome and the body deflecting as shown by the dash lines in Figure 24. It will be readily apparent that the meridional forces and the meridional moments under the 80 pound axial fitment load are negligible, as shown in Figures 25 and 26, respectively. The same is true of the circumferential forces and circumferen-tial moments as shown in Figures 27 and 28, respectively.
Having established the can o Figures 15 and 16 as the preferred embodiment and thus as a standa1~d, 1~ like internal pressure and axial fitment loading tests were run on other configurations. The modified shape parameters and a comparison of the results are found in TABLE I with the standard being identified by dashes and the modified shape parameters being compared with the standard with numeric identification from 1-4, with the numeral 1 showing the test results of the modified shape parameter being better than the standard; the numeral 2 showing the results to be the same as the standard;
the numeral 3 indicating the test results of the modified shape to be worse than those of the standard; and the numeral 4 indicating test results which could possibly be critical including possible rupture or destructive failure of the dome or body.

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It was found that having the lap between the dome and the body located immediately adjacent the toroidal radius 15 of the dome and having the body 8 necked-in pro-duced the most desirable results. However, it was deemed advisable to change the lap location to be 1~2 inch below the dome radius to show the beaming effect of the dome on the lap and to connect the dome to a straight body to show the advantageous effect of the neck-in of the body on the lap.
Accordingly, a can was constructed as shown in Figure 29 wherein the dome 3 included a cylindrical portion 27 having an axial length of 0.5 inch. As will be apparent from the deflection tracing, when the can of Figure 29 is subjected to 100 psi internal pressure, the previously discussed beaming action has a lesser effect on the com-pression of the adhesive as shown in Figure 30 and will be discussed hereinafter. On the other hand, the force and moments of this modified can construction are generally the same as those of tne standard, as indicated in TABLE I.
With respect to the absence of a body neck-in, a can as illustrated in Figure 31 was considered~ As shown in TABI.E I, the force and moments under internal pressuriza-tion and axial fitment loading were generally the same as those of the sample of Figures 15 and 16. On the other hand, normal stresses in the adhesive under pressuriza-tion were below the standard as will be discussed in detail hereinafter.
It has therefore been concluded that the best possible combination is one wherein the lap is immediately adjacent the dome radius or toroidal curve, and there is a necking-in of the body. Returning now to Figure 17, it will be seen that under internal pressurization the dome conical section 16 is angled upwardly to a greater extent and the radius 15 is deformed and moved radially inwardly so as to urge the upper portion of the lip 14 radially inwardly. At t'ne same time the offse-t of the ~6;~

necked-in portion of the body tries to straighten out to eliminate the shoulder 10 and the lower portion of the ring 12 moves radially outwardly so as to compress the adhesive. The placing of the adhesive in compression has the obvious beneficial effect of preventing peel. It further has the unexpected advantageous effeck that when the adhesive is placed under compression it has greater shear strength.
Having determined that the can configuration of Figures 15 and 16 was the most desirable, tests were made by modifying other shape parameters. For example, as indicated in TABLE I, dome angles of 10, 45 and 90 were analytically tested. As shown in TABLE I, a dome angle of 10 is less desirable than a dome angle of 22.5 under both lnternal pressurization and axial fitment loading. As shown in the deflection diagram of Figure 32, the deflection of the dome was greater under internal pressurization while the deflection of the body remained generally the same. Further, a comparison of the meri-dional forces and moments and axial forces and momentsunder internal pressurization approached the critical limits set for stresses and moments as is shown in Figures 33-3~.
The decreased dome angle also resulted in undue downward deflection of the dome and an outward flexing of the dome lap to a point where it approached being critical under the 80 pound axial fitmen-t loading as shown in Figure 37. The critical or worse forces and moments under axial loading are also shown in Figures 3~-40.
When the dome angle was changed to ~5, the forces and moments remained substantially the same as those of the standard, but under internal pressuriza-tion the radial deflection of the adhesive layer worsened as will be specifically indicated herein-after.

.,~

i3~

In a like manner, when the dome angle was changed to 90, which would result in a flat top and therefore not in accordance with the spirit of this invention, the forces and moments were generally the same as those of the stand-ard, but both the radial deflection of the adhesive and thenormal stress in the adhesive under in-ternal pressurization worsened. This will be discussed hereinafter.
Analytical experimentation was conducted relative to the dome torus radius, decreasing it in one experiment to 0.06 inch and increasing it to 0.24 inch in another experiment. As is clearly shown in TABLE I, a reduced dome radius produced undesirable forces and moments when subjected to internal pressurization as shown in Figures 41 and 42. The stress in the adhesive was worse under lS axial loading.
When the dome radius was increased, the forces and moments calculated to be either better or the same as the standard, but under internaa. pressurization the radial deflection of the adhesive layer and the normal stress in the adhesive layer worsened, as will be dis-cussed hereinafter.
When the thickness of the dome was reduced to 4 mils, the conditions worsened except for the radial deflec-tion of the adhesive layer under internal pressurization.
In fact, failure occurred when the dome was analytically subjected to the 80 pound fitment loading.
The can with a modified radius of the neck-in was analytically tested with a neck-in radius of 0.030 inch, and as is clearly shown in TABLE I, the results were not as good as when the radius was 0.060 inch.
The above described analytical tests were made by considering the total adhesive layer as being segmented into 3,6 or 9 smaller circumferen-tial rings as shown in Figures 43-45. This segmentation was necessary to implement the computer code and permit a prediction of the compressive force distribution within the adhesive layer. Under these s~

conditions test results of var.ious body shape parameters relative to compressive ~orces on the adhesive were ob-tained as shown in TABLE II, as follows:

TABLE II
BOSOR 4 ADH~SIVE RING SEGMENT RADIAL STRESSES, LB/IN2 (+ = TENSION) THREE RING SEGMENT MODEL

Load Case Adhesive 100 psi 80 lb. Axial Model Segment Internal Pressure Fitment Load _ Original Con~igura- U = Upper - 183 21 tion M = Middle - 178 23 L = Lower - 545 91 Lowered Lap Joint U - 98 2 (1/2") M - 143 14 No Body Neck U - 169 19 90 Neck~In Body U - 229 3.5 Increase Dome U - 133 8 Radius M - 163 18 (0.12 -~ 0.24) L - 510 94 Decreased Dome U - 282 38 Radius M - 156 31 (0.12 ~ 0.06) L - 578 98 Increase Dome U - 122 7 Radius with Less M - 141 Neck-In L - 318 39 IncreaS Cne~An45gl)e M - 1~8 Decrease Cone Angle U - 178 68 (22.5-~ 10) M -. - 192 47 -., . ~ .

~63~8~
-23~

Comparing the results of TABLE II with the merits of the different shapes of TABLE I, it will be seen that under all conditions the adhesive would be under compression when the can is sub~ected to 100 psi internal pressure.
With respect to TABLE II, .it is pointed out here that the analytical calculations were made without an interference fit and that based simplified calculations for the case of two infinetly long tubes with a 0.012 metal and adhesive fit assuming an adhesive thickness of 1 mil, there must be added to the compressive radial loadings of TABLE II 140 psi; when the metal and adhesive interference is 0.010 there must be added 117 psi; when the metal and adhesive interference is 0.06 there must be added 70 psi, and when the metal and adhesive interference is 0.002 -khere must be added 23 psi.
It will be seen that under 100 psi internal pres-surization and without an interference fit, the adhesive under all circumstances is in compression although the re-sults with respect to the standard can of Figures 15 and 16 are better or at least equal to all conditions except where the dome radius has been decreased to 0.060 inch. However, as discussed above, the reduced dome radius has criticality or worse results in other areas.
It is to be particularly noted that when there is no necking-in of the body, the compressive forces on the adhesive are greatly reduced.
The results set forth in TABLE II are believed to be readily understandable, and where there are worse adhe-sive conditions indicated in TA~LE I, a comparison of the ahdesive loading with respect to the test standard will clearly indicate the basis for the indicated worse conditions.
Other specific tests relative to adhesive loading were made using a six segment adhesive arrangement as shown in Figure ~ when adhesive is applied only to thè lap area, and a nine segment adhesive arrangement as shown in Figure 45 when the adhesive is permitted to fill the space between tho dome and the body b~low the ~ap area.

~3.~

TABLE_III
BOSOR 4 AD~ESIVE RING SEGMENT RADIAL STRESSES
LB/IN (~ = TENSION, - = COMPRESSION) Load Case Adhesive100 psi 80 lb. Axial ModelSegmentInternal Pressure Fitment Load Simplified Original Geometry U - 240 28 ~ - 93 12 6 Segment Adhesive ~
Layer 43 ~ ~ - 107 6 Q) Constant Body ~
Thickness 2 ~ - 219 24 L ~ -1114 220 Simplified Original Geometry U - 129 17 9 Segment Adhesive Layer 7 ~ - 88 5 6 ~ - 90 4 o Constant Body ~
Thickness 5 O - 62 - 6 : __ - 142 ~57 2 -2066 -4~3 _.

:

~635~

Referring to the foregoing TABLE III, it will be seen that when the adhesive fills the space between the dome and the body below the lap the compressive forces on the adhesive are greatly reduced under internal pressuri-zation of the can and, in fact, in the lower part of theadhesive there are high tensile forces. While this would generally indicate that when the space between the dome and the body is filled with adhesive there is a poor joint, it is understood that even if that added adhesive should fail, the net result will be no less than that with the adhesive only in the lap in that the compressive forces on the remaining adhesive will increase to correspond to the case where there is adhesive only in the lap. On the other hand, the added adhesive will serve to prevent the entrance of foreign matter into the space between the lower edge of the dome and the body and thus does serve a useful purpose. Furthermore, because in the assembly of the dome and the body the adhesive is applied to the body ring 12 and there is an interference fit between the dome and the body, any extra adhesive on the body, and there will alwa~s be some, will flow into the lower part of the lap and thus fill the free space between the lower edge of the dome and the adjacent portion of the body.
The above described test results are all the-oretical based upon the soSoR 4 program. In view of the theoretical nature of -the BOSOR 4 program, it was deemed advisable to double check the results by preparing test cans of configurations in accordance with inputs into the BOSOR 4 program and to apply to those test cans sensors which would provide information which could be compared with the results obtained with the BOSOR 4 program.
Referring now to Figure 46, it wil] be seen -that there is plotted the analytical displacement in dash lines and the sensed displacement in a solid line, both superimposed over the original shape of the test can. It will be seen that the analytical (theoretical) and the sensed

5~

displacements favorably compared in Figure 46 with respect to a can body construction of the type illustrated in Figures 15 and 16 so as to lend creditability to the results of the BOSOR 4 program.
Reference is also made to Figure 47 wherein there is shown the analytical displacement and sensed displacement of a can body wherein the dome is provided below the toroidal radius a 0.5" high cylindrical portion.
I-t will be seen that with respect to this can configura-tion the sensed deformation also closely corresponds to the analytical displacement, thereby further verifying the results of the BOSOR 4 program.
With reference to Figures 46 and 47, it is to be understood that at each of the circied points a sensor was bonded to the can prior to the can being in-ternally pressuri~ed and the displacements of the can were re-corded by the sensors at the particular points. The sensors were bonded resistance strain gauges of a 0.015"
gauge length. The sensors were placed both internally and externally.
Reference is now made to Figure 48 wherein there is plotted the shear stresses of different adhesives under various compressive loads. The results of testing by an independent test facility the allowable shear stresses of different adhesives under varied compressive loadings has resulted in the unexpected finding that, when an adhesive is under compression, even though that compres-sion is only on the order of 400 psi, there may be a very marked increase in the allowable shear stress.
The values of adhesive loading in Figure 4~
correspond to the adhesive loadings of TABLE II and TABLE
III, and it will be readily apparent that under the com-pressive loadings of adhesive in accordance with the can configuration of this invention, the adhesive has a much greater shear stress allowance than would normally be expected.

35~3~
~27-It will become apparent from the foregoing dis-closure that novel lightweight pressure holding containers have been developed which adequately contain pressurized beverages, use a minimum amount of metal and strategically employ the metal to obtain a container of improved char-acteristics which constrain the forces to act in a favor-able manner assisting in holding the adhesive bond from being breeched, i ~.

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A metal can comprising a body, a dome, and a lapped joint including an adhesive layer between said body and said dome, and the relationship between said body and said dome being one wherein when said can is filled with a liquid packaged under pressure said dome in the general area of said lapped joint radially inwardly deforms and said body in the general area of said lapped joint radially outwardly deforms with the combined deforma-tion of said dome and said body compressing said adhesive layer.

2. A metal can according to claim 1 wherein said adhesive is of the type wherein the shear strength increases with compression of said adhesive.

3. A metal can according to claim 1 wherein said dome is of a greater wall thickness than said body wherein the resistance of said dome at said lapped joint to radially outwardly directed deformation is greater than that of said body.

4. A metal can according to claim 2 wherein said dome has a lower cylindrical lip forming part of said dome, said lip merges at its upper edge into a toroidal curve which merges into a conical inner and upper portion, and wherein under internal pressure said conical portion is deformed generally axially upward and said toroidal curve is deformed generally radially inwardly with an associated tilting of said lip and a radially inward deformation of at least an upper portion of said lip and compression of an upper part of said adhesive layer.

5. A metal can according to claim 4 wherein said conical portion is disposed at an angle to the hori-zontal generally ranging from 10 degrees to 45 degrees.

6. A metal can according to claim 4 wherein said conical portion is disposed at an angle to the hori-zontal generally on the order of 22.5 degrees.

7. A metal can according to claim 2 wherein an upper end portion of said body is necked-in to define a radially inwardly offset upper ring connected to an adjacent portion of said body by a radially inwardly and axially upwardly sloping shoulder, and internal pressure within said can functioning to straighten out said body in the general area of said shoulder to deform at least a lower portion of said ring radially outwardly to compress at least a lower part of said adhesive layer.

8. A metal can according to claim 4 wherein an upper end portion of said body is necked-in to define a radially inwardly offset upper ring connected to an adjacent portion of said body by a radially inwardly and axially upwardly sloping shoulder, and internal pressure within said can functioning to straighten out said body in the general area of said shoulder to deform at least a lower portion of said ring radially outwardly to compress at least a lower part of said adhesive layer.

9. A metal can according to claim 8 wherein the axial extents of said lip and said ring are generally the same, and said lip and said ring are in full over-lapping relation.

10. A metal can according to claim 8 wherein said dome terminates in a lowermost radially outturned curl and said curl overlies said shoulder within an axial extension of said body, said curl forming means facilitat-ing telescoping of said lip and said ring.

11. A metal can according to claim 10 wherein said adhesive layer extends between said curl and said shoulder.

12. A metal can according to claim 8 wherein said body terminates in an uppermost radially inwardly directed curl, said curl forming means facilitating tele-scoping of said lip and said ring.

13. A metal can according to claim 8 wherein there is an interference fit between said lip and said ring wherein in a non-loaded state of said can said adhe-sive layer is in a compressed state.

14. A metal can according to claim 8 or claim 3 wherein said body and said dome are both formed of aluminum, said dome has a wall thickness on the order of 0.009 inch and said body has a wall thickness on the order of 0.004 inch.

15. A metal can according to claim 4 wherein said body has a bottom, and said dome has a fitment re-ceiving opening, said opening having an area less than 30 percent of the area of said bottom.

16. A metal can according to claim 1 wherein said adhesive is a flexible adhesive.

17. A metal can according to claim 4 wherein said conical portion has at least one annular step.

18. A metal can according to claim 1 wherein said dome has a short axial length as compared to said body.

19. A metal can according to claim 1 wherein said can is formed of sheet steel.

20. A metal can according to claim 1 wherein said body is formed of sheet steel having a thickness no greater than 0.002 inch.

21. A metal can according to claim 1 wherein said body is formed of sheet steel having a thickness on the order of 0.003 inch.

22. A metal can according to claim 1 wherein said body, said dome and said lapped joint all can sustain an 80 pound axial load in the empty can state and an internal pressure of 100 psi.

23. A metal can according to claim 22 wherein said body and said dome are both formed of aluminum, said dome has a wall thickness on the order of 0.009 inch and said body has a wall thickness on the order of 0.004 inch.