CA1185544A - Method for forming a tapered nestable can - Google Patents
Method for forming a tapered nestable canInfo
- Publication number
- CA1185544A CA1185544A CA000403189A CA403189A CA1185544A CA 1185544 A CA1185544 A CA 1185544A CA 000403189 A CA000403189 A CA 000403189A CA 403189 A CA403189 A CA 403189A CA 1185544 A CA1185544 A CA 1185544A
- Authority
- CA
- Canada
- Prior art keywords
- cup
- sidewall
- tapered
- blank
- curvature
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Landscapes
- Containers Having Bodies Formed In One Piece (AREA)
Abstract
NESTABLE CAN AND METHOD OF MANUFACTURE
ABSTRACT
A nestable can and method of manufacture is described wherein a blank cut from sheet metal stock is drawn into a tapered die with a tapered drawhorn to form a first stage cup having a bottom, a tapered cylindrical sidewall and a peripheral flange. Care is taken to avoid coining of the sidewall in the first stage of manufacture. The partially formed can is then reformed by expanding the sidewall while maintaining its taper, thereby removing wrinkles and forming a second stage cup having smooth interior and exterior sidewall surfaces. The nestable quality of the cup is dependent upon a novel profile created while reforming the first stage cup. In that operation the upper end of the cup is reshaped to form an upper rim that is off-set from a tapered sidewall and having convex contact surfaces that support one cup within another. The location of the contact surfaces is such that adjacent sidewalls of two nested cups are spaced apart by at least .0015 inch, the peripheral rims being vertically spaced by at least .140 inch to facilitate cup separation.
ABSTRACT
A nestable can and method of manufacture is described wherein a blank cut from sheet metal stock is drawn into a tapered die with a tapered drawhorn to form a first stage cup having a bottom, a tapered cylindrical sidewall and a peripheral flange. Care is taken to avoid coining of the sidewall in the first stage of manufacture. The partially formed can is then reformed by expanding the sidewall while maintaining its taper, thereby removing wrinkles and forming a second stage cup having smooth interior and exterior sidewall surfaces. The nestable quality of the cup is dependent upon a novel profile created while reforming the first stage cup. In that operation the upper end of the cup is reshaped to form an upper rim that is off-set from a tapered sidewall and having convex contact surfaces that support one cup within another. The location of the contact surfaces is such that adjacent sidewalls of two nested cups are spaced apart by at least .0015 inch, the peripheral rims being vertically spaced by at least .140 inch to facilitate cup separation.
Description
The present invention relates to a nestable can and a method of manufacturin~ such a nestable can.
The present invention is particularly useful in providing a container of high integrity which is suitable for packaging food products, such as fish.
One element of its utility is in providing a nestable can that may be shipped to the user in packages of high density.
Prior art can constructions currently in use most commonly provide a three-piece soldered can compris-ing a cylindrical can body and a pair of endsO The can body is first made in a right cylindrical configura-tion but then collapsed to increase shipping density.
Upon arrival at the packer's plant, the can body is reformed to a round configuration and one end is seamed on prior to filling. The operation of collapsing the can and reforming them at the point of use is deleterious, both to the can body seams and to the coating which is conventionally applied during or prior to manufacture.
It has been recognized that a two-piece can construction comprising a cup having an integral sidewall and bottom is a preferred construction since it solves problems of`seam leakage and coating removal. However, conventional two-piece canshave not been made which can be economically shipped and/or reassembled at the packers' plantl although it is apparent that a tapered nestable can may be made to increase shipping density.
The production of an acceptable two-piece can has proven di~ficult using conventional drawing methods, except for very shallow cups, since the cans must be free of wrinkles and bulges and the coating must be maintained when using precoated stock. It is believed that the can industry generally considers the manufacture of tapered two-piece containers to be difficult to the point of impractical.
Notwithstanding, it is to be recognized that two-piece cans comprised of a one-piece cup and closure lid are known, and such cans have been made with nestable tapered sidewalls, such as tau~ht in U.S. Patent 3,248,003.
It is to be further understood that the manufacture of S5~ ~
nestable plastic containers and cups is well-known as exemplified by the teaching conta.ined in United States Patent Nos. 2,879,917; 3,091,360, and 3,139,213. The present invention, however, differs from earlier teachings both in the method of manufacture and in providing a cup configuration which can be internested, stacked and subsequently separated for process filling with conven-tional machines.
The present invention comprises a method for forming a tapered nestable can from sheet metal stock comprising the steps: cutting a blank ~rom sheet metal stock, and drawing the blank into a tapered die with a tapered drawhorn while forming a first stage cup having a bottom, a tapered cylindrical sidewall and a peripheral flange, said blank being drawn with out coining said sidewall and allowing wrinkles to form therein; and reforming the first stage cup by expanding the diameter of the tapered cylindrical sidewall to remove the wrinkles while maintaining substantially the same taper, the diameter 20 of said sidewall after expanding being less than five percent (5%) greater than the diameter of the sidewall of the first state cup.
fr f,~, 5'~ ~
The objects and advantages of this invention will become apparent in view of the following detail~d description and the accompanying drawings.
In the drawings forming a part of this applica-tion and in which like parts are identified by likereference numerals throughout the same, Fig. l is a vertical center section of a plurality of nestable cans made in accordance wi-th this invention;
Figs. 2, 3 and 4 illustrate sequential stages of manufacturing each can; and Fig. 5 is an enlarged vertical section taken on the lines 5-5 of Fig. 1 showing structural relation-ships of and between cans that are nested.
Referring to Fig. l of the drawings, there is shown a plurality of internested cups C, each cup being formed in essentially three stages as contemplated by this invention. Figs 2-4 illustrate the three stages of manufacture. First, as shown in Fi~. 2, a circular blank (cut from precoated sheet metal stock) is drawn into a tapered die with a tapered drawhorn, froming a first stage cup having a bottom 10, a tapered cylindrical sidewall ll, and a peripheral flange l~.
The preferred embodiment of can is made with a sidewall that tapers upwardly from a bottom plane at an angle of 87 ~3 taper relative to the vertical).
The first stage cup is formed without "coining"
the sidewaIl. (~he term "coining" as used herein is defined as the stamping or extrusion of metal to change its shape and thinness). To avoid "coining" during the manufacture of the first stage cup a spacing is maintained between surfaces of the die and drawhorn, and that spacing should be equal to at least two metal , thicknesses of the sheet metal stock from which the blank is formed. For example 75# sheet steel stock of .0083 inch thick is a suitable material/ and at least twice that thick~ess (.0166 inch) should be used as clearance when such material is used. As a consequence, the first stage cup will possess longitudinal wrinkles in the sidewall. Those wrinkles are then removed in a reforming process wherein the first stage cup is expanded or cylindrically enlarged using a tapered drawhorn of increased size, but of substantially the same taper as that used in the initial drawing opera-tion. In the reforming process the sidewall of the f~rst stage cup is diametrically enlarged, but the finished diameter of the sidewall is less than five per-cent (5%) greater than the diameter of the sidewallof the first stage cup. An increase of between two and three percent (2-3%) has been found to produce smooth sidewall surfaces while preserving the integrity o~
coatingsapplied to precoated metal stock. Expanding the diameter size above five percent (5%) tends to cause metal fractures and serious impairment of the coating.
Fig. 3 illustrates the preferred shape of the second stage cup having a sidewall lOa, a bottom lla and an upper rim 13. In reforming~ both the upper end and bottom wall of the first stage cup is reshaped and profiled. It will be noted that rim 13 is laterally and outwardly offset from the reformed sidewall lOa, and the bottom is profiled to increase its strength.
3¢ Thereafter, the flange portion of the rim is trimmed or cut to a precise diameter, as shown in Fig. 4, to form the finished cup.
Fig. 5 illustrates details of a rim profile which provides both the feature of nesting as well as selected spacing of nested cans. More particularly, rim 13 is f~rmed with first, second and third curvatures, the first curvature being formed on a radius rl and defining a first interior convex surface 15, the second curvature being formed on a radius r2 and definin~ an exterior convex surface 16, and the third curvature being formed on a radius r3 and defining a second interior convex surface 17. The first curvature projects the rim radially outward and of~set from tapered sidewall lOa; the second curvature directs a section o~ the rim vertically upward to support an inner cup; and the third curvature connects to a radial flange 18. The radii of the three convex surfaces are selected and located one to another such that the finished cups nest within another t the exterior convex surface 16 of an inner cup resting upon the second interior convex surface 17 of an outer cup and providing a spacing between adjacent sidewalls (shown by the letter "d'~ which is at least .0015 inch. The spacing -between sidewalls is critical in that a spacing of side-walls closer than .0015 may present problems in the separation of nested cups. Closer spacings of side-walls tend to result in vacuum type lock-ups and a separation of such cups may cause scuffing of the coated can surfaces.
It is also to be noted that the radius r2 forming convex surface 16 is substantially less than the radius r3 forming convex surface 17, and contact between nested cups occurs at a point of cotangency whose vertical projected line image "b' is within the concave profile of convex surface 17. Thus, once contact is made between surfaces of nested cups, the inner cup is supported on a circular ring of point contacts within the outer cup.
Separation of cups is thereby inhanced by virtue of the small area of surface contact and smooth-ness of surfaces.
It will be apparent that the packing density of nested cups increases in direct proportion to the flange spacing "D" between cups. This follows since the cup diameter and height are fixed. Therefore, the closer the flange spacing, the more dense the pack.
Although a minimum flange spacing has not been established, it has been determined that a flange spacing of .1~0 to .190 inch works well with standard processing equipment.
It may be noted that a geometric and dimen-sional relationship exists in forming rim 13. The flange space D is a linear distance function of flange displacement distance S (a vertical distance from the surface of one cup flange 18 to the corresponding surface of a nested cup flange 18) and the flange thickness T. (D = S-T). But displacement distance S is also a function of the clearance spacing d between sidewalls, the maximum thickness t of the sidewalls and the angle of sidewall taper ~. This latter relationship may be expressed by the formula S = dtan t~ , and that formula may be used to determine or select flange spacing. As an example, and assuming the following values by engineering design, if d = .001~", t = .0083", and ~ = 3, then S = .1875". If engineering design also suggests a flange thickness T of .0105", then flange spacing D will be .177".
The distance S, it will be evident, also describes or is equal to the axial distance between the convex surfaces 16 and 17 at points of contact with nested cups. Thus, once distance S is selected, the locations of the convex surfaces (and the location of the circular ring of contacts) become fixed; and ~the profile of rim 13 is then functionally de-termined.
Although a preferred embodiment of the invention has been illustrated and described, various modifications and changes may be resorted to without departing from the spirit of the invention or the scope of the appended claims, and each of such modifications and chang~s is contemplated.
The present invention is particularly useful in providing a container of high integrity which is suitable for packaging food products, such as fish.
One element of its utility is in providing a nestable can that may be shipped to the user in packages of high density.
Prior art can constructions currently in use most commonly provide a three-piece soldered can compris-ing a cylindrical can body and a pair of endsO The can body is first made in a right cylindrical configura-tion but then collapsed to increase shipping density.
Upon arrival at the packer's plant, the can body is reformed to a round configuration and one end is seamed on prior to filling. The operation of collapsing the can and reforming them at the point of use is deleterious, both to the can body seams and to the coating which is conventionally applied during or prior to manufacture.
It has been recognized that a two-piece can construction comprising a cup having an integral sidewall and bottom is a preferred construction since it solves problems of`seam leakage and coating removal. However, conventional two-piece canshave not been made which can be economically shipped and/or reassembled at the packers' plantl although it is apparent that a tapered nestable can may be made to increase shipping density.
The production of an acceptable two-piece can has proven di~ficult using conventional drawing methods, except for very shallow cups, since the cans must be free of wrinkles and bulges and the coating must be maintained when using precoated stock. It is believed that the can industry generally considers the manufacture of tapered two-piece containers to be difficult to the point of impractical.
Notwithstanding, it is to be recognized that two-piece cans comprised of a one-piece cup and closure lid are known, and such cans have been made with nestable tapered sidewalls, such as tau~ht in U.S. Patent 3,248,003.
It is to be further understood that the manufacture of S5~ ~
nestable plastic containers and cups is well-known as exemplified by the teaching conta.ined in United States Patent Nos. 2,879,917; 3,091,360, and 3,139,213. The present invention, however, differs from earlier teachings both in the method of manufacture and in providing a cup configuration which can be internested, stacked and subsequently separated for process filling with conven-tional machines.
The present invention comprises a method for forming a tapered nestable can from sheet metal stock comprising the steps: cutting a blank ~rom sheet metal stock, and drawing the blank into a tapered die with a tapered drawhorn while forming a first stage cup having a bottom, a tapered cylindrical sidewall and a peripheral flange, said blank being drawn with out coining said sidewall and allowing wrinkles to form therein; and reforming the first stage cup by expanding the diameter of the tapered cylindrical sidewall to remove the wrinkles while maintaining substantially the same taper, the diameter 20 of said sidewall after expanding being less than five percent (5%) greater than the diameter of the sidewall of the first state cup.
fr f,~, 5'~ ~
The objects and advantages of this invention will become apparent in view of the following detail~d description and the accompanying drawings.
In the drawings forming a part of this applica-tion and in which like parts are identified by likereference numerals throughout the same, Fig. l is a vertical center section of a plurality of nestable cans made in accordance wi-th this invention;
Figs. 2, 3 and 4 illustrate sequential stages of manufacturing each can; and Fig. 5 is an enlarged vertical section taken on the lines 5-5 of Fig. 1 showing structural relation-ships of and between cans that are nested.
Referring to Fig. l of the drawings, there is shown a plurality of internested cups C, each cup being formed in essentially three stages as contemplated by this invention. Figs 2-4 illustrate the three stages of manufacture. First, as shown in Fi~. 2, a circular blank (cut from precoated sheet metal stock) is drawn into a tapered die with a tapered drawhorn, froming a first stage cup having a bottom 10, a tapered cylindrical sidewall ll, and a peripheral flange l~.
The preferred embodiment of can is made with a sidewall that tapers upwardly from a bottom plane at an angle of 87 ~3 taper relative to the vertical).
The first stage cup is formed without "coining"
the sidewaIl. (~he term "coining" as used herein is defined as the stamping or extrusion of metal to change its shape and thinness). To avoid "coining" during the manufacture of the first stage cup a spacing is maintained between surfaces of the die and drawhorn, and that spacing should be equal to at least two metal , thicknesses of the sheet metal stock from which the blank is formed. For example 75# sheet steel stock of .0083 inch thick is a suitable material/ and at least twice that thick~ess (.0166 inch) should be used as clearance when such material is used. As a consequence, the first stage cup will possess longitudinal wrinkles in the sidewall. Those wrinkles are then removed in a reforming process wherein the first stage cup is expanded or cylindrically enlarged using a tapered drawhorn of increased size, but of substantially the same taper as that used in the initial drawing opera-tion. In the reforming process the sidewall of the f~rst stage cup is diametrically enlarged, but the finished diameter of the sidewall is less than five per-cent (5%) greater than the diameter of the sidewallof the first stage cup. An increase of between two and three percent (2-3%) has been found to produce smooth sidewall surfaces while preserving the integrity o~
coatingsapplied to precoated metal stock. Expanding the diameter size above five percent (5%) tends to cause metal fractures and serious impairment of the coating.
Fig. 3 illustrates the preferred shape of the second stage cup having a sidewall lOa, a bottom lla and an upper rim 13. In reforming~ both the upper end and bottom wall of the first stage cup is reshaped and profiled. It will be noted that rim 13 is laterally and outwardly offset from the reformed sidewall lOa, and the bottom is profiled to increase its strength.
3¢ Thereafter, the flange portion of the rim is trimmed or cut to a precise diameter, as shown in Fig. 4, to form the finished cup.
Fig. 5 illustrates details of a rim profile which provides both the feature of nesting as well as selected spacing of nested cans. More particularly, rim 13 is f~rmed with first, second and third curvatures, the first curvature being formed on a radius rl and defining a first interior convex surface 15, the second curvature being formed on a radius r2 and definin~ an exterior convex surface 16, and the third curvature being formed on a radius r3 and defining a second interior convex surface 17. The first curvature projects the rim radially outward and of~set from tapered sidewall lOa; the second curvature directs a section o~ the rim vertically upward to support an inner cup; and the third curvature connects to a radial flange 18. The radii of the three convex surfaces are selected and located one to another such that the finished cups nest within another t the exterior convex surface 16 of an inner cup resting upon the second interior convex surface 17 of an outer cup and providing a spacing between adjacent sidewalls (shown by the letter "d'~ which is at least .0015 inch. The spacing -between sidewalls is critical in that a spacing of side-walls closer than .0015 may present problems in the separation of nested cups. Closer spacings of side-walls tend to result in vacuum type lock-ups and a separation of such cups may cause scuffing of the coated can surfaces.
It is also to be noted that the radius r2 forming convex surface 16 is substantially less than the radius r3 forming convex surface 17, and contact between nested cups occurs at a point of cotangency whose vertical projected line image "b' is within the concave profile of convex surface 17. Thus, once contact is made between surfaces of nested cups, the inner cup is supported on a circular ring of point contacts within the outer cup.
Separation of cups is thereby inhanced by virtue of the small area of surface contact and smooth-ness of surfaces.
It will be apparent that the packing density of nested cups increases in direct proportion to the flange spacing "D" between cups. This follows since the cup diameter and height are fixed. Therefore, the closer the flange spacing, the more dense the pack.
Although a minimum flange spacing has not been established, it has been determined that a flange spacing of .1~0 to .190 inch works well with standard processing equipment.
It may be noted that a geometric and dimen-sional relationship exists in forming rim 13. The flange space D is a linear distance function of flange displacement distance S (a vertical distance from the surface of one cup flange 18 to the corresponding surface of a nested cup flange 18) and the flange thickness T. (D = S-T). But displacement distance S is also a function of the clearance spacing d between sidewalls, the maximum thickness t of the sidewalls and the angle of sidewall taper ~. This latter relationship may be expressed by the formula S = dtan t~ , and that formula may be used to determine or select flange spacing. As an example, and assuming the following values by engineering design, if d = .001~", t = .0083", and ~ = 3, then S = .1875". If engineering design also suggests a flange thickness T of .0105", then flange spacing D will be .177".
The distance S, it will be evident, also describes or is equal to the axial distance between the convex surfaces 16 and 17 at points of contact with nested cups. Thus, once distance S is selected, the locations of the convex surfaces (and the location of the circular ring of contacts) become fixed; and ~the profile of rim 13 is then functionally de-termined.
Although a preferred embodiment of the invention has been illustrated and described, various modifications and changes may be resorted to without departing from the spirit of the invention or the scope of the appended claims, and each of such modifications and chang~s is contemplated.
Claims (10)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A method for forming a tapered nestable can from sheet metal stock comprising the steps:
cutting a blank from sheet metal stock, and drawing the blank into a tapered die with a tapered drawhorn while forming a first stage cup having a bottom, a tapered cylindrical sidewall and a peripheral flange, said blank being drawn without coining said side-wall and allowing wrinkles to form therein; and reforming the first stage cup by expanding the diameter of the tapered cylindrical sidewall to remove the wrinkles while maintaining substantially the same taper, the diameter of said sidewall after expanding being less than five percent (5%) greater than the diameter of the sidewall of the first stage cup.
cutting a blank from sheet metal stock, and drawing the blank into a tapered die with a tapered drawhorn while forming a first stage cup having a bottom, a tapered cylindrical sidewall and a peripheral flange, said blank being drawn without coining said side-wall and allowing wrinkles to form therein; and reforming the first stage cup by expanding the diameter of the tapered cylindrical sidewall to remove the wrinkles while maintaining substantially the same taper, the diameter of said sidewall after expanding being less than five percent (5%) greater than the diameter of the sidewall of the first stage cup.
2. The method of Claim 1, said step of drawing the blank being done while maintaining a sidewall forming space between the die and drawhorn equal to at least two metal thicknesses of the blank from which the cup is made.
3. The method of Claim 1, the tapered sidewall of the cup being formed by drawing and expanding the blank at an angle of approximately 87° relative to the bottom of the cup.
4. The method of Claim 1, and then trimming the offset upper rim to a selected diameter for seaming with a closure lid.
5. The method of Claim 1, the step of reshaping the upper end of the cup to form an offset upper rim having a profile including first, second and third curvatures, the first curvature forming a first interior convex surface, the second curvature forming an exterior convex surface and the third curvature forming a second interior convex surface, the first curvature projecting said rim radially outward and offset from the tapered sidewall, said second curvature directing a section of said rim convergently relative to an imaginary extension of the tapered sidewall, and said third curvature forming an outwardly curved lip, said convex surfaces being of a length and located that one finished cup nests within another, the exterior convex surface of the inner cup contacting the second interior convex surface of the outer cup when said cups are nested and providing a spacing between adjacent sidewalls of at least .0015 inch.
6. The method of Claim 5, the axial length of the offset upper rim from the points of contact between nested cups to the end of the outwardly curved lip providing a flange spacing of at least .140 inches between nested cups.
7. The method of Claim 5, the tapered side-wall being formed by drawing and expanding the blank at an angle of approximately 87° relative to the bottom of the cup.
8. The method of Claim 5, and then trimming the offset upper rim to a selected diameter for seaming with a closure lid.
9. The method of Claim 5, the second curvature being formed on a radius substantially less than the radius of the third curvature, contact between nested cups being made on a circular ring of point contacts, the vertically projected line image of each point contact being within the concave profile of the second interior convex surface.
10. The method of Claim 1, the diameter of said fully drawn and expanded sidewall being two to three percent (2-3%) greater than the diameter of the first stage cup.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000403189A CA1185544A (en) | 1982-05-18 | 1982-05-18 | Method for forming a tapered nestable can |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000403189A CA1185544A (en) | 1982-05-18 | 1982-05-18 | Method for forming a tapered nestable can |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1185544A true CA1185544A (en) | 1985-04-16 |
Family
ID=4122805
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000403189A Expired CA1185544A (en) | 1982-05-18 | 1982-05-18 | Method for forming a tapered nestable can |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1185544A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| USD962702S1 (en) | 2020-06-19 | 2022-09-06 | Silgan Containers Llc | Stackable, thin-metal cup |
| USD1000211S1 (en) | 2021-07-19 | 2023-10-03 | Silgan Containers Llc | Thin metal cup |
-
1982
- 1982-05-18 CA CA000403189A patent/CA1185544A/en not_active Expired
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| USD962702S1 (en) | 2020-06-19 | 2022-09-06 | Silgan Containers Llc | Stackable, thin-metal cup |
| USD1021538S1 (en) | 2020-06-19 | 2024-04-09 | Silgan Containers Llc | Stackable, thin-metal cup |
| USD1000211S1 (en) | 2021-07-19 | 2023-10-03 | Silgan Containers Llc | Thin metal cup |
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