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
  • 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
  • B65D1/12—Cans, casks, barrels, or drums
  • B65D1/14—Cans, casks, barrels, or drums characterised by shape
  • B65D1/16—Cans, casks, barrels, or drums characterised by shape of curved cross-section, e.g. cylindrical
  • B65D1/165—Cylindrical cans
• • 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
  • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
  • B21D22/20—Deep-drawing
  • B21D22/30—Deep-drawing to finish articles formed by deep-drawing
• • 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
  • B21D25/00—Working sheet metal of limited length by stretching, e.g. for straightening
• • 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
  • 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
  • B65D1/40—Details of walls

Definitions

• the disclosed concept relates generally to containers and, more particularly, to metal containers such as, for example, beer or beverage cans, as well as food cans.
• the disclosed concept also relates to cups and blanks for forming cups and containers.
• the disclosed concept further relates to methods and tooling for selectively forming a cup or bottom portion of a container to reduce the amount of material in the cup or bottom portion.
• cup begins as a generally planar blank 1 cut from sheet material.
• the blank 1 is then drawn into a cup 2.
• the cup 2 is generally shorter and wider than the finished container. Accordingly, the cups 2 are typically subjected to a variety of additional processes that further form the cup into the finished container.
• the cup includes a base 3 having an upwardly depending sidewall 4.
• the container body, hereinafter can body 5 (Figure 2), is formed by additional processes such as, but not limited to, drawing, redrawing, and ironing the cup 1.
• the can body 5 also includes a base 6 and a sidewall 7.
• the can body base 6 includes a bottom profile.
• a "bottom profile” is the shape of the base 3, 6 after forming.
• a beverage can body 5A the bottom profile slopes inwardly from an annular ridge 8 to form an inwardly projecting, generally hemispherical dome 9.
• a food can body 5B (shown during formation in Figure 4E) has a generally flat bottom profile.
• the dome 9 is formed by a "domer” during the forming of the cup 2 and/or a can body 5.
• the apparatus and tooling structured to form a cup 2 and/or a can body 5 is shown in U. S. Patent Application Serial No. 15/286,954, which is incorporated by reference.
• base gauge means the initial thickness of the material and is not limited to the thickness of the base portion/element.
• Tooling for forming domed cups or can bodies has conventionally included a curved, or arcuate, punch core and a die core with a corresponding curvature, such that a domed can body is formed from material (e.g., without limitation, a sheet metal blank) conveyed between the punch core and the die core.
• material e.g., without limitation, a sheet metal blank
• the punch core extends downwardly into the die core, forming the domed cup or can body.
• the material is drawn between the punch core and the die core. That is, in order to maintain the thickness of the domed portion, the material is relatively lightly clamped on either side of the portion to be domed.
• the material can move (e.g., slide) or flow toward the dome as it is formed in order to maintain the desired thickness in the bottom profile.
• U. S. Patent No. 5,394,727 it is known to form a bottom profile including generally planar (when viewed in cross-section) surfaces instead of a dome.
• Such protrusions are also formed by drawing the material over a die.
• the domes and protrusions of the known art are structured to generally maintain the thickness of the material during the formation of a dome.
• can bodies formed from a cup with a generally hemispherical dome also have disadvantages.
• certain beverage can bodies are formed by reversing, or flattening, the dome on the cup and reforming the dome on the can body.
• the steps to this process are shown in Figures 3A-3C and include reversing the dome ( Figures 3B and 3C) and reforming a can body dome ( Figures 3D and 3E).
• a cup's generally arcuate dome i.e., a generally hemispherical dome is generally arcuate in cross- section as shown in the figures, defines a volume of metal. This volume of metal must be reformed when the cup is formed into a can body.
• a generally arcuate dome includes a greater volume of metal relative to other shapes such as, but not limited to a truncated dome, as shown in Figure 5A, discussed below.
• This greater volume of metal allows the metal to wrinkle or have other defects during the formation of the can body.
• food can bodies which typically have a generally planar bottom, when formed from a cup with a generally arcuate dome. That is, the steps of forming a food can body are shown in Figures 4A-4E.
• the greater volume of metal in a generally hemispherical dome i.e., a generally arcuate dome when viewed in cross-section, allows for the formation of defects in the food can body when the cup is reformed.
• the disclosed and claimed concept provides for a formed blank including a stretched portion and/or a truncated protrusion, a tooling assembly structured to form a formed blank including a stretched portion and/or a truncated protrusion, and a method of forming a formed blank including a stretched portion and/or a truncated protrusion.
• the formed blank includes a base and a depending sidewalk
• the stretched portion and/or the truncated protrusion is disposed on the formed blank base and the thickness of the stretched portion and/or the truncated protrusion is less than the sidewalk
• the stretched portion and/or the truncated protrusion utilizes less material relative to an unformed base that has about the same thickness as the sidewalk
• Figure 1 is a cross-sectional view of a prior art cup.
• Figure 2 is a cross-sectional view of a prior art can body.
• Figures 3 A-3E show the formation of a prior art beverage can body.
• Figures 4A-4E show the formation of a prior art food can body.
• Figure 5A is a cross-sectional view of a formed blank in the form of a cup.
• Figure 5B is a cross-sectional view of a formed blank in the form of a can body.
• Figure 6 is a partially schematic, cross-sectional view of a tooling assembly.
• Figure 7 is a detail cross-sectional view of a domer structured to form a truncated protrusion.
• Figures 8A-8E show the formation of a beverage can body from a cup with a truncated dome.
• Figures 9A-9E show the formation of a food can body from a cup with a truncated dome.
• Figure 10 is a flow chart for the disclosed method. DESCRIPTION OF THE PREFERRED EMBODFMENTS
• structured to [verb] means that the identified element or assembly has a structure that is shaped, sized, disposed, coupled and/or configured to perform the identified verb.
• a member that is "structured to move” is movably coupled to another element and includes elements that cause the member to move or the member is otherwise configured to move in response to other elements or assemblies.
• structured to [verb] recites structure and not function.
• structured to [verb] means that the identified element or assembly is intended to, and is designed to, perform the identified verb.
• an element that is merely capable of performing the identified verb but which is not intended to, and is not designed to, perform the identified verb is not "structured to [verb]."
• association means that the elements are part of the same assembly and/or operate together, or, act upon/with each other in some manner.
• an automobile has four tires and four hub caps. While all the elements are coupled as part of the automobile, it is understood that each hubcap is “associated” with a specific tire.
• two or more parts or components are “coupled” shall mean that the parts are joined or operate together either directly or indirectly, i.e., through one or more intermediate parts or components, so long as a link occurs.
• directly coupled means that two elements are directly in contact with each other.
• fixedly coupled or “fixed” means that two components are coupled so as to move as one while maintaining a constant orientation relative to each other.
• a "fastener” is a separate component structured to couple two or more elements.
• a bolt is a “fastener” but a tongue-and-groove coupling is not a “fastener.” That is, the tongue-and-groove elements are part of the elements being coupled and are not a separate component.
• the phrase "removably coupled” or “temporarily coupled” means that one component is coupled with another component in an essentially temporary manner. That is, the two components are coupled in such a way that the joining or separation of the components is easy and would not damage the components.
• fasteners that are not difficult to access
• fasteners that are not difficult to access are "removably coupled”
• two components that are welded together or joined by difficult to access fasteners are not “removably coupled.”
• a "difficult to access fastener” is one that requires the removal of one or more other components prior to accessing the fastener wherein the "other component” is not an access device such as, but not limited to, a door.
• temporary disposed means that a first element(s) or assembly (ies) is resting on a second element(s) or assembly(ies) in a manner that allows the first element/assembly to be moved without having to decouple or otherwise manipulate the first element.
• a book simply resting on a table i.e., the book is not glued or fastened to the table, is “temporarily disposed” on the table.
• operatively coupled means that a number of elements 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 so that as the first element moves from one position/configuration to the other, the second element moves between positions/configurations as well. It is noted that a first element may be "operatively coupled" to another without the opposite being true.
• a "coupling assembly” includes two or more couplings or coupling components.
• the components of a coupling or coupling assembly are generally not part of the same element or other component. As such, the components of a coupling or coupling assembly
• Coupled assembly may not be described at the same time in the following description.
• a "coupling” or “coupling component(s)” is one or more component(s) of a coupling assembly. That is, a coupling assembly includes at least two components that are structured to be coupled together. It is understood that the components of a coupling assembly are compatible with each other. For example, in a coupling assembly, if one coupling component is a snap socket, the other coupling component is a snap plug, or, if one coupling component is a bolt, then the other coupling component is a nut.
• “correspond” indicates that two structural components are sized and shaped to be similar to each other and may be coupled with a minimum amount of friction.
• an opening which "corresponds" to a member is sized slightly larger than the member so that the member may pass through the opening with a minimum amount of friction.
• This definition is modified if the two components are to fit "snugly" together. In that situation, the difference between the size of the components is even smaller whereby the amount of friction increases.
• the element defining the opening and/or the component inserted into the opening are made from a deformable or compressible material, the opening may even be slightly smaller than the component being inserted into the opening.
• surfaces, shapes, and lines two, or more, "corresponding" surfaces, shapes, or lines have generally the same size, shape, and contours.
• a "planar body” or “planar member” is a generally thin element including opposed, wide, generally parallel surfaces, i.e., the planar surfaces of the planar member, as well as a thinner edge surface extending between the wide parallel surfaces. That is, as used herein, it is inherent that a "planar” element has two opposed planar surfaces.
• the perimeter, and therefore the edge surface may include generally straight portions, e.g., as on a rectangular planar member, or be curved, as on a disk, or have any other shape.
• a "path of travel” or “path,” when used in association with an element that moves, includes the space an element moves through when in motion. As such, any element that moves inherently has a “path of travel” or “path.”
• the statement that two or more parts or components "engage” one another shall mean that the elements exert a force or bias against one another either directly or through one or more intermediate elements or components. Further, as used herein with regard to moving parts, a moving part may "engage” another element during the motion from one position to another and/or may “engage” another element once in the described position. Thus, it is understood that the statements, “when element A moves to element A first position, element A engages element B," and “when element A is in element A first position, element A engages element B" are equivalent statements and mean that element A either engages element B while moving to element A first position and/or element A either engages element B while in element A first position.
• operatively engage means “engage and move.” That is, "operatively engage” when used in relation to a first component that is structured to move a movable or rotatable second component means that the first component applies a force sufficient to cause the second component to move.
• a screwdriver may be placed into contact with a screw. When no force is applied to the screwdriver, the screwdriver is merely “coupled” to the screw. If an axial force is applied to the screwdriver, the screwdriver is pressed against the screw and "engages" the screw.
• unitary means a component that is created as a single piece or unit. That is, a component that includes pieces that are created separately and then coupled together as a unit is not a “unitary” component or body.
• number shall mean one or an integer greater than one (i.e., a plurality).
• [x] moves between its first position and second position
• [y] is structured to move [x] between its first position and second position
• [x] is the name of an element or assembly.
• [x] is an element or assembly that moves between a number of positions
• the pronoun "its” means “[x],” i.e., the named element or assembly that precedes the pronoun "its.”
• a "radial side/surface” for a circular or cylindrical body is a side/surface that extends about, or encircles, the center thereof or a height line passing through the center thereof.
• an "axial side/surface” for a circular or cylindrical body is a side that extends in a plane extending generally perpendicular to a height line passing through the center. That is, generally, for a cylindrical soup can, the "radial side/surface” is the generally circular sidewall and the "axial side(s)/surface(s)" are the top and bottom of the soup can.
• can and “container” are used substantially interchangeably to refer to any known or suitable container, which is structured to contain a substance (e.g., without limitation, liquid; food; any other suitable substance), and expressly includes, but is not limited to, beverage cans, such as beer and soda cans, as well as food cans.
• a substance e.g., without limitation, liquid; food; any other suitable substance
• beverage cans such as beer and soda cans, as well as food cans.
• a "contour” means the line or surface, that defines an object. That is, for example, when viewed in cross-section, the surface of a three-dimensional object is reduced to two dimensions; thus, a portion of a three-dimensional surface contour is represented by a two-dimensional line contour.
• a “perimeter portion” means the area at the outer edge of a defined area, surface, or contour.
• a "truncated protrusion” is a profile for a cup base or a can body base that includes a “stretched portion” and a generally planar portion at the distal end of the protrusion, i.e., the end of the protrusion located furthest from the base.
• a "truncated protrusion” inherently includes a stretched portion and a generally planar portion.
• a "generally planar portion" of a “truncated protrusion” includes both substantially planar elements and elements that include beads, corrugations, or similar constructs structured to accommodate additional material in a defined area and relative to a substantially planar element having the same defined area so long as the area including beads, corrugations, or similar constructs has generally planar contour over the defined area.
• a "truncated protrusion” is formed and offset inwardly. That is, a “truncated protrusion” is formed by deforming material into the space partially enclosed by a base and sidewall, such as on a cup of can body.
• an outwardly protruding bead extending about base does not convert the generally planar portion of the base encircled by the bead into a "truncated protrusion" because the generally planar portion of the base encircled by the bead is not formed or offset inwardly.
• a "truncated protrusion forming profile” is a surface on a forming element, such as, but not limited to, the surface of a die, structured to form a material into a "truncated protrusion” as defined above.
• a "die truncated protrusion forming profile” is a surface on a die, structured to form a material into a “truncated protrusion” as defined above.
• a "truncated dome” is a “truncated protrusion” having a generally curvilinear (or arcuate) portion and a generally planar portion when viewed in a lateral cross-section; that is, a truncated dome is a dome wherein a generally planar portion is disposed where the vertex of the dome would be, i.e., a dome with a generally flat top.
• the "stretched portion” and the "generally planar portion” are one configuration selected from the group consisting of coextensive ⁇ i.e., fully overlapping), partially coextensive ⁇ i.e., partially overlapping), or separate ⁇ i.e., no overlap).
• a "truncated dome forming profile” is a surface on a forming element, such as, but not limited to, the surface of a die, structured to form a material into a "truncated dome” as defined above.
• a "die truncated dome forming profile” is a surface on a die, structured to form a material into a "truncated dome” as defined above.
• a "stretched portion” is a portion of a material formed by stretching the material. Further, as used herein, a “stretched portion” is not an
• a "formed blank” means a cup as well as a can body that has been formed from a cup.
• depending means to extend at an angle other than zero (0°) from another element without regard to direction. That is, for example, a “depending" sidewall may extend generally upwardly from a base.
• generally curvilinear includes elements having multiple curved portions, combinations of curved portions and planar portions, and a plurality of planar portions or segments disposed at angles relative to each other thereby forming a curve.
• a formed blank 10 i.e., a cup 2 or a can body 5 is formed from a blank 1. That is, blank 1 is formed by a tooling assembly 100, shown partially schematically in Figure 6.
• the tooling assembly 100 includes a first tool assembly 102 and a second tool assembly 104. At least one of the first tool assembly 102 and the second tool assembly 104 is movable and is coupled to a press 106 or similar device.
• the first tool assembly 102 includes a forming punch 108 and the second tool assembly 104 includes a forming die 110.
• the press 106 is structured to, and does, move the first tool assembly 102 between a first position, wherein the first tool assembly 102 is spaced from the second tool assembly 104, and a second position, wherein the first tool assembly 102 is immediately adjacent and minimally spaced from the second tool assembly 104. That is, as the first tool assembly 102 moves from the first position to the second position, the forming punch 108 engages and deforms blank 1 and forms the blank into a formed blank 10.
• the tooling assembly 100 in one embodiment, is supplied with pre-cut blanks 1 to be formed into cups 2. In another embodiment, the tooling assembly 100 is supplied with a sheet of material (not shown) and cuts blanks 1 from the sheet as part of the forming operation.
• the following disclosure details the formation of a cup 2 which is then formed into a can body 5, as is generally known.
• the cup 2, and the subsequent can body 5, hereinafter and collectively the formed blank 10 includes a truncated protrusion 20, as shown in Figures 5A and 5B.
• the following disclosure details the configuration of the finished formed blank 10. That is, the formed blank 10 includes a body 11 having a base 12 and a depending sidewall 14. Further, as is known, a can body base 12 includes a ridge 16 extending about the base 12. In an exemplary embodiment, the base 12 is generally circular and, as such, the depending sidewall 14 is generally cylindrical and the ridge 16 is an annular ridge 16' . Further, in an exemplary
• the truncated protrusion 20 is a truncated dome 22. That is, the base 12 includes a truncated protrusion 20 including a number of generally curvilinear portion(s) 30 and a generally planar portion 32.
• the cup 2 shown in Figure 5A has a single bead (not numbered) and is a cup 2 for a beverage can body 5A.
• the cup shown in Figure 9A (not numbered) has two beads and is for a food can body 5B.
• a cup 2 for a food can body 5B has a greater diameter than a cup 2 for a beverage can body 5 A and, as such, can accommodate another bead.
• a truncated dome 22 has a "reduced volume.”
• a “reduced volume” means a protrusion formed in the bottom of a cup, such as, but not limited to, a truncated dome that has a reduced volume of metal compared to a generally hemispherical dome, i.e., a generally arcuate dome when viewed in cross- section.
• the length of the bottom profile (when viewed in cross-section as shown in Figure 5 A) of a truncated dome 22, i.e., the length from the outer edge of the truncated dome 22 to the center of the truncated dome 22 is shorter than the length of a generally hemispherical dome because the generally planar portion 32 of a truncated dome 22 has a shorter length relative to an arc on a generally hemispherical dome.
• an arc within and confined by a perimeter, e.g., sidewalls 14 when viewed in cross-section), is flattened to a generally straight line, the length of the now flattened line is shorter relative to the previously existing arc.
• the volume of the truncated dome 22 is less than a generally hemispherical dome having the same diameter.
• the single curvilinear portion 30 that extends between the annular ridge 16' and the generally planar portion 32.
• the single curvilinear portion 30 is, in an exemplary embodiment, an arcuate portion 40.
• arcuate portion refers to the shape of the truncated protrusion 20 when viewed in cross-section, as shown in Figure 5A; it is understood that the curvilinear portion 30 (or arcuate portion 40) when rotated about an axis in three dimensions forms a dome, or dome-like, shape.
• the number of generally curvilinear portion(s) 30 includes a first generally curvilinear portion 34 and a second generally curvilinear portion 36.
• the truncated dome first generally curvilinear portion 34 has a first center
• the truncated dome second generally curvilinear portion 36 has a second center.
• the "center" of a curvilinear line means a point that is disposed generally an equal distance from all points on the curvilinear line; for an arcuate line, the "center” means a point that is disposed substantially an equal distance from all points on the arcuate line.
• the first generally curvilinear portion 34 and the second generally curvilinear portion 36 are a first generally arcuate portion 44 and a second generally arcuate portion 46, respectively.
• a portion of the truncated protrusion 20 is stretched (hereinafter the "stretched portion" 38) during the forming process so that the material forming the truncated protrusion 20, or a portion of the truncated protrusion 20, is thinner than the base gauge of the original material, i.e., the base gauge of the blank 1 which, in an exemplary embodiment, is also the thickness of the sidewall 14.
• substantially all of the truncated protrusion 20 (or truncated dome 22) has a uniform thickness.
• the stretched portion 38 extends over substantially all of the curvilinear portion(s) 30 (34, 36) as well as the planar portion 32. In other embodiments, the stretched portion 38 extends over only a portion of the curvilinear portion(s) 30 (34, 36) and/or the planar portion 32. Further, in an exemplary embodiment, the truncated protrusion 20 (or truncated dome 22) has a thickness that is between about 0.0003 inch and 0.002 inch thinner than the base gauge of the original material and/or the sidewall 14.
• the tooling and method of forming a cup 2 or can body 5 with a stretched dome is disclosed in U.S. Patent Application Serial No. 15/286,954.
• the following disclosure addresses the details of the tooling assembly 100, shown in Figure 6, and method ( Figure 10) for forming a truncated protrusion 20 (or truncated dome 22).
• the tooling assembly 100 includes a first tool assembly 102 and a second tool assembly 104 structured to form a blank 1 into formed blank 10, i.e., a cup 2 or a can body 5.
• the blank 1 has a base gauge (thickness) and that, after the initial formation of the formed blank 10, the base 12 and the sidewall 14 have substantially the same thickness as the base gauge.
• the tooling assembly 100 is structured to, and does, maintain the thickness of the sidewall 14 substantially at the base gauge.
• the first tool assembly 102 and second tool assembly 104 are further structured to, and do, clamp the blank 1 of material at the periphery of the base 12.
• the periphery of the base 12 is defined by the ridge 16; thus, the first tool assembly 102 and second tool assembly 104 are further structured to, and do, clamp the blank 1 of material at the ridge 16.
• the first tool assembly 102 and the second tool assembly 104 are structured to, and do, stretch a portion of the base 12 and thereby thin the base stretched portion 38 relative to the base gauge of the material and/or the sidewall 14.
• the stretched portion 38 in an exemplary embodiment, has a generally uniform thickness. Further, in an exemplary embodiment, the stretched portion 38 is coextensive with the entire base 12.
• the formed blank 10 is moved by the forming punch 108 to the forming die 110.
• the forming punch 108 in this embodiment, is an elongated, generally cylindrical body 112 with a cavity 114 at the distal end.
• the cavity 114 in one embodiment, is generally concave and contoured to correspond to the shape of a forming surface 120, discussed below.
• the cavity 114 is generally cylindrical; that is, the forming punch 108 is generally hollow.
• the forming surface 120 is disposed on the forming die 110 of the second tool assembly 104.
• the forming die 110 remains substantially stationary relative to the forming punch 108. That is, the forming punch 108 reciprocates in a generally vertical direction and the upper surface of the forming die 110 has a convex protrusion 111 that defines the forming surface 120.
• the forming surface 120 includes a truncated protrusion forming profile 122.
• the forming punch 108 is structured to, and does, move the blank 1 of material into contact with the truncated protrusion forming profile 122.
• the truncated protrusion forming profile 122 is a truncated dome forming profile 122'.
• the truncated dome forming profile 122' includes a number of generally curvilinear portions 126 and a planar portion forming construct 128.
• the truncated dome forming profile number of generally curvilinear portions 126 includes a first generally curvilinear portion 130 and a second generally curvilinear portion 132.
• the truncated dome forming profile first generally curvilinear portion 130 has a first center 134 and the truncated dome forming profile second generally curvilinear portion 132 has a second center 136.
• the truncated dome forming profile first generally curvilinear portion 130 is a first generally arcuate portion 140
• the truncated dome forming profile second generally curvilinear portion 132 is a second generally arcuate portion 142.
• the truncated dome forming profile planar portion forming construct 128 is in one exemplary embodiment, not shown, a generally planar surface. That is, the truncated dome forming profile 122' is generally flat at the vertex. In the embodiment shown, the truncated dome forming profile planar portion forming construct 128 is a cavity 150. That is, the truncated dome forming profile 122' is defined by the number of generally curvilinear portions 126. The truncated dome forming profile planar portion forming construct is the cavity 150 in the die. Stated alternately, the number of generally curvilinear portions 126 extend generally concentrically about a cavity 150.
• the formed blank 10, and more specifically the base 12 is clamped between the first tool assembly 102 and the second tool assembly 104 as it is moved into the forming die 110.
• the forming punch 108 moves the base 12 over the truncated dome forming profile 122', the material of the base 12 is stretched and thinned.
• the material of the base 12 is formed to the contour of the truncated dome forming profile 122'. That is, a portion of the base 12 is formed to the truncated dome forming profile first generally curvilinear portion 130 and the truncated dome forming profile second generally curvilinear portion 132.
• the center of the forming die 110 is hollow (and as the forming punch 108 is also hollow) the center of the base 12 remains generally planar while being thinned.
• the first tool assembly 102 and the second tool assembly 104 are structured to form the formed blank sidewall 14 with a thickness about the same as the base gauge.
• the first tool assembly 102 and the second tool assembly 104 are also structured to form the formed blank truncated protrusion with a thickness that is less than the formed blank sidewall 14.
• the first tool assembly 102 and the second tool assembly 104 are structured to form the formed blank truncated protrusion 20 with a thickness that is between about 0.0003 inch and 0.002 inch thinner than the formed blank sidewall 14.
• a method of forming a formed blank within a tooling assembly 100 includes forming 1000 a blank 1 of material to include a base 12 and a depending sidewall 14, clamping 1002 the blank 1 between the first tool assembly 102 and the second tool assembly 104 at the periphery of the base 12, and stretching 1004 the base 12, thereby thinning a portion of the base 12 relative to the sidewall 14 to form a stretched portion 38.
• stretching 1004 the base 12, thereby thinning a portion of the base 12 relative to the sidewall 14 to form a stretched portion 38 includes stretching 1006 the base stretched portion so as to have a generally uniform thickness.
• stretching 1004 the base 12, thereby thinning a portion of the base 12 relative to the sidewall 14 to form a stretched portion 38 includes forming 1010 a truncated protrusion 20.
• forming 1010 a truncated protrusion 20 includes forming 1012 a truncated dome 22.
• forming 1012 a truncated dome includes: forming 1020 a dome with a first generally curvilinear portion and a second generally curvilinear portion, forming 1022 the first generally curvilinear portion about a first center, and forming 1024 the second generally curvilinear portion about a second center. Further, to form the truncated dome 22 described above forming 1000 the blank 1 of material to include a base 12 and a depending sidewall 14 includes forming 1030 the sidewall 14 with a thickness generally corresponding to the base gauge of the material.
• stretching 1004 the base 12, thereby thinning a portion of the base 12 relative to the sidewall 14 includes forming 1032 the stretched portion 38 with a thickness that is less than the formed blank sidewall 14. Further, in an exemplary embodiment, stretching 1004 the base 12, thereby thinning a portion of the base 12 relative to the sidewall 14 includes forming 1036 the stretched portion 38 with a thickness that is between about 0.0003 inch and 0.002 inch thinner than the sidewall 14.
• the process described above discloses forming a blank 1 into a cup 2 having a truncated protrusion 20. It is understood that such a cup 1 is then formed into a can body 5 either in the same device or the cup 2 is transported to a bodymaker, as is known.
• the can body 5 made from such a cup 2 also includes the truncated protrusion 20.
• a can body 5 made from a cup 2 having a truncated protrusion 20 is also a formed blank 10 having a truncated protrusion 20 regardless of whether the truncated protrusion 20 is reformed at a later stage of processing.
• cup 2 with a truncated protrusion 20 is formed into a beverage can body 5' . That is, as shown in Figures 8A-8C, the cup 2 is reformed by inverting the truncated protrusion 20. During this forming process, the bottom of the cup 2 is reformed so as to be substantially planar. Thus, as shown in Figures 8D and 8E, when the can beverage can body 5' is reformed with a dome, the bottom of the cup 2 forms over the domer 180 with no loose metal as in the prior art.
• Figures 9A-9E show the formation of a food can body 5".
• the cup 2 and the truncated protrusion 20 are reformed as substantially planar elements. Because the generally planar portion 32 is already generally planar, the reformed can body does not include an offset portion which is a remnant of the dome.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Ceramic Engineering (AREA)
• Containers Having Bodies Formed In One Piece (AREA)
• Details Of Rigid Or Semi-Rigid Containers (AREA)
• Rigid Containers With Two Or More Constituent Elements (AREA)
• Buffer Packaging (AREA)
• Shaping Metal By Deep-Drawing, Or The Like (AREA)

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• 2016
  • 2016-12-19 US US15/382,850 patent/US20180170606A1/en active Pending
• 2017
  • 2017-12-12 JP JP2019531444A patent/JP2020508933A/ja active Pending
  • 2017-12-12 BR BR112019012726-7A patent/BR112019012726B1/pt active IP Right Grant
  • 2017-12-12 EP EP17883511.2A patent/EP3554732A4/de active Pending
  • 2017-12-12 WO PCT/US2017/065671 patent/WO2018118495A1/en active Application Filing
  • 2017-12-12 CN CN201780078521.0A patent/CN110087792B/zh active Active
• 2022
  • 2022-01-24 JP JP2022008421A patent/JP2022068163A/ja active Pending

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