Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
  • B65D23/00—Details of bottles or jars not otherwise provided for
  • B65D23/02—Linings or internal coatings
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
  • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
  • B65D1/02—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents
  • B65D1/0223—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents characterised by shape
  • B65D1/023—Neck construction
  • B65D1/0246—Closure retaining means, e.g. beads, screw-threads
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
  • B65D7/00—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, components made wholly or mainly of metal
  • B65D7/02—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, components made wholly or mainly of metal characterised by shape
  • B65D7/04—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, components made wholly or mainly of metal characterised by shape of curved cross-section, e.g. cans of circular or elliptical cross-section
• • 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
  • B21D22/28—Deep-drawing of cylindrical articles using consecutive dies
• • 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
  • B21D51/00—Making hollow objects
  • B21D51/16—Making hollow objects characterised by the use of the objects
  • B21D51/24—Making hollow objects characterised by the use of the objects high-pressure containers, e.g. boilers, bottles
• • 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
  • B21D51/00—Making hollow objects
  • B21D51/16—Making hollow objects characterised by the use of the objects
  • B21D51/26—Making hollow objects characterised by the use of the objects cans or tins; Closing same in a permanent manner
• • 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
  • B21D51/00—Making hollow objects
  • B21D51/16—Making hollow objects characterised by the use of the objects
  • B21D51/26—Making hollow objects characterised by the use of the objects cans or tins; Closing same in a permanent manner
  • B21D51/2615—Edge treatment of cans or tins
  • B21D51/2638—Necking
• • 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
  • B21D51/00—Making hollow objects
  • B21D51/16—Making hollow objects characterised by the use of the objects
  • B21D51/26—Making hollow objects characterised by the use of the objects cans or tins; Closing same in a permanent manner
  • B21D51/2676—Cans or tins having longitudinal or helical seams
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
  • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
  • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
  • B65D1/02—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
  • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
  • B65D1/02—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents
  • B65D1/0207—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents characterised by material, e.g. composition, physical features
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
  • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
  • B65D1/02—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents
  • B65D1/0223—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents characterised by shape
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
  • B65D23/00—Details of bottles or jars not otherwise provided for
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
  • B65D23/00—Details of bottles or jars not otherwise provided for
  • B65D23/08—Coverings or external coatings
  • B65D23/0807—Coatings
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
  • B65D41/00—Caps, e.g. crown caps or crown seals, i.e. members having parts arranged for engagement with the external periphery of a neck or wall defining a pouring opening or discharge aperture; Protective cap-like covers for closure members, e.g. decorative covers of metal foil or paper
  • B65D41/02—Caps or cap-like covers without lines of weakness, tearing strips, tags, or like opening or removal devices
  • B65D41/04—Threaded or like caps or cap-like covers secured by rotation
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
  • B65D41/00—Caps, e.g. crown caps or crown seals, i.e. members having parts arranged for engagement with the external periphery of a neck or wall defining a pouring opening or discharge aperture; Protective cap-like covers for closure members, e.g. decorative covers of metal foil or paper
  • B65D41/32—Caps or cap-like covers with lines of weakness, tearing-strips, tags, or like opening or removal devices, e.g. to facilitate formation of pouring openings
  • B65D41/34—Threaded or like caps or cap-like covers provided with tamper elements formed in, or attached to, the closure skirt

Definitions

• This disclosure relates to a metal elongated bottle and its method of production, and, in particular, to an elongated low-spread aluminum bottle and its method of production.
• Beverage containers are often made from a metal sheet due to the robust structure, light weight, and good thermal conductivity of metal sheet materials.
• metal cans are prevalent in the beverage industry and are made from aluminum sheet coils that are cut, drawn, formed, trimmed and coated to form cylindrical containers. The cylindrical containers are then filled with a beverage and sealed with a single-use lid.
• metal sheet material has also been used to create aluminum, bottle- shaped containers that have a narrow neck and an open end that is either threaded to receive a cap or includes a crimped crown.
• the narrow neck and slender shape of aluminum bottles provide more comfort for drinkers holding the bottle and also provide an appealing visual appearance.
• the elongate shaped body and the narrow neck of aluminum bottles require increased plastic deformation of the original aluminum sheet material when the bottle is formed. The increased deformation of the aluminum sheet has resulted in increased manufacturing defects and higher rejection rates when compared with aluminum can manufacturing.
• the low-spread metal elongated bottle is formed from a low-spread metal and includes an elongated body shape and a narrow neck.
• the low-spread metal has a low spread between a yield state corresponding to the yield stress of the sheet metal and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal.
• the spread of the sheet metal equals to the arithmetic difference between the yield stress and the ultimate tensile stress.
• the difference between the yield stress and ultimate tensile stress of the low-spread sheet metal is about 22.4 MPa or 3.25 ksi.
• the yield stress of the low- spread sheet metal is about 200 MPa or 29 ksi.
• a method for manufacturing an elongated bottle that includes providing a piece of sheet metal having a low spread between a yield state and an ultimate tensile state.
• the yield state corresponds to the yield stress of the sheet metal
• the ultimate tensile state corresponds to the ultimate tensile stress of the sheet metal.
• the piece of sheet metal is formed into a circular cup.
• the circular cup is drawn into a cylindrical container having an open end and a closed end.
• the closed end of the cylindrical container is formed into a concave bottom portion.
• the open end of the cylindrical container is narrowed into a neck portion.
• the method further includes trimming the open end for a straight edge prior to narrowing the open end into the neck portion.
• narrowing the open end of the cylindrical container into a neck portion further includes applying a pressure perpendicular to the cylindrical axis of the central container near the open and.
• the method further includes applying a layer of paint onto the outer surface of the elongated bottle.
• the layer of transparent seal is further applied onto the layer of paint.
• the method further includes applying a film of seal onto the inner surface of the elongated bottle.
• the spread of the sheet metal is the arithmetic difference between the yield stress and the ultimate tensile stress of the sheet metal. In some embodiments, the spread is within about 22.4 MPa or 3.25 ksi.
• an elongated bottle that includes a sheet metal formed body, wherein the sheet metal of the sheet metal formed body has a low spread between a yield state corresponding to the yield stress of the sheet metal and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal.
• the body also includes a concave bottom portion that has a circular perimeter and a cylindrical portion that extends from the circular perimeter of the bottom portion.
• the cylindrical portion has a uniform diameter.
• the bottle also includes a neck portion that has a varying diameter reduced from the uniform diameter of the cylindrical portion to form a tapered profile.
• the bottle also includes an opening.
• the arithmetic difference between the yield stress and the ultimate tensile stress of the sheet metal is between about 21 MPa or 3.05 ksi and about 23.1 MPa or 3.35 ksi.
• the arithmetic difference between the yield stress and the ultimate tensile stress of the sheet metal is between about 21.4 MPa or 3.1 ksi and about 22.8 MPa or 3.3 ksi.
• the arithmetic difference between the yield stress and the ultimate tensile stress of the sheet metal is about 22.1 MPa or 3.2 ksi.
• the yield stress of the sheet metal is between about 196.5 MPa or 28.5 ksi and about 217.2 MPa or 31.5 ksi.
• the yield stress of the sheet metal is between about 29 ksi and about 31 ksi.
• the yield stress is about 29.8 ksi.
• the cylindrical portion of the bottle has a length between about 114 mm or 4.490" and about 162 mm or 6.381".
• the cylindrical portion has a length of about 162 mm.
• the bottle has a total length between about 190mm and about 238mm.
• the bottle has a total length of about 238 mm.
• the neck portion of the bottle includes a threaded portion.
• the threaded portion of the neck portion includes a folded flange.
• the bottle includes a threaded cap that is couplable with the threaded portion.
• a method for manufacturing an elongated bottle that includes providing sheet metal having a low spread between a yield state corresponding to the yield stress of the sheet metal and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal.
• the method includes forming the sheet metal into a circular cup and drawing and ironing the circular cup into a cylindrical container having an open end and a closed end.
• the method also includes forming the closed end of the cylindrical container into a concave bottom portion and cutting the open end of the cylindrical container.
• the method also includes forming the open end of the cylindrical container into a neck portion.
• the method includes forming the container to have a total length between about 127 mm or 5" and about 254 mm or 10".
• the method includes forming the container to have a total length of about 238 mm.
• an arithmetic difference between the yield stress and the ultimate tensile stress is about 22.4 MPa or 3.2 ksi.
• a method for manufacturing a beverage bottle that includes forming sheet metal into a circular cup, wherein the sheet metal has a low spread between a yield state corresponding to the yield stress of the sheet metal and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal.
• the arithmetic difference between the yield stress and the ultimate tensile stress of the sheet metal is about 22 MPa or 3.2 ksi and the yield stress is about 205.5 MPa or 29.8 ksi.
• the method also includes drawing and ironing the circular cup into a cylindrical container that has an open end and a closed end.
• the method also includes forming the closed end of the cylindrical container into a concave bottom portion and cutting the open end of the cylindrical container.
• the method also includes narrowing the open end of the cylindrical container into a neck portion and folding an edge of the open end outward to form a flange.
• the bottle has a total length of about 238 mm.
• the method includes forming a shoulder portion at an angle of about 45 degrees to a body portion of the container.
• FIG. 1 is a schematic of an embodiment of an elongated bottle made of a low- spread metal in accordance with this disclosure.
• FIGS. 2A and 2B are graphs showing a stress-strain relationship of the low-spread metal used to make the elongated bottle shown in FIG. 1.
• FIG. 3 is a schematic of a cap for sealing the elongated bottle of FIG. 1.
• FIG. 4 is a flow chart illustrating an embodiment of a method for producing the elongated bottle of FIG. 1.
• Metal elongated bottles have many advantages over traditional can-shaped containers (as briefly discussed in the background). However, during manufacturing, rejection rates for elongated bottles may be higher than rejection rates of traditional cans due to the more complicated geometry of the bottle and the higher plastic deformation required for the elongated shape and narrower neck of the bottle. For example, rejections rates in the production of metal bottles may range from about 5% to about 95% due to defects such as excessive metal expansion and brim roll splitting.
• the cup is then necked and threaded, and a brim roll is applied to the bottle opening.
• the heat treating of the metal in conjunction with the low spread metal, removes a sufficient amount of work hardening to allow for necking, threading and brim rolling at high production speeds with low defect rates.
• This disclosure presents a low-spread metal elongated bottle and a production method for reducing rejection rates associated with the production of aluminum bottles.
• the production method described herein also allows for the production of an elongated bottle that is taller than previously available aluminum bottles.
• the production method described herein also allows for a thinner side wall thickness and thus a lower aluminum material usage than previously available. Further, the disclosed processes and apparatuses may be used to form complicated bottle shapes that are less feasible with non-low- spread metals.
• FIG. 1 is a schematic of an elongated bottle 100 made of a low-spread sheet metal 101.
• the elongated bottle 100 can be mass-produced from coils of the low-spread sheet metal 101 using "drawing and ironing" manufacturing methods. In some embodiments, for a thicker wall thickness, impact extrusion methods may also be used with slugs of similar physical properties.
• the low-spread sheet metal 101 is a heat treated and chemical treated aluminum alloy that has a low spread (i.e., arithmetic difference) between a yield state corresponding to the yield stress of the sheet metal 101 and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal 101.
• the elongated bottle 100 shown in FIG. 1 is an example of a bottle 100 made using low spread metal and other geometries, designs, and variations are possible.
• the elongated bottle 100 includes a concave bottom portion 115, a cylindrical portion 110 and a neck portion 105 that includes a threaded portion 120.
• the bottom portion 115 includes a circular perimeter 117.
• the concave shape of the bottom portion 115 provides structural support for pressurized beverage fluids contained therein.
• the bottom portion 115 is created from the center portion of the sheet metal 101 and forms a closed end.
• the cylindrical portion 110 extends from the circular perimeter 117 and has a uniform diameter 112. During production, the cylindrical portion 110 is drawn and ironed to a length slightly exceeding the height of the bottle 100.
• the cylindrical portion 110 has a wall thickness of between about 0.213 mm or 0.0084" and about 0.239 mm or 0.0094". In other embodiments, the cylindrical portion 110 has a wall thickness of about 0.165 mm or 0.0065".
• the neck portion 105 is formed near the open end 191 of the bottle 100.
• the neck portion 105 has a varying diameter reduced from the uniform diameter 112 of the cylindrical portion 110.
• the varying diameter forms a tapered profile 107 that gradually constricts the neck portion 105 toward the opening 123.
• a shoulder portion 111 of the neck portion 105 extends at an angle of about 45 degrees from the cylindrical portion 110.
• a top neck portion 113 of the neck portion 105 extends at an angle of about 6 degrees from a center line 103 of the bottle 100.
• the top neck portion 113 of the neck portion 105 extends at an angle of about 5.75 degrees from the center line 103 of the bottle 100.
• the neck portion 105 includes a threaded portion 120 that has one or more threads 122 exposed on the outer surface of the threaded portion 120.
• the threads 122 enables a threaded cap 300 (FIG. 3) to close and seal the opening 123.
• the threaded portion 120 further includes a folded flange 125 that is folded outwardly from the opening 123 for safe contact when a beverage is consumed from the bottle 100.
• a printed indicia 118 is applied onto the outer surface of the bottle 100.
• the print indicia 118 may be further sealed with a clear or transparent coat 119 applied to the outer surface of the bottle 100.
• An inner coating 130 may be applied to an inner surface of the elongated bottle 100 for separating a beverage from the sheet metal 101.
• the cylindrical portion 110 of the bottle 100 has a height of between about 114 mm or 4.490" and about 162 mm or 6.381". In some embodiments, the cylindrical portion 110 has a height of between about 120 mm or 4.7244" and about 155 mm or 6.1024". In other embodiments, the cylindrical portion 110 has a height of about 162 mm or 6.3779". In some embodiments, the bottle 100 has an overall height of between about 190mm or 7.48" and about 238mm or 9.37". In other embodiments, the bottle 100 has an overall height of between about 200 mm or 7.874" and about 220 mm or 8.661". In other embodiments, the bottle 100 can have an overall height up to about 762 mm or 30".
• bottles of this height were previously difficult to form on a consistent basis at high production rates due to high defect rates.
• the increased amount of cold working of metal involved in forming a taller container caused the metal to become more brittle, leading to an increased rate of manufacturing defects.
• the present disclosure allows for consistent, low-defect-rate production of bottles 100 with an overall height of about 238 mm (9.37") or taller at high production speeds.
• FIGS. 2A and 2B show embodiments of an example stress-strain relationship of a low-spread sheet metal 210 and a non-low-spread sheet metal 220.
• FIGS. 2A and 2B are for illustration purposes and other materials with other stress-strain relationships are within the scope of this disclosure.
• a stress-strain curve of a low- spread sheet metal is shown at 210 and a stress-strain curve of a non-low-spread sheet metal is shown at 220.
• the horizontal axis of the FIG. 2A shows the strain variable ( ⁇ ) and the vertical axis shows the stress variable ( ⁇ ).
• the two different metals represented by curves 210 and 220 have the same elasticity modulus (E) shown at numeral 215 and the same yield stress ( ⁇ ⁇ ) shown at numeral 202.
• the ultimate tensile stress of the low-spread metal 210 is represented by O U L, shown at numeral 204, and the ultimate tensile stress of the non-low-spread metal 220 is represented by O U N, shown at numeral 206.
• O U L and O U both correspond to the same ultimate tensile strain ⁇ shown at numeral 224.
• the ultimate tensile strain ⁇ ⁇ may also have respective values for the low- spread metal 210 and the non-low-spread metal 220.
• a uL and a uN may vary depending on heat treatment, variations in the alloy elements, chemical treatment, or other alternations to the structure of the metal crystals.
• the difference between the yield stress and the ultimate tensile stress of the low-spread metal 210 is less than the difference between the yield stress and the ultimate tensile stress of the non-low-spread metal, such that O U L - O Y L ⁇ O U - ⁇ ⁇ ⁇ .
• the difference (i.e., spread) between the ultimate tensile stress and the yield stress a Y L of the low-spread sheet metal 210 is significantly smaller than the difference between the ultimate tensile stress O U and the yield stress ⁇ ⁇ of the non-low-spread sheet metal 220.
• the low-spread sheet metal 210 has an ultimate tensile stress of about 227.53 MPa or 33ksi and a yield stress of about 205.46 MPa or 29.8 ksi
• a typical non- low-spread sheet metal has an ultimate tensile stress of about 268.9-317.2 MPa or 39-46 ksi and a yield stress of about 241-289.6 MPa or 35-42 ksi.
• the ultimate tensile stress of the low-spread aluminum sheet material is between about 213.7 MPa or 31 ksi and about 241.3 MPa or 35 ksi. In some embodiments, the ultimate tensile stress of the aluminum sheet material is about 227.5 MPa or 33 ksi. In some embodiments, the yield stress of the aluminum sheet material is between about 196.5 MPa or 28.5 ksi and about 217.2 MPa or 31.5 ksi. In other embodiments, the yield stress is about 205.5 MPa or 29.8 ksi. It has been found that yield stress below about 193 MPa or 28 ksi may result in a loss of buckle strength of the bottle 100.
• the arithmetic difference between the yield stress and the ultimate tensile stress of the low-spread metal is between about 21 MPa or 3.05 ksi and about 23.1 MPa or 3.35 ksi. In other embodiments, the arithmetic difference between the yield stress and the ultimate tensile stress in the low-spread metal is between about 21.4 MPa or 3.1 ksi and about 22.1 MPa or 3.2 ksi. In some embodiments, the arithmetic difference between the yield stress and the ultimate tensile stress in the low-spread metal is about 22.4 MPa or 3.25 ksi.
• the low spread - ⁇ is therefore within about 22.4 MPa (or 3.25 ksi).
• the arithmetic difference in non-low-spread metal between the yield stress and the ultimate tensile stress is typically about 255.1 MPa or 37 ksi.
• the achievable maximum plastic deformation of the low- spread sheet metal 210 is SL shown at numeral 233, wherein ⁇ - is the elastic strain.
• the maximum plastic deformation of the non-low-spread sheet metal 220 is S shown at numeral 231, wherein ⁇ - is the elastic strain. Because O U is greater than O U L, and both metals 210 and 220 have the same elasticity modulus E 215, the achievable plastic deformation SL 233 is greater than S 231. Therefore, it has been found that the low-spread metal 210 can withstand greater plastic deformation during high speed metal bottle production than non-low- spread metal 220.
• low spread metal having a spread of about 3.2 ksi has produced bottles 100 at a rate of about 1,200 bottles per minute with a defect rate of about 3%, as compared with defect rates from about 10% to about 60% with non-low-spread material.
• FIG. 2B shows a second example set of stress-strain curves comparing a low- spread sheet metal 260 and a non-low-spread sheet metal 270. Similar to FIG. 2A, the horizontal axis of FIG. 2B shows the strain variable ( ⁇ ) and the vertical axis shows the stress variable ( ⁇ ).
• the two different metals 260 and 270 have the same elasticity modulus E 215 and the same yield stress ⁇ ⁇ 252.
• the ultimate tensile stress of the low-spread metal 260 is 254, and the ultimate tensile stress of the non-low-spread metal 270 is O U N 256.
• 254 corresponds to the ultimate tensile strain ⁇ 275 and O U 256 corresponds to the ultimate tensile strain ⁇ supervise ⁇ 285.
• the low-spread sheet metal 260 has a lower spread than the non-low-spread sheet metal 270, or, in other words, a uL - a yL ⁇ a uN - ⁇ ⁇ .
• the lower ultimate tensile strength O U L 254 corresponds to a greater ultimate tensile strain 275 than S U 285, i.e., S U L > ⁇ district ⁇ .
• the achievable maximum plastic deformation of the low-spread sheet metal 260 is SL 273, wherein S U L - &L is the elastic strain.
• the maximum plastic deformation of the non-low-spread sheet metal 270 is S 283, wherein S U - is the elastic strain. Because O U is greater than ⁇ , and the both metals 210 and 220 has the same elasticity modulus E 215, the elastic deformation portion (S U - ⁇ ⁇ ) is greater than (s uL - s L ). Furthermore, s L is greater than ⁇ ⁇ . Therefore, it has been found that the low-spread metal 260 can withstand much greater plastic deformation than the non-low- spread metal 270 at high production rates. It has also been found that the difference between SL 273 and ⁇ ⁇ 283 can help reduction of rejection rates during production by providing a higher strain value s L for plastic deformation. It has been found that a wide spread is not necessary because the pre-form container can be consistently formed without manufacturing defects. In fact, it has been found that a wide spread increases the rate of manufacturing defects related to neck and thread formation.
• FIG. 3 is a schematic of a cap 300 for sealing the elongated bottle 100 of FIG. 1.
• the cap 300 includes a spiral thread 310 that corresponds to the spiral thread 122 of the bottle 100.
• the spiral thread 310 can engage the threaded portion 120 to seal the elongated bottle 100.
• the cap 300 may be made of metal, plastic, or other suitable materials.
• the cap 300 may also include a component indicating the cap 300 has been opened once, such as a breakable band at the bottom edge of the cap 300.
• FIG. 4 is a flow chart 400 of a method for producing the elongated bottle 100 of FIG. 1.
• low-spread sheet metal is provided for making the elongated bottle 100.
• the low-spread sheet metal has a low spread between a yield state corresponding to the yield stress of the sheet metal and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal.
• the low spread of the sheet metal equals to the arithmetic difference between the yield stress and the ultimate tensile stress.
• the arithmetic difference between the yield stress and ultimate tensile stress of the low-spread metal is about 22.4 MPa or 3.25 ksi.
• the sheet metal is formed into a cup.
• the cup is then drawn into a cylindrical container at step 406.
• the cylindrical container has an open end and a closed end.
• a concave bottom portion is formed at the closed end of the cylindrical container.
• the open end is trimmed for a straight edge prior to narrowing the open end into the neck portion.
• a decorative coating and sealer are applied to the cup.
• a layer of paint is applied onto the outer surface of the elongated bottle 100 and a layer of transparent sealer 119 may further be applied onto the layer of paint.
• a film of sealer 130 may be applied onto the inner surface of the elongated bottle 100 for separating the drink from the sheet metal.
• the cylindrical container may be heat treated to remove some or all of the work hardening effect incurred at previous steps and to dry the decorative coating or sealer applied to the cup.
• a neck portion is formed near the opening 123 of the cylindrical container 100.
• the neck portion 105 may be formed in a necking operation and may have a varying diameter forming a narrowing tapered profile 107.
• a threaded portion 120 is formed on the neck portion 105 by deforming or indenting a portion of the neck portion 105 to form one or more threads 122.
• the threads 122 are exposed on the outer surface of the elongated bottle 100.
• a flange 125 at the edge of the opening 123 is folded outwardly to provide a rounded rim.
• the temperature set points and cycle duration during step 412 are configured to cure any decorative coating applied to the bottle and to thermally recover the metal.
• the coated bottle 100 may pass through a washer dry-off oven, a pin oven, and a bake oven.
• the coated bottle 100 may travel at about 5-17 ft/min through the washer dry-off oven at about 275-500 °F. Then the coated bottle 100 may travel at the rate of about 200-1500 cans/min through the pin oven at about 390-500 F. And finally the coated bottle 100 may travel through the bake oven at a maximum speed of about 12- 22 ft/min.
• the inside oven temperature can be about 290-340 °F in a first zone, 410-500 °F in a second zone, and 400-500 °F in a third zone.
• the coated bottle 100 may travel at about 6-14 ft/min through the washer dry-off oven at about 280-350 °F. Then the coated bottle 100 may travel at the rate of about 400-1300 cans/min through the pin oven at about 425-485 °F. And finally the coated bottle 100 may travel through the bake oven at a maximum speed of about 14-20 ft/min.
• the inside oven temperature can be about 300-330 °F in a first zone, about 450-490 °F in a second zone, and about 440-490 °F in a third zone.
• the coated bottle 100 may travel at about 7-12 ft/min through the washer dry-off oven at about 300-320 °F. Then the coated bottle 100 may travel at the rate of about 600-1200 cans/min through the pin oven at about 460-470 °F. And finally the coated bottle 100 may travel through the bake oven at a maximum speed of about 16-18 ft/min.
• the inside oven temperature can be about 310-320 °F in a first zone, about 465-475 °F in a second zone, and about 460-470 °F in a third zone. It has been found that, in some embodiments, the above temperatures and travel rates recover at least some of the work hardening of the material to allow the low spread metal to be formed into the shape of a bottle with a neck-shaped portion, as described above.

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