CN112118919A

CN112118919A - Method and apparatus for forming can shells using a drawing process

Info

Publication number: CN112118919A
Application number: CN201980032137.6A
Authority: CN
Inventors: D·C·斯塔蒙; S·T·奥尔布赖特; P·K·麦卡蒂; E·E·唐纳森
Original assignee: Stolle Machinery Co LLC
Current assignee: Stolle Machinery Co LLC
Priority date: 2018-05-15
Filing date: 2019-04-22
Publication date: 2020-12-22
Also published as: WO2019221877A1; JP2021523021A; EP3793756A4; EP3793756A1; US20190351473A1

Abstract

A housing (20) comprising: a body (22) having a center panel (30), a countersink (32), a chuck wall (34), and a stretched outer portion (26). The countersink region (32) has a base thickness. The outer portion (26) has a reduced thickness. The shell countersink (32) has substantially the same thickness as the sheet (1) prior to forming. In this configuration, the housing (20) maintains the bending resistance of a standard housing but uses less material.

Description

Method and apparatus for forming can shells using a drawing process

Cross Reference to Related Applications

This application claims priority to U.S. patent application serial No.15/980,090, filed 2018, 5, month 15, incorporated herein by reference.

Technical Field

The disclosed and claimed concept relates to metal shells and/or can ends and, more particularly, to shells and/or can ends made from reduced volume metal. The disclosed concept also relates to tool assemblies and related methods for providing such shells and/or can ends.

Background

Metal containers (e.g., cans) are configured to hold products such as, but not limited to, food and beverages. Typically, metal containers include a can body and a can end. In an exemplary embodiment, the can body includes a base and a depending sidewall. The can body defines a generally enclosed space that is open at one end. The can end is coupled to the can body at the open end after the can body is filled with product. In some cases, the container is heated to cook and/or sterilize its contents. This process increases the internal pressure of the container. Further, in some instances, the container contains a pressurized product, such as, but not limited to, a carbonated beverage. Therefore, for various reasons, the container must have minimal strength.

The can end may be a "sanitary" can end or an "easy open" end. As used herein, a "sanitary" end is a can end that does not have a tab or score profile to open, and would have to be opened by using a can opener or other device. As used herein, an "easy open" end may include a tear panel and a tab. The tear panel is defined by a score contour or score line on an outer surface (identified herein as the "public side") of the can end. The tab is attached (e.g., without limitation, riveted) adjacent to the tear panel. The tab is configured to be lifted and/or pulled to sever the score line and deflect and/or remove the severable panel to form an opening for dispensing the contents of the container. The following addresses "easy open" can ends, but is also applicable to "sanitary" can ends. That is, a "sanitary" can end is produced in a similar manufacturing process and is joined to the can body in a similar manner. Thus, as used herein, a can end is further defined as a construct that includes both a "sanitary" can end and an "easy open" end.

Generally, the strength of the container is related to the thickness and/or volume of the metal forming the can body and can end, as well as the shape of these elements. This application mainly addresses the problem of can ends rather than can bodies. In manufacturing can ends, it starts with a blank that is cut from a sheet metal product (e.g., without limitation, aluminum sheet, steel sheet). As used herein, a "blank" is a portion of material that forms a product. The term "blank" applies to a portion of material before all forming operations are completed. Further, as used herein, "aluminum" and "steel" include aluminum alloys and steel alloys, respectively.

In an exemplary embodiment, the blank is formed into a "shell" in a shell punch. As used herein, a "shell" or "initial can end" is a construct that begins with a generally planar blank and has been subjected to forming operations other than the well-known scoring, paneling, rivet forming, and tab riveting. Fig. 1 shows selected portions of a prior art housing 2, the housing 2 including a chuck wall (chuck wall)3, a can mating radius 4, a tear panel 5, and a bead 6. Once all forming operations are completed, the blank/shell is formed into a can end that is configured to be coupled to a can body as is well known. It will therefore be appreciated that the forming operation of the shell is related to the characteristics of the subsequently formed can end and container. Further, as the shell becomes a can end, any discussion or description of "shell" hereinafter also applies to "can end".

In one embodiment, the punch cuts a blank from a sheet of material and forms the housing at a single station. In another embodiment, the blank is cut from a sheet of material, or is provided as a blank and then moved intermittently, or "indexed" as used herein through a plurality of stations. That is, the blank is moved and stopped at each station where the forming operation is performed (it being understood that in some embodiments, some stations are "empty" stations where no forming operation is performed). Alternatively, the punch is a conversion punch configured to cut a blank from the sheet and form the can end opposite the shell. That is, "can end" includes additional constructions such as, but not limited to, a tab that is coupled to the shell by a rivet.

In the can making industry, large quantities of metal are required to make a large number of cans. This is a problem. Thus, a continuing goal of the industry is to reduce the amount of metal used for each can. The reduction in the amount of metal is achieved by reducing the thickness or gauge of the stock material (also referred to as "down gauging") or reducing the volume of metal used to manufacture the can end or body. However, such can ends are susceptible to wrinkling and/or buckling, among other drawbacks associated with forming the can ends from thinner gauge materials or reduced volume metals. That is, the can end will buckle if it is not constructed to resist buckling and/or is made from too thin a material due to the pressure created by the product contained in the can to which it is attached. Such pressure is generated from a carbonated beverage or as a result of a sterilization or pasteurization process involved in food and/or beer/beverage applications. A standard can end has the "flex resistance" of a standard can end, as used herein, means that the can end is configured to resist buckling when exposed to pressures associated with a standard container of standard dimensions made from standard materials.

Standard sized containers made from standard materials are well known in the art. For example, a standard "soda" or "soda" container is a twelve ounce aluminum container as is well known in the art. Furthermore, the pressures that such can ends and containers must resist are well known. Currently, can ends of such containers are made from blanks and/or shells having a "standard volume" as used herein. That is, "standard volume" refers to the volume of material associated with a shell or can end of a standard size container. A twelve ounce aluminum container is a well known example. However, it will be appreciated that there are many standard sized containers made of different materials. For example, a standard soup container includes an 18.6 ounce steel (or steel alloy) container. Thus, "standard volume" refers to the volume of material known in the art to be associated with the shell or can end of a standard size container. As noted above, there is a continuing need to reduce the amount of materials used for the shell, can end and container. Thus, the use of a shell or can end formed from a blank having a standard volume is a problem. Accordingly, there is a need for a shell and/or can end that utilizes a reduced amount of metal while maintaining bend resistance.

Furthermore, there is a need for a shell and/or can end that is configured to be operable with a standard filling line having standard ends without requiring any modification to the filling line/closure or closure chuck. That is, any new shell and/or can end must be compatible with existing standard seamers. A "seamer" is a machine configured to roll and coin the distal end of the can body sidewall and the peripheral edge of the can end together. Since many can bodies and ends are manufactured in standard sizes (such as, but not limited to, twelve ounce beverage cans), the can bodies and ends must be compatible with seamers that accommodate such standard sizes. Thus, as used herein, a "standard seamer" is a machine that couples a can end to a can body, wherein the can body and can end are manufactured in standard sizes, such as, but not limited to, twelve ounce beverage cans. If the can body and can end are not of standard size, the user will need to purchase machinery configured to fit non-standard sized can bodies and can ends. This is a problem.

Accordingly, there is a need to reduce the amount of material in the shell and/or can end in order to reduce the total amount of material used to manufacture the can end. There is a further need for a shell and/or can end having a reduced amount of material to be compatible with existing machinery used to process shells, can ends and can bodies.

Disclosure of Invention

These needs and others are met by at least one embodiment of the disclosed and claimed concept, which provides a housing made from a sheet blank having a reduced volume. As used herein, "reduced volume" refers to the reduced volume of that volume relative to prior art housings configured to couple to the same size can body, where the housings are made of the same material, that is, the same type of metal having the same thickness. As used herein, a housing has a body with an "interior" that includes a center panel and a countersink portion. As used herein, adjacent to the housing interior is the housing "exterior" which includes the chuck wall, crown radius, can mating radius, and curl. The disclosed and claimed concept provides a housing "exterior" having a reduced thickness.

That is, in an exemplary embodiment, the housing includes a body having a stretched chuck wall, a crown radius, a can mating radius, and/or a curl. The central panel and the counterbore portion have a base thickness. Any of the chuck wall, crown radius, can mating radius, and/or curl has a reduced thickness. The shell countersink and shell chuck walls have substantially the same thickness as the sheet material prior to forming. In this configuration, the housing retains the flex resistance of a standard housing, but uses less material. The use of such a housing solves the above-mentioned problems. Furthermore, the shell is compatible with existing machinery for machining the shell, can end and can body. A press and method for forming such a housing are also disclosed which address the above-mentioned problems.

Drawings

A full understanding of the present invention can be obtained when the following description of the preferred embodiments is read in conjunction with the following drawings, in which:

FIG. 1 is a schematic cross-sectional side view of a prior art housing;

FIG. 2 is a partial cross-sectional side view of an unrolled housing;

FIG. 3 is a partial schematic side view and a partial cross-sectional side view of the punch;

FIG. 4 is a partial schematic side view and a partial cross-sectional side view of a first forming station;

5A-15A are detailed cross-sectional side views of one embodiment of the first forming station in a subsequent configuration during formation of the housing;

5B-15B are detailed cross-sectional side views of another embodiment of the first forming station in a subsequent configuration during shell formation;

FIG. 15C is a schematic cross-sectional view comparing the profiles of the tools in FIGS. 5A and 5B;

FIG. 16 is a flow chart of the disclosed method;

FIG. 17A is a schematic cross-sectional side view of a housing having a reduced profile;

fig. 17B is a schematic cross-sectional side view of a housing having a maximum reduced profile.

Detailed Description

It is to be understood that the specific elements shown in the drawings herein and described in the following specification are simply exemplary embodiments of the disclosed concept, which are provided as non-limiting examples for purposes of illustration only. Hence, specific dimensions, orientations, components, numbers of parts used, configuration of embodiments, and other physical characteristics relating to the embodiments disclosed herein are not to be considered limiting on the scope of the disclosed concepts.

Directional phrases used herein, such as, for example, clockwise, counterclockwise, left, right, top, bottom, upward, downward and derivatives thereof, relate to the orientation of the elements shown in the drawings and are not limiting upon the claims unless expressly recited therein.

As used herein, the singular forms "a", "an" and "the" include plural references unless the context clearly dictates otherwise.

As used herein, "configured to [ verb ]" means that the identified unit or component has a structure that is shaped, designed, arranged, coupled, and/or configured to perform the identified verb. For example, a member that is "configured to move" is movably coupled to another unit and includes a unit that causes the member to move, or the member is configured to move in response to other units or assemblies. Thus, as used herein, "configured as [ verb ]" recites a structure and not a function. Further, as used herein, "configured to [ verb ]" means that the identified unit or component is intended and designed to execute the identified verb. Thus, a unit that is only capable of executing the identified verb but is not intended and not designed to execute the identified verb is not "constructed as [ verb ]".

As used herein, "associated" means that the units are part of the same component and/or together or somehow operate with each other/interoperate. For example, a vehicle has four tires and four hubcaps. While all of the units are coupled as part of the vehicle, it is understood that each hubcap is "associated" with a particular tire.

As used herein, a "coupling assembly" includes two or more coupling or coupling components. The components of the coupling or coupling assembly are typically not part of the same unit or other component. As such, the components of the "coupling assembly" may not be described at the same time in the following description.

As used herein, a "coupling" or "one or more coupling components" is one or more components of a coupling assembly. That is, the coupling assembly includes at least two components configured to be coupled together. It will be appreciated that the components of the coupling assembly are compatible with each other. For example, in the coupling assembly, if one coupling member is a socket, the other coupling member is a snaptop, or if one coupling member assembly is a bolt, the other coupling member is a nut.

As used herein, a "fastener" is a separate component configured to couple two or more units. Thus, for example, a bolt is a "fastener" and a tongue and groove joint is not a "fastener". That is, the tongue and groove unit is part of the coupled unit, not a separate component.

As used herein, the statement that two or more parts or components are "coupled" shall mean that the parts are joined together or operate together either directly or indirectly (i.e., through one or more intermediate parts or components) as long as a link occurs. As used herein, "directly coupled" means that two units are in direct contact with each other. As used herein, "fixedly coupled" or "fixed" means that two components are coupled to move as one while maintaining a constant orientation relative to each other. Thus, when two units are coupled, all portions of the units are coupled. However, the description of the specific portion of the first unit coupled to the second unit (e.g., coupled to the axle first end of the first wheel) means that the specific portion of the first unit is disposed closer to the second unit than the other portions. Furthermore, an object that rests on another object that is held in place solely by gravity will not "couple" to a lower object unless the upper object is held substantially in place only. That is, for example, a book on a table is not coupled to the table, but a book pasted on the table is coupled to the table.

As used herein, the phrases "removably coupled" or "temporarily coupled" refer to one component being coupled to another component in a substantially temporary manner. That is, the two components are coupled such that the joining or separating of the components is easy and the components are not damaged. For example, two components that are secured to one another using a limited number of easily accessible fasteners (i.e., non-accessible fasteners) are "removably coupled," whereas two components that are welded together or joined by non-accessible fasteners are not "removably coupled. An "inaccessible fastener" is a component that requires removal of one or more other components prior to access to the fastener, where the "other components" are not access devices such as, but not limited to, doors.

As used herein, "temporarily disposed" means that a first unit or component rests on a second unit or component in a manner that allows the first unit/component to move without disengaging from or otherwise manipulating the first unit. For example, a book that simply rests on a table (i.e., the book is not glued or otherwise secured to the table) is "temporarily placed" on the table.

As used herein, "operably coupled" means that a plurality of units or assemblies (each of which is movable between a first position and a second position or a first configuration and a second configuration) are coupled such that as a first unit moves from one position/configuration to another position/configuration, a second unit also moves between the positions/configurations. It is noted that a first unit may be "operably coupled" to another unit, and the opposite is not true.

As used herein, "corresponding" means that the two structural components are sized and shaped to be similar to each other and can be coupled with a minimal amount of friction. Thus, the aspect ratio of the opening "corresponding" to the member is designed to be slightly larger than the member so that the member can pass through the opening with a minimal amount of friction. This definition may be modified if two components are to be "tightly" fitted together. In that case, the difference between the sizes of the components is even smaller, thereby increasing the amount of friction. The opening may even be slightly smaller than the part inserted into the opening if the unit defining the opening and/or the part inserted into the opening is made of a deformable or compressible material. With respect to surfaces, shapes and lines, two or more "corresponding" surfaces, shapes or lines typically have the same size, shape and contour.

As used herein, a "travel path" or "path," when used in association with a moving unit, includes the space through which the unit passes as it moves. In this way, any inherently moving unit has a "travel path" or "path". Further, "travel path" or "path" relates to the movement of a structure, which can be identified as a whole, relative to another object. For example, a rotating wheel (an identifiable structure) on an automobile does not typically move relative to the automobile body (another object) assuming the road is perfectly smooth. That is, the wheel as a whole does not change its position relative to, for example, an adjacent fender. Thus, the rotating wheel does not have a "travel path" or "path" relative to the body of the automobile. In contrast, the intake valve on that wheel (identifiable structure) does have a "travel path" or "path" relative to the vehicle body. That is, as the wheels rotate and move, the intake valve as a whole moves relative to the vehicle body.

As used herein, the statement that two or more parts or components are "engaged" with each other means that the units exert a force or bias against each other either directly or through one or more intermediate units or components. Further, as used herein with respect to moving parts, a moving part may "engage" another unit during movement from one position to another and/or may "engage" another unit once in that position. Thus, it should be understood that the statement that "unit a engages unit B when unit a is moved to unit a first position" and "unit a engages unit B when unit a is in unit a first position" are equivalent statements and mean that unit a engages unit B when moved to unit a first position and/or that unit a engages unit B when in unit a first position.

As used herein, "operably engaged" refers to "engaging and moving.

That is, when used with respect to a first component configured to move a movable or rotatable second component, "operably engaged" means that the first component exerts a force sufficient to cause the second component to move. For example, a screwdriver may be placed in contact with the screw. When no force is applied to the screwdriver, the screwdriver is only "temporarily coupled" to the screw. If an axial force is applied to the screwdriver, the screwdriver is pressed against the screw and "engages" the screw. However, when a rotational force is applied to the screwdriver, the screwdriver "operably engages" the screw and causes the screw to rotate. Further, with respect to electronic components, "operably engaged" means that one component controls another component through a control signal or current.

As used herein, the word "unitary" refers to a component formed as a single piece or body. That is, a component that includes parts that are formed separately and then joined together as a single body is not a "unitary" component or body.

As used herein, the term "number" shall mean one or an integer greater than one (that is, a plurality). That is, for example, the phrase "a plurality of units" refers to one unit or a plurality of units.

As used herein, in the phrase "[ x ] moving between its first and second positions" or "[ y ] configured to move [ x ] between its first and second positions," [ x ] is the name of a unit or component. Further, when [ x ] is a unit or component that moves between locations, the pronoun "it" refers to "[ x ]", i.e., the named unit or component that precedes the pronoun "it".

As used herein, "surrounding" in phrases such as "disposed about" or "extending about" a unit, point or axis "or" X degrees about "a unit, point or axis means encircling, surrounding or measured about. "left and right" when used with reference to a measurement or the like means "about," i.e., within an approximate range associated with the measurement, as understood by one of ordinary skill in the art.

As used herein, a "radial side/surface" for a circular or cylindrical body is an extended side/surface that surrounds or encircles its center or encircles a height line through its center. As used herein, an "axial side/surface" for a circular or cylindrical body is a side that extends in a plane that extends generally perpendicular to a height line passing through the center. That is, typically, for a cylindrical soup can, the "radial sides/surfaces" are the generally circular side walls, and the "axial sides/surfaces" are the top and bottom of the soup can.

As used herein, "product side" refers to the side of the construct that is used in a container, which contacts or may contact a product such as, but not limited to, a food or beverage. That is, the "product side" of the construct is the side of the construct that ultimately defines the interior of the container.

As used herein, "consumer side" refers to the side of the construct that is used in the container that does not contact or is unlikely to contact a product such as, but not limited to, a food or beverage. That is, the "customer side" of the construct is the side of the construct that ultimately defines the exterior of the container.

As used herein, "substantially curvilinear" includes cells having multiple curved portions, combinations of curved and flat portions, and multiple flat portions or line segments arranged at angles relative to each other to form a curve.

As used herein, "substantially" refers to the "general manner" associated with the modified term as understood by one of ordinary skill in the art.

As used herein, "substantially" refers to "a majority" in relation to terms that are modified as understood by one of ordinary skill in the art.

As used herein, "at … …" means at and/or near … … in relation to terms that are modified as understood by one of ordinary skill in the art.

As used herein, "standard" as used in "standard container" or "standard housing" refers to a construct used in conjunction with a particular product, the construct being used by multiple product manufacturers. As noted above, many manufacturers use aluminum twelve fluid ounce containers for products such as soda, soda and/or beer. Such containers and their components (e.g., shell, can end, and can body) are thus "standard" containers, "standard" shells, "standard" can ends, and "standard" can bodies. "standard" containers and their components are well known in the art.

As used herein, "drawing" refers to clamping and pulling a portion of the metal blank between forming structures. This action can either pull the metal or stretch the metal. As used herein, "drawing" the metal refers to thinning the metal by pulling the metal between two dies, the distance between the two dies being thinner than the metal. As used herein, "stretching" a metal means that the metal is held in multiple positions and pulled. This action results in thinning of the metal between the holding points. Thus, "stretching" the blank combines these two actions. Further, as used herein, "stretching" is not the same as any of "drawing," "stretching," or ironing a metal. Further, as used herein, "clamping" refers to disposing the blank between two forming structures and applying a biasing force to the blank that is sufficient to prevent wrinkles from forming, but insufficient to prevent metal from moving between the forming structures.

The following description is for forming housing 20 as shown in fig. 2, which includes an inner portion 24 and an outer portion 26 separated by a boundary "B". The housing 20 is made of a reduced volume material and has a stretched outer portion 26. That is, as used herein, outer portion 26 includes a chuck wall 34, a can mating radius 35, a crown radius 36, and a bead 38. As used herein, the chuck wall 34, stretched can mating radius 35, stretched crown radius 36, stretched bead 38 are thinned via stretch forming, or all of the cells (i.e., outer portion 26) are thinned together via stretch forming.

As is known, the shell 20 is initially a blank 10 cut from the sheet 1 (fig. 3). The sheet 1 and thus the blank 10 have a basic thickness. Unless altered by the forming operation, the blank 10 and various portions of the shell 20, and thus the can end (not shown), will maintain a base gauge, as described below. That is, as shown in fig. 3, the blank 10 includes a center panel portion 11, a countersink portion 12, a chuck wall portion 14, a can mating radius portion 15, a crown radius portion 16, and a curl portion 18, which, after the forming operation, become a center panel 30, a countersink portion 32, a drawn chuck wall 34, a drawn can mating radius portion 35, a drawn crown radius portion 36, and a curl 38, respectively, as described below. As used herein, the stretched chuck wall 34, stretched can mating radius 35, stretched crown radius 36 are collectively identified as "stretched outer portion 26".

Further, the following discussion and accompanying figures exemplify a generally cylindrical housing 20. It should be understood that the disclosed and claimed concept is operable with any shape of housing 20 and that the cylindrical shapes discussed and illustrated are merely exemplary. Further, in the exemplary embodiment, for the dimensions described below, the housing is made of aluminum and is configured to be coupled to a beverage can, i.e., a can configured to hold a beverage such as beer or a carbonated beverage (e.g., "soda" or "soda"). As used herein, such a housing is identified as a "beverage container housing" 20'. One non-limiting example of a beverage can containing the beverage container housing 20' is a twelve ounce beverage container. The "standard volume" as defined above for the blank 10 and subsequent beverage container housing 20' is substantially about 0.0546 cubic inches. As is well known, such a standard blank (not shown) is formed into a shell having the following features. One embodiment of a standard volume beverage container housing 20' (fig. 1) has the following features.

Volume of	0.0546 cubic inch
		Thickness of foundation	0.0086 inch
Pressure configured to resist	90psi

It will be appreciated that the housing 20 (not shown) for other standard containers has different characteristics as is well known in the art.

The blank 10 is formed into a shell 20, the shell 20 including a body 22 having a central panel 30, a counter bored portion 32, a drawn chuck wall 34, a drawn can mating radius 35, a drawn crown radius 36, and/or a drawn bead 38. As used herein, "stretched" means that the identified cell has been stretched to be thinner than the cells in the prior art. Because the stretched unit is thinner, the blank 10 requires less metal, i.e., has a reduced volume, relative to the prior art. This solves the above problems. Furthermore, the thickness of the "stretched" unit is thinner than the base thickness of the sheet and/or blank 10. Thus, as used herein, terms such as "stretched crown radius" 36 recite properties such as, but not limited to, the thickness of the crown radius, without reciting the product of the different processes.

Inner portion 24, center panel 30, and counterbore portion 32 have a base thickness that generally corresponds to the base thickness of sheet 1. The stretched outer portion 26, i.e., the stretched chuck wall 34, the stretched can mating radius 35, the stretched crown radius 36, and/or the stretched bead 38, has a reduced thickness or a particular reduced thickness. That is, as used herein, "reduced thickness" means that the thickness of the stretched chuck wall 34, the stretched can mating radius 35, the stretched crown radius 36, and/or the stretched bead 38 is about 5% to about 21% thinner than the base gauge. As used herein, "specifically reduced thickness" means that the thickness of the stretched chuck wall 34, the stretched can mating radius 35, the stretched crown radius 36, and/or the stretched bead 38 is about 11% thinner than the base gauge. As used herein, the shell 20, including the stretched chuck wall 34, the stretched can mating radius 35, the stretched crown radius 36, and/or the stretched bead 38, is made of a "reduced volume material," but retains the buckling resistance properties of a standard shell. That is, a "beverage" container housing 20' made of a "reduced volume material" including a stretched outer portion 26 has the following features:

volume of	0.0533 cubic inches
		Thickness of foundation	0.0086 inch
Pressure configured to resist	90psi

Further, a beverage container housing 20' according to the present disclosure is shown in fig. 17A, which illustrates the percent reduction in metal thickness (relative to the base thickness) at the stretched chuck wall 34, can mating radius 35, stretched crown radius 36, and bead 38 (e.g., outer portion 26). In this embodiment, the metal volume in stretched crown radius 36 is reduced (relative to a standard volume container shell) by about 5% to about 20%, or by about 11%. In other words, in the reduced volume housing 20 (or reduced volume housing body 22), the stretched chuck wall 34, can mating radius 35, stretched crown radius 36, and bead 38 have a "reduced profile". That is, as used herein, "reduced profile" means that the thickness of the metal is reduced relative to the base thickness at the stretched chuck wall 34, can mating radius 35, stretched crown radius 36, and bead 38 as described in the next sentence. The thickness of the metal is reduced by about 8.9% and 13.2% relative to the base thickness at the drawn chuck wall 34, the can mating radius 35 is reduced by about 13.2% to about 8.9%, the thickness of the metal is reduced by about 8.9% to about 13.2% relative to the base thickness at the drawn crown radius 36, and the thickness of the metal is reduced by about 4.9% to about 10.3% relative to the base thickness at the curl 38.

Further, the housing 20, made of "reduced volume material", including the stretched chuck wall 34, the stretched can mating radius 35, the stretched crown radius 36, and the stretched bead 38 solves the above-described problems. As used herein, the "reduced material volume" of the shell 20' is measured relative to a standard shell and means that the volume of the blank 10/shell 20 is reduced by about 2% to about 4%, or by about 2.4%, from the volume of a blank of a similar blank/shell (i.e., a blank/shell configured to couple to a can body of the same size) without the drawn chuck wall 34, the drawn can mating radius 35, the drawn crown radius 36, the drawn bead 38. Further, as used herein, such a blank 10 or such a housing 20 is a "reduced volume blank" 10 or a "reduced volume housing" 20.

In another exemplary embodiment, as shown in fig. 17B, the beverage container housing 20' (or reduced volume housing body 22) has a "maximum reduced profile". As used herein, "maximum reduction profile" means that the thickness of the metal is reduced as shown in fig. 17B relative to the base thickness at the stretched chuck wall 34, the stretched can mating radius 35, the stretched crown radius 36, and/or the stretched bead 38. As shown, the thickness of the metal is reduced by about 25% to about 27% relative to the base thickness at the drawn chuck wall 34, the can mating radius 35 is reduced by about 25% to about 27%, the thickness of the metal is reduced by about 27% relative to the base thickness at the drawn crown radius 36, and the thickness of the metal is reduced by about 25% relative to the base thickness at the bead 38. Thus, the reduced volume housing 20 (or reduced volume housing body 22) has one of a "reduced profile" or a "maximum reduced profile".

For example, for a beverage container housing 20', the housing body 22 is aluminum and the total thickness of the counterbore portion 32 is between about 0.0082 inches and about 0.0106 inches or about 0.0086 inches. The total thickness of the stretched chuck wall 34 is between about 0.0056 inch to about 0.0090 inch or about 0.0086 inch. The drawn can mating radius 35 has a thickness of between about 0.0056 inch to about 0.0090 inch or about 0.0078 inch. The total thickness of stretched crown radius 36 is between about 0.0056 inch to about 0.0090 inch or about 0.0078 inch. The thickness of the stretch bead 38 is between about 0.0060 inches to about 0.0094 inches or about 0.0082 inches. As used herein, "total thickness" refers to the thickness of a material measured at a particular location along a line that is substantially perpendicular to the surface of the identified portion of the housing 20. Thus, for example, the "overall thickness" of counterbore portion 32 is not intended to refer to the width of counterbore portion 32. Such a beverage container housing 20 'is generally the same size as a standard beverage housing, and thus the beverage container housing 20' is configured to be processed in a substantially similar manner as a standard beverage housing. That is, the beverage container housing 20' does not require the use of new processing equipment, but solves the above-described problems. Further, the beverage container housing 20' is configured to be coupled to a beverage can body (not shown) and is configured to have the "flex resistance" of a standard can end.

As another example, a housing (not shown) for a steel container, such as, but not limited to, an 18.6 ounce soup container, includes a steel housing body 22 formed from a steel sheet material having a base thickness of about 0.0079 inches. The housing 20 for such a container includes a counterbore portion 32, with the total thickness of the counterbore portion 32 being between about 0.0088 inches and about 0.0075 inches, or about 0.0079 inches. Further, in this embodiment, the stretched unit further comprises a stretched chuck wall 34, a stretched can mating radius 35, a stretched crown radius 36, and/or a stretched bead 38. For such a steel shell 20, the overall thickness of the stretched chuck wall 34 is between about 0.0056 inch to about 0.0084 inch, or about 0.0072 inch, and the thickness of the stretched can end radius 35 is between about 0.0056 inch to about 0.0084 inch, or about 0.0072 inch. The total thickness of stretched crown radius 36 is between about 0.0056 inch to about 0.0084 inch or about 0.0072 inch. The thickness of the stretch bead 38 is between about 0.0060 inches to about 0.0088 inches or about 0.0076 inches. Again, the particular reduction in thickness in this segment is exemplary, and the particular thickness of the stretched element varies with the original base thickness of the material.

The housing 20, made of "reduced volume material", including the drawn chuck wall 34, the drawn can mating radius 35, the drawn crown radius 36, and/or the drawn curl 38 is formed in a punch assembly (or "punch") 500 as shown in fig. 2-14. In another embodiment, the housing 20 made of "reduced volume material" including the stretched chuck wall 34, the stretched can mating radius 35, and/or the stretched crown radius 36 is formed in a punch assembly (or "punch") 500. That is, in contrast to the previous embodiment, the stretched bead 38 is not formed in the punch 500, but rather on another station 502 or another punch (not shown). Thus, the punch 500 is configured and does form a reduced volume housing 20.

As noted above, in one embodiment, the punch 500 includes a single station that both cuts the blank 10 from the sheet 1 and forms the blank 10 into the housing 20. In another embodiment, the stamping press 500 includes a plurality of stations 502 (some of which are schematically shown), each performing a plurality of forming operations on the housing 20 (as shown in the figures, the stations are generally identified by reference numeral 502). For example, in one embodiment, the station 502 cuts from the sheet 1a generally circular disk-shaped blank 10, which is a reduced volume blank 10. Instead, a pre-cut reduced volume blank 10 is fed into the punch press 500. Thus, the punch 500 is configured and does form the housing 20 from the blank 10, wherein the blank 10 is cut from the sheet 1. Whether the punch 500 cuts the blank 10 from the sheet 1 is irrelevant to the present disclosure. Further, in an exemplary embodiment, a forming operation is performed on the sheet 1 prior to cutting the blank 10 from the sheet 1, or prior to the forming operation by the "first" forming station 530, as described below. Thus, as used herein, the blank 10 is also the shell 20. Accordingly, the following discussion is directed to the punch 500 acting on the blank 10 or housing 20.

As described above, in one embodiment, the housing 20 is formed in a one-step process. That is, as used herein, "one-step process" means that all forming operations occur at a single station. In other words, for a "one-step process," the plurality of stations 502 includes only a single station, which is identified herein as the "first" forming station 530. In another embodiment, the blank 10 and/or housing 20 are moved through the punch press 500 on a conveyor 504, the conveyor 504 being schematically illustrated in fig. 3 and configured and indeed to move intermittently or indexed. In the exemplary embodiment, conveyor 504 is a belt 506 (shown schematically) that includes a plurality of notches (not shown). The strap 506 moves a set distance and then stops before moving the set distance again. As the strap 506 moves, the blanks 10/shells 20 move sequentially through the converting punches of the stations 502, wherein each station 502 performs a single forming operation or multiple forming operations on the blanks 10/shells 20 as described above.

The punch 500 also includes a frame 508 and a drive assembly (not shown), as well as a plurality of upper tool assemblies 510 and a plurality of lower tool assemblies 520. In the exemplary embodiment, each lower tool assembly 520 is movably coupled, movably coupled directly or secured to the press frame 508, and is generally stationary. Each upper tool assembly 510 is structured and operative to move between a first position in which the upper tool assembly 510 is spaced apart from the lower tool assembly 520 and a second position in which the upper tool assembly 510 is adjacent (in one exemplary embodiment, immediately adjacent) to the lower tool assembly 520. As used herein, "immediately adjacent" means that the upper tool assembly 510 is spaced apart from the lower tool assembly 520 such that the

tool assemblies

510, 520 form, i.e., change, the shape of the blank 10/shell 20. In the exemplary embodiment, each of upper tool assembly 510 and lower tool assembly 520 for a plurality of stations 502 are integral or coupled and support dies, punches, and other units for each station. In this configuration, the upper tool assemblies 510 for the stations move simultaneously and are driven by a single driver assembly (not shown). Further, as is well known, the upper tool assembly 510 and the lower tool assembly 520 comprise individually movable units, such as punches, dies, liners, shims, risers, and other sub-units (hereinafter collectively referred to as "sub-units") discussed below, that are configured and do move apart from one another. However, all of the units typically move with the upper tool assembly 510 between the first and second positions. That is, typically, the sub-units move relative to each other, but as a whole, the upper tool assembly 510 moves between the first and second positions as described above. Further, it should be understood that the drive assembly includes cams, linkages, and other units configured to move the sub-units of the upper tool assembly 510 and the lower tool assembly 520 in the appropriate sequence. That is, selected sub-units of the upper tool assembly 510 and the lower tool assembly 520 are configured to move independently of other selected sub-units. For example, one selected subunit is configured to move into and stay in the second position, while the other subunit moves into and out of the second position. Such selective movement of subunits is known in the art. For purposes of this disclosure, only the first forming station 530 or the single forming station 530 is relevant and the upper tool assembly 510 and the lower tool assembly 520 are identified hereinafter as the upper tool assembly 510 of the first forming station and the lower tool assembly 520 of the first forming station. As described above, the first forming station 530 is configured and does form the shell body 22 to have the center panel 30, the counterbore portion 32, the stretched chuck wall 34, and the stretched crown radius 36. In other words, the upper tool assembly 510 of the first forming station and the lower tool assembly 520 of the first forming station are configured and positively form the housing body 22 to have the center panel 30, the counter bored portion 32, the stretch chuck wall 34, the stretched can mating radius portion 35, and the stretched crown radius portion 36. That is, the upper tool assembly 510 of the first forming station and the lower tool assembly 520 of the first forming station are configured to and do form the counterbore portion 12 as the counterbore portion 32, the chuck wall portion 14 as the stretched chuck wall 34, the can mating radius portion 15 as the stretched can mating radius portion 35, and the crown radius portion 16 as the stretched crown radius portion 36. Thus, the upper tool assembly 510 of the first forming station and the lower tool assembly 520 of the first forming station are configured to and do stretch the chuck wall portion 14/can mating radius 15/crown radius 16 to produce an outer portion 26 or crown radius 36 having a reduced thickness. Further, the punch 500 is configured to form the center panel 30 and the countersink 32 or inner portion 24 while substantially maintaining the base caliper of the sheet 1. In this configuration, a blank 10/shell 20 having a reduced volume and having a stretched outer portion 26 solves the above-described problems.

In the exemplary embodiment, upper tool assembly 510 of the first forming station includes a "blank & pull" die punch 512, an upper piston 514, and a die center punch 516. The upper tool assembly blank and pulling die punch 512 of the forming station (hereinafter referred to as "upper blank and pulling die punch of the first forming station" 512) includes a generally annular body 531. The upper blank of the first forming station and the pulling die punch body 531 includes an axial surface 532 and an inner radial surface 534. The inner intersection of the upper blank of the first forming station and the annular body axial surface 532 of the pulling die punch and the upper blank of the first forming station and the annular body inner radial surface 534 of the pulling die punch is curvilinear and this transition region is herein the "inner radius" 536. That is, the term "inner radius" does not refer to the radius of the annular body inner radial surface 534 defining the upper blank and the pulling die punch of the first forming station. Further, in the exemplary embodiment, the inner radial surfaces 536 of the upper blank of the first forming station and the pulling die punch are "reduced radii" (hereinafter also identified as "the reduced inner radial surfaces 536 of the upper blank of the first forming station and the pulling die punch"). As used herein, "reduced radius" means that the radius is reduced by about 68% to about 88%, or by about 80%, relative to the radius of the inner radial surface of a comparable first forming station upper blank and pulling die punch that is configured to make a similar shell.

Fig. 5A-15A illustrate an embodiment of the stamping press 500 in which the upper tool assembly 510 of the first forming station includes a die center punch 516A. Fig. 5B-15B illustrate an embodiment of the stamping press 500 in which the upper tool assembly 510 of the first forming station includes a die center punch 516B. Fig. 15C shows a comparison between the die center punch 516A and the die center punch 516B. As shown in fig. 5A-15A and 5B-15B, one of ordinary skill in the art will understand the movement of the units of the first forming station 530.

Further, in the exemplary embodiment, lower tool assembly 520 of the first forming station includes a lower piston 522 (hereinafter "lower piston of first forming station" 522), a die core ring 524, and a panel punch 526. The die core ring 524 of the lower tool assembly of the first forming station (hereinafter "lower die core ring of the first forming station" 524) includes a generally annular body 540 having an axial surface 542 and an outer radial surface 544. The intersection of the toroid axial surface 542 of the lower die core ring of the first forming station and the toroid outer radial surface 544 of the lower die core ring of the first forming station is curvilinear and this transition region is used herein as the "outer radius" 546. That is, the term "outer radius" does not refer to the radius of the annular body outer radial surface 544 defining the upper blank and the pulling die punch of the first forming station. Further, in the exemplary embodiment, an outer radius 546 of the lower mold core ring of the first forming station is a "reduced radius" (identified below as "reduced inner radius of the lower mold core ring of the first forming station" 546). As used herein, "reduced radius" means that the radius is reduced by about 30% to about 60%, or by about 50%, relative to the radius of the radial surface of the lower die core ring of a control first forming station configured to produce a similar shell.

In an exemplary embodiment where the punch is configured to form the beverage container housing 20', the radius of the inner radial surface 536 of the upper blank and pulling die punch of the first forming station is about 0.019 inches and the radius 546 of the outer portion of the lower die core ring of the first forming station is about a 0.022 inch radius.

Further, the stretched outer portion 26 is formed by "stretching" as defined above. Thus, the punch 500 is configured and does "grip" the crown radius portion 16 of the blank 10 as defined above. Thus, when the upper tool assembly 510 of the first forming station is in the second position, the upper blank and pulling die punch 512 of the first forming station and the lower piston 522 of the first forming station apply a force of about 60psi to about 250psi or about 110psi to the blank 10/housing 20. In other words, for these components, the pressure increases by about 20% to about 400% or by about 200% relative to the prior art pressure of 50 psi. In addition, the upper piston 514 and the lower die core ring 524 of the first forming station exert a force between about 100psi and about 600psi or about 110 psi. In other words, for these components, the pressure increases by about 100% to about 1100% or about 800% relative to the prior art 50psi pressure.

As used herein, the pressure ranges mentioned in the previous paragraph are "stretch" pressure ranges for the identified component. That is, a force between about 60psi and about 250psi is the "stretch" pressure range of the upper blank of the first forming station and the pulling die punch 512 and the die piston 522 of the first forming station. The punch 500 is configured to and does apply a "stretch" pressure range to each pair of components. Further, the particular pressure referred to in the previous paragraph is the "stretch" pressure of the identified component. The punch 500 is configured and does apply a "stretching" pressure to each pair of components.

As mentioned above, the terms blank 10 and shell 20 are interchangeable. Thus, as used herein in discussing the punch press 500, the terms "blank" 10 or "shell" 20 are interchangeable and refer to the construct being formed.

It will be appreciated that the combination of the reduced inner radial surface 536 of the upper blank and pulling die punch of the first forming station, the reduced outer radius 546 of the lower die core ring of the first forming station, and the increased pressure of the upper blank and pulling die punch 512 of the first forming station and the lower piston 522 of the first forming station configured and positively forming the stretched outer portion 26 solves the above-described problems.

As shown in fig. 16, a method of forming a housing 20 having a stretched outer portion 26 includes: providing 1000 a sheet 1, the sheet 1 having a base caliper; cutting 1002 a blank 10 from a sheet 1, the blank 10 comprising a countersink portion 12, a chuck wall portion 14, and a crown radius portion 16; providing 1004 a punch assembly 500 including a frame 508, a plurality of punch stations 502 including a first forming station 530, the first forming station 530 including an upper tool assembly 510 and a lower tool assembly 520, the upper tool assembly 510 of the first forming station being configured to move between an upper first position in which the upper tool assembly 510 of the first forming station is spaced apart from the lower tool assembly 520 of the first forming station and a lower second position in which the upper tool assembly 510 of the first forming station is immediately adjacent the lower tool assembly 520 of the first forming station, wherein the upper tool assembly 510 of the first forming station and the lower tool assembly 520 of the first forming station are configured to form a stack including the center panel 30, the first forming station and the second forming station when the upper tool assembly 510 of the first forming station and the lower tool assembly 520 of the first forming station are in the second position, Countersink portion 32 chuck wall 34, can mating radius 35, crown radius 36, and housing body 22 of curl 38, disposing blank 1006 between upper tool assembly 510 of the first forming station and lower tool assembly 520 of the first forming station, clamping 1008 any of can mating portion 15, crown radius 16, and curl 18 between upper tool assembly 510 of the first forming station and lower tool assembly 520 of the first forming station, and performing 1010 the forming operation. Performing 1010 the forming operation includes drawing 1020 any or all of the chuck wall portion 14, can mating radius portion 15, crown radius portion 16, bead portion 18, and/or outer portion 26 to form a drawn chuck wall 34, a drawn can mating radius portion 35, a drawn crown radius portion 36, and/or a drawn bead 38 (or drawn outer portion 26), and forming 1022 the counterbore portion 12 into the counterbore portion 32. As described above, after the counter bored portion 32 is formed 1022, the center panel 30 has a thickness corresponding to the blank 10, which in turn has a thickness corresponding to the sheet 1 of material 10.

Further, providing 1004 the punch assembly 500 includes: providing 1030 an upper tool assembly 510 of a first forming station comprising a blank and pulling die punch 512, an upper piston 514, and a die center punch 516; a first forming station lower tool assembly 520 is provided 1032 that includes the lower piston 522, the die core ring 524, and the panel punch 526, wherein the first forming station upper blank and the pulling die punch 512 includes an inner radial surface 536, wherein the first forming station upper blank and the pulling die punch inner radial surface 536 is a reduced radius, wherein the first forming station lower die core ring 524 includes an outer radius 546, wherein the first forming station lower die core ring outer diameter 546 is a reduced radius. Further, providing 1004 the punch assembly 500 includes: providing 1034 the upper blank of the first forming station and the pulling die punch 512 with a radius of the inner radial surface 536 of about 0.019 inches; and the lower die core ring 524 of the first forming station is provided 1036 with an outer radius 546 of about 0.022 inches.

Further, stretching 1020 chuck wall portion 14, can mating radius portion 15, crown radius portion 16, and/or bead portion 18 to form stretched can mating radius portion 35, stretched crown radius portion 36, and/or stretched bead 38 (or stretched outer portion 26) includes applying 1040 a force between about 1,153lbf to about 3,890lbf to blank 10, and/or applying 1042 a force of about 2,442lbf to blank 10.

In the exemplary embodiment, cutting 1002 the blank 10 from the sheet 1 includes cutting 1050 a blank 10 having a reduced volume. As mentioned above, cutting the blank 10 is equivalent to providing a blank. Thus, as used herein, cutting 1050 a blank having a reduced volume is the same as providing a blank 10 having a reduced volume. Further, in the exemplary embodiment, performing 1010 the forming operation includes forming 1060 the blank 10 into a standard beverage housing 20'.

As mentioned above, the example used is typically an aluminum standard beverage housing 20'. However, it should be understood that the concepts disclosed above are also applicable to can ends made from other materials, such as, but not limited to, steel and steel alloys. It will also be appreciated that steel cans and can ends are typically made from a material having a base thickness that is thinner than the end of an aluminum can. Thus, as described below, a steel can end including the down-gauging concepts disclosed herein will have a base thickness that is thinner than the dimensions of an aluminum can, and a base thickness that is thinner than the metal used to manufacture can ends that do not include the concepts disclosed herein.

While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the claims appended and any and all equivalents thereof.

Claims

1. A housing (20) comprising:

a body (22) including a center panel (30), a countersink (32), a chuck wall (34), a can mating radius (4, 35), a crown radius (36), and a curl (6);

wherein the center panel (30) and the countersink (32) have a base thickness; and is

Wherein the body (22) has a reduced volume.

2. The shell (20) of claim 1, wherein the crown radius (36) is a stretched crown radius (36).

3. The housing (20) of claim 2, wherein the housing body (22) has one of a reduced profile or a maximum reduced profile.

4. The housing (20) of claim 1, wherein:

the body (22) is aluminum;

the total thickness of the countersink region (32) is between about 0.0104 inches and about 0.0078 inches;

the center panel (30) has a total thickness of between about 0.0104 inches to about 0.0078 inches; and is

The stretched crown radius (36) has a total thickness of between about 0.009 inches and about 0.0064 inches.

5. The housing (20) of claim 4, wherein:

the total thickness of the countersink region (32) is about 0.0086 inches;

the center panel (30) has a total thickness of about 0.0086 inches; and is

The crown radius (36) has a total thickness of about 0.0076 inches.

6. The housing (20) of claim 1, wherein:

the body (22) is steel;

the countersink region (32) has a total thickness of between about 0.0065 inches and about 0.0090 inches;

the center panel (30) has a total thickness of between about 0.0065 inches to about 0.0090 inches; and is

The crown radius (36) has a total thickness of between about 0.0050 inch and about 0.0090 inch.

7. The housing (20) of claim 6, wherein:

the total thickness of the countersink region (32) is about 0.0080 inches;

the center panel (30) has a total thickness of about 0.0080 inches; and is

The crown radius (36) has a total thickness of about 0.0080 inches.

8. A punch assembly (500) configured to form a housing (20) from a blank (10) cut from a sheet (1), the sheet (1) having a base thickness, the punch (500) comprising:

a frame (508);

a plurality of stamping stations (502) including a first forming station (530);

said first forming station (530) comprising an upper tool assembly (510) and a lower tool assembly (520);

the upper tool assembly (510) of the first forming station is configured to move between an upper first position in which the upper tool assembly (510) of the first forming station is spaced apart from the lower tool assembly (520) of the first forming station and a lower second position in which the upper tool assembly (510) of the first forming station is immediately adjacent to the lower tool assembly (520) of the first forming station;

wherein the upper tool assembly (510) of the first forming station and the lower tool assembly (520) of the first forming station are configured to form a housing (22) comprising a center panel (30), a countersink portion (32), a chuck wall (34), and a crown radius (36);

wherein the upper tool assembly (510) of the first forming station and the lower tool assembly (520) of the first forming station are further configured to stretch the crown radius (36) to produce a crown radius (36) having a reduced thickness; and is

Wherein the upper tool assembly (510) of the first forming station and the lower tool assembly (520) of the first forming station are further configured to form the center panel (30) and the countersink portion (32) at the base gauge.

9. The punch assembly (500) according to claim 8, wherein:

the upper tool assembly (510) of the first forming station includes a blank and pull die punch (512), an upper piston (514), and a die center punch (516);

the lower tool assembly (520) of the first forming station includes a lower piston (522), a die core ring (524), and a panel punch (526);

the upper blank of the first forming station and a pulling die punch (512) include an inner radius (534);

wherein the inner radius (534) of the upper blank and the pulling die punch of the first forming station is a reduced radius;

the lower die core ring (524) of the first forming station includes an outer radius (546); and is

Wherein an outer radius (546) of a lower die core ring of the first forming station is a reduced radius.

10. The punch assembly (500) according to claim 9, wherein:

the inner radius (534) of the upper blank of the first forming station and the pulling die punch is a radius of about 0.019 inches; and is

The outer radius (546) of the lower die core ring of the first forming station is a radius of about 0.022 inches.

11. The punch assembly (500) of claim 9, wherein the upper blank of the first forming station and the pulling die punch (512) and the lower piston (522) of the first forming station clamp the blank (10) when the upper tool assembly (510) is in the second position.

12. The punch assembly (500) of claim 11, wherein the upper piston (514) of the first forming station and the lower die core ring (524) of the first forming station apply a force to the blank (10) of between about 100psi and about 600psi when the upper tool assembly (510) is in the second position.

13. The punch assembly (500) of claim 12, wherein the upper piston (514) of the first forming station and the lower die core ring (524) of the first forming station apply a force of about 110psi to the blank (10) when the upper tool assembly (510) is in the second position.

14. A method of forming a housing (20), comprising:

providing (1000) a sheet (1), the sheet (1) having a base caliper;

cutting (1002) a blank (10) from the sheet (1), the blank (10) comprising a countersink portion (32), a chuck wall portion (34), and a crown radius portion (16);

providing (1004) a punch assembly (500) comprising a frame (508), a plurality of punch stations (502) including a first forming station (530), the first forming station (530) including an upper tool assembly (510) and a lower tool assembly (520), the upper tool assembly (510) of the first forming station being configured to move between an upper first position in which the upper tool assembly (510) of the first forming station is spaced apart from the lower tool assembly (520) of the first forming station and a lower second position in which the upper tool assembly (510) of the first forming station is proximate to the lower tool assembly (520) of the first forming station, wherein when the upper tool assembly (510) of the first forming station and the lower tool assembly (520) of the first forming station are in the second position, the upper tool assembly (510) of the first forming station and the lower tool assembly (520) of the first forming station are configured to form a housing body (22) including a center panel (30), a countersink portion (32), and a crown radius (36);

arranging (1006) the blank (10) between the upper tool assembly (510) and the lower tool assembly (520);

clamping (1008) the crown radius portion (16) between an upper tool assembly (510) of the first forming station and a lower tool assembly (520) of the first forming station;

performing (1010) a shaping operation comprising:

drawing (1020) the crown radius portion (16) to form a drawn crown radius portion (36);

forming (1022) the counter bored portion (12) as a counter bored portion (32); and

drawing (1020) the chuck wall portion (14) into a drawn chuck wall (34).

15. The method according to claim 14, wherein the thickness of the countersink region (32) corresponds to a base thickness of the sheet (1).

16. The method according to claim 13, wherein providing (1004) a punch assembly (500) comprises:

providing (1030) an upper tool assembly (510) of a first forming station comprising a blank and pulling die punch (512), an upper piston (514), and a die center punch (516);

providing (1032) a lower tool assembly (520) of a first forming station including a lower piston (522), a die core ring (524), and a panel punch (526);

wherein the upper blank of the first forming station and the pulling die punch (512) comprise an inner radius (536);

wherein the inner radius (536) of the upper blank and the pulling die punch of the first forming station is a reduced radius;

wherein the lower die core ring (524) of the first forming station includes an outer radius (546); and is

17. The method according to claim 16, wherein providing the punch assembly (500) comprises:

providing (1034) an upper blank and a pulling die punch (512) of the first forming station, wherein the inner radius (536) is a radius of about 0.019 inches; and

providing (1036) a lower die core ring (524) of the first forming station, wherein an outer radius (546) is a radius of about 0.022 inches.

18. The method of claim 14, wherein stretching the crown radius portion (16) to form a stretched crown radius portion (36) comprises applying a force between about 100psi to about 600psi to the blank (10).

19. The method of claim 18, wherein stretching the crown radius portion (16) to form a stretched crown radius portion (36) comprises applying a force of about 110 psi.

20. The method of claim 14, wherein cutting (1002) a blank (10) from the sheet (1) comprises cutting (1050) a blank (10) having a reduced volume.

21. The method of claim 20 wherein performing (1010) a forming operation comprises forming (1060) the blank (10) into a standard beverage housing (20).