Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
  • B21D22/20—Deep-drawing
  • B21D22/201—Work-pieces; preparation of the work-pieces, e.g. lubricating, coating
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M105/00—Lubricating compositions characterised by the base-material being a non-macromolecular organic compound
  • C10M105/08—Lubricating compositions characterised by the base-material being a non-macromolecular organic compound containing oxygen
  • C10M105/32—Esters
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M2207/00—Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
  • C10M2207/28—Esters
  • C10M2207/281—Esters of (cyclo)aliphatic monocarboxylic acids
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M2207/00—Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
  • C10M2207/28—Esters
  • C10M2207/282—Esters of (cyclo)aliphatic oolycarboxylic acids
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M2207/00—Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
  • C10M2207/28—Esters
  • C10M2207/283—Esters of polyhydroxy compounds
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
  • C10M2207/00—Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
  • C10M2207/28—Esters
  • C10M2207/286—Esters of polymerised unsaturated acids
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2040/00—Specified use or application for which the lubricating composition is intended
  • C10N2040/20—Metal working
  • C10N2040/24—Metal working without essential removal of material, e.g. forming, gorging, drawing, pressing, stamping, rolling or extruding; Punching metal
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2040/00—Specified use or application for which the lubricating composition is intended
  • C10N2040/20—Metal working
  • C10N2040/241—Manufacturing joint-less pipes
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2040/00—Specified use or application for which the lubricating composition is intended
  • C10N2040/20—Metal working
  • C10N2040/242—Hot working
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2040/00—Specified use or application for which the lubricating composition is intended
  • C10N2040/20—Metal working
  • C10N2040/243—Cold working
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2040/00—Specified use or application for which the lubricating composition is intended
  • C10N2040/20—Metal working
  • C10N2040/244—Metal working of specific metals
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2040/00—Specified use or application for which the lubricating composition is intended
  • C10N2040/20—Metal working
  • C10N2040/244—Metal working of specific metals
  • C10N2040/245—Soft metals, e.g. aluminum
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2040/00—Specified use or application for which the lubricating composition is intended
  • C10N2040/20—Metal working
  • C10N2040/244—Metal working of specific metals
  • C10N2040/246—Iron or steel
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2040/00—Specified use or application for which the lubricating composition is intended
  • C10N2040/20—Metal working
  • C10N2040/244—Metal working of specific metals
  • C10N2040/247—Stainless steel

Definitions

• the present invention relates generally to containers and more particularly to an improved stock material for making containers and a method for forming seamless drawn and ironed containers from the improved stock material.
• the use of a two-piece container for packaging beer and/or carbonated beverages has become very popular in recent years.
• the two-piece container consists of a container sidewall or body that has a unitary end wall at one end thereof.
• the second piece for the container consists of an end which is seamed to the open end of the container.
• a finished container is produced by initially cutting a disc from a sheet or coil of stock material and substantially simultaneously transforming the disc into a shallow cup in a conventional cupping machine that forms part of a can manufacturing line.
• the shallow cup is then converted into a drawn and ironed container in a body maker wherein the shallow cup is reformed into a cup of different dimensions and then passed through a plurality of ironing rings that cooperate with a punch to decrease the wall thickness of the reformed cup and produce a seamless container.
• the cup may initially have a diameter substantially equal to the final diameter so that the reforming or redrawing in the body maker is not necessary.
• a lubricant-coolant is utilized in the cupper for providing the necessary lubricity between the surface of the sotck material and the tooling.
• the body making machinery also incorporates mechanism for flowing a lubricant-coolant to the surface of the container and to the ironing dies utilized in cooperation with the punch.
• the lubrican coolant consists of a mixture of water and an emulsified oil or emulsified synthetic lubricant, such as a commercially available Texaco 591 product.
• tinplate One acceptable alternative for the drawn and ironed aluminum container is commonly referred to as tinplate.
• This material includes a base plate of low carbon steel, such as black plate which has both surfaces covered with a thin layer of tin.
• the tin coating acts as a low friction, ductile material during the ironing process and also resists corrosion.
• tinplate has been found to be an acceptable alternate for aluminum, the availability of this material is limited and the cost is high. Bethlehem Steel Corporation also has continued its development efforts for producing a beer and carbonated beverage container from black plate using conventional machinery by applying organic coating to the black plate which can then be drawn and ironed at a price which is competitive to the present day tinplate or aluminum container. To this end, a proposed process is disclosed in United States Patent No.
• This process contemplates the formation of special organic coating systems that enable container manufacturers to produce drawn and ironed beer and softdrink cans from black plate.
• the foregoing patent describes two coating concepts that have been developed for black plate, one of which consists of admixing a thermosetting coating and a lubricant and applying this mixture to both sides of the black plate blank and partially curing the mixture before the blank is converted into a finished container.
• the other concept contemplates supplying the coating-lubricant mixture to only the one side of the blank (the side forming the outside of the can), and applying a coating lubricant alone to the other side of the blank (the side that forms the inside of the can) ,
• a metal base of stock material that is to be used for forming a drawn and ironed seamless container first has a thin layer of lubricant applied to at least one surface of the metal stock or blank and a disc is cut from the metal blank and formed into a shallow cup without the use of any additional lubricant or coolant.
• the shallow cup is then further drawn and ironed to produce a seamless container which again is done without the use of any additional lubricant in the liquid coolant, such as water, in the drawing and ironing machine.
• the thin layer of lubricant consists essentially of a fatty acid ester of a mono or polyhydric alcohol and the layer has a distribution or thickness preferably less than 0.5 mg./cm.
• a black plate container can be formed by initially applying a layer of curable polymeric coating on a surface of the black plate which will become the external surface of a container, partially curing the coating within certain critical limits, and applying the lubricant to the other surface of the black plate.
• the curable polymeric coating is applied in an amount of about 0.2 (1) to about 0.7 mg./cm. (4 mg./in. 2 ) of blank area. It has also been determined that the optimum thickness of the coating should be about 0.3 (2) to about 0.5 mg./cm. 2 (3 mg./in. 2 ) on the surface of the metal plate.
• the coating can be cured to the desired degree by continuously feeding the coated stock through an oven to achieve a temperature for the metal portion of the strip of more than about 204 degrees C but less than the degradation temperature for the applied coating and maintaining the strip within the oven for a time period of approximately one minute.
• the partial curing may also be accomplished by baking the coated blank at a temperature of approximately 177 degrees C for a period of approximately 10 minutes.
• the present process is particularly well suited for the manufacture of containers from pure ferrous metal such as black plate of tin-free steel stock.
• the present invention contemplates precoating a metal sheet or coil with a thin layer of lubricant to one surface only of the metal sheet or coil, cutting a disc from the metal sheet or coil with the lubricant applied to one surface, forming a shallow cup from the disc subsequently redrawing and ironing the shallow cup into a full sized container.
• a stock material such as an aluminum, black plate, or tinplate metal sheet or coil
• a laye of lubricant consisting essentially of a fatty acid ester of a mono or polyhydric alcohol applied to one surface of the stock material to a thickness of less than 0.5 mg./cm. 2 (3 mg./in. 2 ) and preferably about 0.2 mg./cm. (1 mg./in. 2 ) and the pretreated stock material is then utilized in forming a seamless drawn and ironed container that has a bottom wall and an integral sidewall in conventional cupping and body making machinery that is presently utilized for making such containers.
• One lubricant that is suitable for carrying out the present invention is a fatty acid ester of a mono or polyhydric alcohol.
• a commercially available lubricant of this type is produced by Mobil Chemical Company under the designation S-6661-003. More specifically, this ester is made from a monomeric polyhydric alcohol having three to six hydroxyls and a 14 to 20 carbon fatty acid.
• the Mobil lubricant was successfully applied to one surface of black plate, tinplate and aluminum plate by a lubricator to produce a thin layer of lubricant having a thickness or distribution of less than 0.5 mg./cm. 2 (3 mg./in. 2 ). on the surface of the stock material that ultimately becomes the inside of the container. If necessary, to produce the desired thickness of the layer, it may be necessary to either thin, the fatty acid ester with a solvent before it is applied to the surface of the stock material, or simply by heating the material before it is applied by the lubricator. A further alternative form of heating would be to heat the rollers that form part of the lubricator.
• black plate When black plate is used as the base material, it is preferably pretreated by applying an organic or polymeric coating to at least one surface thereof and partially curing the coating.
• Curable organic or polymeric coatings suitable for the purposes of the present invention are exemplified by the curable epoxy resins, e.g., the glycidyl polyethers of polyhydric phenols , the epoxy novolac resins , the glycidyl ethers of aliphatic polyols, the cycloaliphatic epoxy resins, and the like, the curable vinyl resins, the curable epoxy-urea-formaldehyde resins, and similar curable polymers.
• the curable epoxy resins e.g., the glycidyl polyethers of polyhydric phenols , the epoxy novolac resins , the glycidyl ethers of aliphatic polyols, the cycloaliphatic epoxy resins, and the like
• the curable vinyl resins e.g., the glycidyl polyethers of polyhydric phenols
• the epoxy novolac resins e.g., the epoxy
• Preferred for the present purposes are the curable epoxy resins having a chain of alternating glycidyl and divalent phenolic units united through an ether oxygen and having glycidyl units in the terminal positions of the chain.
• the ether oxygen (as distinguished from the oxirane or hydroxy oxygen) is linked to the primary carbon atoms of the glycidyl units.
• These particular epoxy resins are glyc idyl polyethers of polyhydric phenols.
• Exemplary are the reaction products of epichlorohydrin with a dihydric phenol represented by the general formula as follows: wherein n can have a value of 1 to about 20, wherein R can be
• R 1 can be any organic radical
• Suitable dihydric phenols for reaction with "epichlorohydrin to produce the aforementioned resins are resorcinol, catechol, the polynuclear phenols such as
• a portion of the foregoing reaction product can be combined with a reactive modifier to increase toughness, flexibility, elongation and/or adhesive peel strength.
• a particularly preferred modifier is a xylene-formaldehyde resin condensed with the aforementioned reaction product.
• a particular preferred curable polymeric composition for the practice of the present invention comprises a 4,4'- isopropylidene-diphenol-epichlorohydrin resin having a portion of the resin condensed with a xylene-formaldehyde resin.
• a curable polymeric composition of this type is available commercially from Mobil Chemical Company under the designation S-9019-001.
• the degree of cure of the applied curable coating for drawing and ironing is very important.
• the applied coating should be about 50 to about 75% cured before drawing and ironing, and preferably about 60 to about 70% cured. Stated in another way, the coating should be cured to a degree so that about 25% to about 50% of the coating constituents are extractable, preferably about 30 to about 40% of the constituents are extractable by methylene chloride
• the coating was extracted in the following manner:
• Example I Laboratory tests were conducted by applying a layer of approximately 0.2 mg./cm. 2 (1.25 mg./in. 2 ) of the above Mobil lubricant on one surface of a sheet of tinplate stock material.
• the sheet of stock material was then cut and formed into a shallow cup in a conventional manner without the addition of any further lubricant or without any water.
• the cups with the layer of lubricant on the inner surface were then reformed into finished containers in a conventiona body maker where only water alone or water with 0.05% rust inhibitor was circulated through the tooling used in producing the finished container.
• Some containers were made using a water-emulsion oil mixture for the coolant. Containers made from the organic ester preapplied sheets or coils consistently showed better cleanability when water alone was used as the coolant.
• Aluminum stock material in the form of plates was coated on one side with an organic ester, such as the Mobil lubricant, to produce a layer on one surface having a distribution of approximately 0.2 mg./cm. 2 (1.25 mg./in. 2 ).
• organic ester such as the Mobil lubricant
• These plates were then converted into cups and subsequently cans utilizing a commercially available cupper and body maker.
• the plates were positioned so that the lubricated surface became the internal surface of the cup and no additional lubricant or water was needed to produce satisfactory cups from the plates.
• the cups were then converted to finished containers in the body maker utilizing only tap water. Several thousand of such cups and containers were produced and inspection of the finished containers showed that the containers had a shiny outside surface and a scratch-free inside surface.
• the containers were then cleaned using several standard cleaners with less than the present standard recommended concentration to remove all of the lubricants from the container surfaces.
• Example III A coil of black plate stock material was cut into sheets and each of the sheets was coated on one surface with Mobil S-9019-001 organic coating to produce a layer of approximately 0.5 mg./cm. 2 (3 mg./in. 2 ) and the plate was baked at 177 degrees C for five minutes to partially cure the coating.
• a Mobil S-6661-003 lubricant was then roll-coated with a thin layer (0.4 mg./cm. 2 ) on the other surface of the sheets to produce a thin layer of lubricant.
• the sheets were then stacked and delivered to a cupping machine and during this process some of the lubricant was transferred to the coated, partially-cured surface of the sheets.
• Discs were then cut from the sheets and converted into shallow cups using commercial cupping equipment without the use of any water or additional lubricant.
• the shallow cups had the layer of lubricant on the inner surface and the organic coating on the outer surface.
• the cups were then converted into drawn and ironed containers in a commercial body maker. Some containers were formed from cups using only water aa the cooling agent while other containers were formed using a lubricant-coolant.
• This lubricant-coolant was a water and emulsified oil mixture which included about 15% of a Texaco 591 emulsified oil. In all instances, the containers formed with water alone had as good or better surface appearance then those formed using the lubricant-coolant mixture.
• Example IV A coil of dry black plate was coated with a Mobil S-9019-001 organic coating to produce a layer of approximately 0.55 mg./cm. (3.25 mg./in. 2 ).
• the coated coil was passed through an oven that had three temperature zones so that the metal surface temperature reached approximately 216 degrees C to partially cure the coating.
• the coil with partiallycured coating was then subjectee to an extraction test and it was determined that 34% of the coating was extracted, ie, the coating was about 66% cured.
• the other surface was roll-coated with Mobil
• drawn and ironed containers can be formed from coated black plate, aluminum or tinplate by precoating the stock material with a thin layer of an organic ester lubricant and the drawn and ironed containers can be formed without the use of water or emulsifiable oils in the cupper and using only water as a coolant in the body maker or drawing and ironing machine.
• the organic ester lubricant provides better lubrication for the tooling than the water-lubricant mixture. This is believed to result from the fact that the lubricant is initially located directly between the tooling and the container surface interface and also from the fact that the organic ester lubricants withstand the high . temperatures encountered during ironing of the metal body without deterioration. Also, applying the layer of lubricant to the surface which becomes the inner surface of the container is believed to aid in stripping the ironed container from the punch.
• both surfaces of the stock material could be coated with a lubricant and/or the distribution or thickness of the layer or layers could be increased.
• tests have shown that increasing the thickness of the coating on one surface only will not increase the efficiency of the operation but will increase the cost without any additional benefits.
• Respecting the two-sided coating with lubricant it was determined that the additional coating on the second side increased the costs without deriving any benefits from the increased cost.
• tests showed that one side coated material would have enough lubricant transferred to the other side during the processing of the stock material and in the cupper and body maker to eliminate the need for applying lubricant to the second side.
• the lubricant is preferably applied as the stock material is fed to the cupping machine.
• the coating and lubricant could simultaneously be applied to opposite sides of the stock material with a lubricator and the material could then be passed through an oven to partially cure the organic coating. It has been determined that the heating of the lubricant in the oven has no deleterious affect on the lubricant.
• the lubricant could also be applied in other ways. For example, it would be possible to apply the lubricant to the stock material in the cupping machine as the discs are being severed from the stock material and the appended claims are intended to cover such alternate method of application.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Health & Medical Sciences (AREA)
• Emergency Medicine (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Oil, Petroleum & Natural Gas (AREA)
• Organic Chemistry (AREA)
• Shaping Metal By Deep-Drawing, Or The Like (AREA)

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Publications (3)

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• 1978
  • 1978-11-14 JP JP50014578A patent/JPS54500094A/ja active Pending
  • 1978-11-14 DE DE7878900302T patent/DE2862444D1/de not_active Expired
  • 1978-11-14 WO PCT/US1978/000146 patent/WO1979000297A1/en unknown
• 1979
  • 1979-06-06 EP EP78900302A patent/EP0006957B1/de not_active Expired

Patent Citations (3)

Non-Patent Citations (6)

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