WO2017100548A1 - Produits métalliques et procédés de formation de composants comprenant lesdits produits - Google Patents

Produits métalliques et procédés de formation de composants comprenant lesdits produits Download PDF

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Publication number
WO2017100548A1
WO2017100548A1 PCT/US2016/065793 US2016065793W WO2017100548A1 WO 2017100548 A1 WO2017100548 A1 WO 2017100548A1 US 2016065793 W US2016065793 W US 2016065793W WO 2017100548 A1 WO2017100548 A1 WO 2017100548A1
Authority
WO
WIPO (PCT)
Prior art keywords
workpiece
emf
feature
inductor
die
Prior art date
Application number
PCT/US2016/065793
Other languages
English (en)
Inventor
Robert E. Dick
Jeremy N. PEPPER
Barry E. SOXMAN
Anthony J. Fedusa
Gary L. HUNKER
Christopher L. WALTERS
Mikhail GERSHENZON
Original Assignee
Alcoa Usa Corp.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Alcoa Usa Corp. filed Critical Alcoa Usa Corp.
Priority to US16/060,863 priority Critical patent/US20190001390A1/en
Publication of WO2017100548A1 publication Critical patent/WO2017100548A1/fr

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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
    • B21D26/00—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces
    • B21D26/14—Shaping without cutting otherwise than using rigid devices or tools or yieldable or resilient pads, i.e. applying fluid pressure or magnetic forces applying magnetic forces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
    • B21C51/005—Marking devices
    • 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
    • B21D51/2623—Curling
    • 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
    • B21D51/38—Making inlet or outlet arrangements of cans, tins, baths, bottles, or other vessels; Making can ends; Making closures
    • 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
    • B21D51/38—Making inlet or outlet arrangements of cans, tins, baths, bottles, or other vessels; Making can ends; Making closures
    • B21D51/40—Making outlet openings, e.g. bung holes
    • 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
    • B21D51/2607—Locally embossing the walls of formed can bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44B—MACHINES, APPARATUS OR TOOLS FOR ARTISTIC WORK, e.g. FOR SCULPTURING, GUILLOCHING, CARVING, BRANDING, INLAYING
    • B44B5/00—Machines or apparatus for embossing decorations or marks, e.g. embossing coins

Definitions

  • the instant disclosure is directed towards EMF-forming workpieces, More specifically, the instant disclosure is directed towards different embodiments of imparting EMF- features onto workpieces, where workpieces are configured as metal containers.
  • the present disclosure relates to electromagnetic forming (EMF) processes for shaping metal containers (e.g. bottles and cans) and imparting certain components (e.g. EMF- features) onto metal containers (e.g. segmented aluminum bottle threads on metal containers).
  • EMF electromagnetic forming
  • a metal container e.g. aluminum or aluminum alloy
  • the EMF feature includes an asymmetrical configuration
  • the asymmetrical configuration of the EMF feature includes: a thread (e.g. configured along the upper portion of the metal container); a stamped feature (e.g. logo) on the body (e.g. configured/positioned below the neck, if the metal container is necked); a stamped feature (e.g. logo) positioned on the bottom (e.g. dome, if domed) of the metal container.
  • a thread e.g. configured along the upper portion of the metal container
  • a stamped feature e.g. logo
  • the body e.g. configured/positioned below the neck, if the metal container is necked
  • a stamped feature e.g. logo
  • asymmetrical configurations of the EMF feature include: a crown-style threaded upper portion; a PET-style threaded upper portion; and combinations thereof.
  • the EMF feature includes a symmetrical configuration.
  • the symmetrical configuration of the EMF feature includes: a PET-style threaded upper portion: a stamped feature (e.g. logo) on the body (e.g. configured positioned below the neck, if the metal container is necked); a stamped feature (e.g. logo) positioned on the bottom (e.g. dome, if domed) of the metal container; a carrier ring, and combinations thereof.
  • a stamped feature e.g. logo
  • the bottom e.g. dome, if domed
  • a formed metal container e.g. drawn, drawn and ironed, impact extruded, pressure ram fomiing, three-piece welded, two-piece welded, electrohydrodynamic fanning, hydraulic blow forming (hydro fomiing) having an EMF-feafure thereon configured to promote threaded engagement with a closure device (e.g. lid, cap, cover, etc) having corresponding thread to enable a secure fit or seal,
  • a closure device e.g. lid, cap, cover, etc
  • a formed metal container e.g. drawn, drawn and ironed, impact extruded
  • an EMF-feature comprising a PET-style threaded finish.
  • PET-style thread is similar to the thread finish on a PET bottle.
  • the PET-style thread is integrally formed on a metal container (e.g. EMF- feature).
  • the PET-style thread comprises a continuous thread path (e.g. configured in a helical direction) intermpied with at least one vent slot (e.g. configured in a generally axial direction), wherein the vent slots are configured to provide a path for the release of internal gases upon opening of the container (See. e.g. Figure 4).
  • the forme metal container is configured with a twist-off crown thread (integrally formed on aluminum container).
  • a metal container e.g. formed metal container
  • the roll on pilfer proof (ROPP) thread includes one continuous thread configured to receive a closure having a tamper evident band configured/positioned beneath the thread.
  • the twist-off crown thread is a continuous thread with a pitch less than the ROPP thread. In some embodiments, the twist-off crown thread is configured such that, the beginning of one thread is directly axially in line and/or overlapping with another thread.
  • the twist-off crown thread is configured, with lugs, such that the beginning of one thread is not directly axially in line and/or overlapping with another thread.
  • a twist-off crown is configured with an. angle of attenuation of the summa tion of the thread lengths at less than 360°.
  • a kg is configured such that the angle of attenuation of the summation of the thread lengths is not greater than 360°.
  • a metal container e.g. formed metal container
  • the metal container configured with an integrally formed asymmetrical thread (e.g. twist-off crown- lid or PET- Style thread).
  • a formed metal container is configured with a PET-styie threaded finish and a PET closure attached thereto.
  • the PET-style threads include PET bottle finishes configured for use on bottles retaining carbonated soft drinks.
  • PET bottle finishes for carbonated soft drinks include: bottle finishes PCO 1810 or PCO 38 (e.g. having intermittent threads) and bottle finish Alcoa 1690 or Alcoa 1716 (e.g. each having vent slots).
  • a metal container is configured with/comprises a segmented thread configured to improve venting during opening.
  • a formed metal container having an EMF-feature comprises a twist-off crown finish.
  • the twist-off crown finish is configured for a metal crown, plastic cap, a roll-on pilfer-proof closure/cap. or combinations thereof.
  • twist-off crown finishes include: screw threads, screw-top. screw- cap, helix, coil, duplex, external screw thread, and combinat ons thereof.
  • a metal container is configured with an EMF-feature.
  • the EMF-feature selected from the group consisting of: a thread configured proximate to the open, upper end of the closed metal container; an upper rim configured from an EMF-operation (e.g. trimming): a cur! configured from an EMF-operation (e.g. curling); an imprinted portion configured along the sidewall of the body (e.g. cylindrical porti on of the metal container); a carrier ring configured on an upper open portion of the metal container, positioned beneath the threaded portion; a carrier ring comprising: a carrier ring insert (e.g. plastic or metal ring) and a carrier ring lip (e.g.
  • the earner ring is configured on an upper open portion of the metal container, and positioned beneath the threaded portion; an imprinted portio configured along the bottom of the body (e.g. dome or base of the metal container); and combinations thereo
  • thread configuratio s and/or lug patterns are referred to herein. It is noted that, lugs and threads are used interchangeably, though a lug (e.g. a projection on an object by which it may be carried or fixed in place) and a thread (a helical ridge on the outside of an object configured, to allow two parts to be mechanically attach ed serewed together) may differ slightly in how they are interpreted.
  • the thread configuration comprises a continuous threaded finish configured to be used, with ROPP cap/closure.
  • the thread configuration comprises a discontinuous/segmented thread finish, in some embodiments, the segmented thread finish is configured to be usable with a ROPP cap or a PET ⁇ style plastic cap or lug cap.
  • one or more of the various embodiments is configured to make asymmetric forming of a shaped can (e.g. aluminum can or bottle) for differentiated products branding
  • EMF-features are configured on the sidewall bottom, dome, upper end of the workpiece (metal container), and combinations thereof.
  • resistance e.g. electrical resistance
  • inductor e.g. via the electrical connections, volume of material in the coil, or insulators
  • the EMF-formed threads are configured with thread depths having a sufficient depth to enable secure mechanical attachment with a corresponding closure (e.g. cap, lid, cover), In some embodiments, the EMF-formed threads are configured with thread depths having radii/angles to enable secure mechanical attachment with a corresponding closure (e.g. cap, lid, cover), in some embodiments, the EMF-formed threads are configured to enable secure mechanical attachment of the closure (e.g. lid, cover, cap) and retain contents of the metal container which are pressurized and/or vacuum packed (e.g. food and/or beverages).
  • a formed aluminum bottle is configured with thread, wherein the thread is configured to accept a plastic cap. In some embodiments, a formed aluminum bottle is configured with thread, wherein the thread is configured to accept a lug cap. In some embodiments, a formed aluminum bottle is configured with thread, wherein the thread is configured to accept a ROPP cap.
  • a formed aluminum bottle with at least one EMF-feature is provided, wherein the EMF-features are selected from the group consisting of: threads, lugs, imprinted portions of the body, imprinted portions of the bottom/dome, carrier rings, carri er ring inserts, and combinations thereof.
  • the segmented thread is configured to provide easier openabiliiy. In some embodiments, the segmented thread is configured to provide improved venting of earbonatioxi gases (e.g. directed out from the upper end of the container via the recesses/grooves in the threaded pattern). In. some embodiments, the thread is configured to provide improved axial column loading (e.g. measured/quantified and/or simulated).
  • the skin layer, or thickness into which the EMF field penetrates into the metal substrate depends upon the frequency of the electromagnetic pulse.
  • a method comprising: positioning the workpiece adjacent to an inductor of an EMF device, wherein at least a portion of the workpiece (the substrate) is positioned between an inductor coil and a die; discharging a power source of the EMF device to generate an electromagnetic frequency via the inductor; and generating an electromagnetic force via the inductor, wherein the inductor is positioned such that the electromagnetic force acts upon (imparts force onto) the workpiece,
  • the workpiece and inductor are placed adjacent to (but not in contact with each other, in order to prevent arching or transferring electiicai current from the inductor into the workpiece.
  • the higher the frequency of the electromagnetic pulse the thinner the sheet that can be EM formed.
  • the thinner the substrate of the workpiece the lower the selected energy needed to impart an EMF feature on the workpiece.
  • a. method comprising: disposing/positioning an inductor in electrical communication with a pulsed magnetic device, such that the inductor is configured to impart a magnetic force to at least a portion of a workpiece (e.g. sidewall or bottom of a workpiece); energizing the inductor via power source to a voltage potential via transducer, capacitor, and induction coil configuration; imparting a pulsed electromagnetic frequency into the portion of the workpiece sufficient to impart a deformation in the workpiece adjacent to the inductor; directing the workpiece onto a support surface die (e.g. with thread configuration, imprinted logo), imparting via the s pport surface (e.g. die or imprinting/stamp) and EMF frequency, an EMF feature configured onto the workpiece.
  • a support surface die e.g. with thread configuration, imprinted logo
  • EMF frequency an EMF feature configured onto the workpiece.
  • the directing step includes: imprinting the workpiece with the pattern on the die. h some embodiments, ihe directing step includes i molding the workpiece with the pattern on the die. In some embodiments, the directing step comprises impacting the die with the workpiece. In some embodiments, the directing step further comprises deforming the metal into the workpiece.
  • the directing step further comprises engraving.
  • the directing step further comprises incising
  • the electromagnetic force actuates the metal normally (peipendicular to a plane) away from the inductor (e.g. to create a curling operation, a trimming operation).
  • the imparting step comprises imparting (forming via electromagnetic force acting upon the workpiece and the workpiece being directed onto the support surface (e.g. threading die)) a thread on an upper portion of the neck of a metal container (e.g. aluminum bottle).
  • the imparting step comprises: curling the upper portion of the top portion (forming via EMF acting upon a base portion configured as an actuator to press the workpiece onto a curling tie/tooling to impart a curl on the upper end).
  • the method comprises imparting art EMF-feature (e.g. ernboss/siamp) on the bottom (e.g. dome) or sidewall (e.g. non-necked portion of the workpiece/metal container) prior to necking, in some embodiments, once the EMF-feature (e.g. stamp/emboss logo) is imparted onto the workpiece (metal container), then the container undergoes a necking step (e.g. configured via a forming operation).
  • art EMF-feature e.g. ernboss/siamp
  • sidewall e.g. non-necked portion of the workpiece/metal container
  • the method comprises imparting an EMF-feature (e.g. thread configuration and/or lug pattern) on the upper portion (e.g. adjacent to/proximate the open end of the metal container).
  • imparting an EMF-feature comprising a thread is completed after necking (e.g. such thai the upper end is configured/necked to the approximate thread diameter of the sidewall (e.g. non-necked portion of the workpiece metal container), in some embodiments, once the EMF-feature (e.g. stamp/emboss logo) is imparted onto the workpiece (metal container), then the container undergoes a neck step (e.g. configured via a forming operation).
  • a neck step e.g. configured via a forming operation
  • a method includes: trimming an upper end/portion posltioned'proximate to the open end of a closed metal container (workpiece) to provide a trimmed upper end.
  • the method includes: positioning a first die (threading die) and/or a second die (curling die) around the upper end of the closed metal container such that the die surfaces are positioned adjacent to the outer sidewall of the metal container, and configured proximate to die trimmed upper end; positioning a first inductor inside the open upper end of the container such that the first inductor is secured inside the container adjacent to the inner sidewall; positioning a second inductor beneath a bottom of the closed metal container, wife a metallic base portion positioned between the second inductor and the bottom of the container and configured as an actuator when under an EMF-feature forming force; and directing a first electromagnetic force towards the workpiece/snbstrate via the first inductor to impart a first BMP-feature (e.g.
  • the threading and curling steps are performed simultaneously.
  • the threading and curling steps are performed sequentially.
  • more than one die can be employed to impart two EMF- features on a workpiece (e.g. closed-bottom, metal container) via an inductor directed electromagnetic pulse.
  • a workpiece e.g. closed-bottom, metal container
  • two dies are positioned along the outer sidewall. of the workpiece, including a first die (threading die) and a second die (trimming die) are employed where the trimming die is positioned with a taller height (e.g. closer to the upper, open end of the closed bottom metal container (workpiece)).
  • the inductor is positioned inside the upper, open end of the metal container such that, as the pulse-magnetic device discharges and creates an electromagnetic pulse, through cooperation with the inductor (generating the electromagnetic pulse) and the dies, the metal workpiece is directed away front the inductor, in a generally outward direction, imparting a thread configuration-lug pattern on the upper end of the closed metal container (via the first die/threading die) and also imparting a trim along a portion of the metal container above the threaded configuration/lug pattern (via the second die/trimming die).
  • a method including: threading an upper end of the workpiece (e.g. closed bottom, metal container, aluminum bottle) via the cooperation of a threading die attached to an upper end of the workpiece and a pulsed electromagnetic force generated via. an inductor of a pulsed-magnetie device; trimming the upper portion of the open end to define an upper rim posiiioned above the thread; and curling the upper rim to form a thread configured to receive a corresponding closure (e.g. lid, cover, cap having a corresponding thread and/or lugs).
  • a corresponding closure e.g. lid, cover, cap having a corresponding thread and/or lugs
  • the trimming step is completed, via at least one of: a lathe-type trim or rolling-cutting edge (e.g. configured perpendicularly to the edge) such that the rolling cutting edge is configured to cut/shear the metal off to form the upper rim.
  • the trimming step is completed as an EMF-operation (e.g. with a second die positioned in staggered height from the first, threading die during forming of the E F-feature (thread) on the upper, open end of the workpiece).
  • the curling step is completed via forming operations with dies, in some embodiments, the curling step is completed via a pulsed electromagnetic force generated from an inductor (as set out. herein).
  • the threading die is configured to simultaneously form in the portion of the workpiece adjacent to the inductor a thread configuration via EMF with longitudinal grooves/channels for gas outlet and circular threads/lugs grooves to secure the closure (e,g, lid, cover, or a cap),
  • electromagnetic forming means: a type of high velocity, cold forming process, generally utilized in conjunction with electrically conductive metals.
  • electromagnetic forming refers to an impulse or high-speed forming technology using a pulsed magnetic field to apply Lorentz ' forces to workplaces (e.g. metal containers, aluminum, aluminum alloys, steel, steel alloys).
  • EMF imparts deformation of the workpiece (via at least one corresponding die) without the inductor corning into contact with the workpiece. [0058] In some embodiments, EMF imparts deformation of the workpieces without a working medium.
  • the inductor and die are configured to expand at least a portion of the workpiece (i.e. inductor positioned inside the metal container/workpiece adjacent to the inner sidewail and die positioned outside the workpiece adjacent to outer sidewail).
  • the inductor and die are configured to compress (e.g. neck) at least a portion of the workpiece (i.e. inductor positioned outside the metal container/workpiece adjaeent to the outer sidewail and the die positioned inside the workpiece adjacent to the inner sidewail).
  • pulsed EMF methods and/or the corresponding pulsed magnetic device is/are utilized to provide various EMF-features configured on metal containers.
  • EMF-features include: asymmetrical features, symmetrical features, finishes (e.g. thread configurations, lug patterns), other features (e.g. earner ring, pilfer band, imprinted features, stamped features, logos, graphics, text, a curl, hem) and/or combinations thereof
  • pulsed EMF methods and/or the corresponding pulsed magnetic device is/are utilized to provide EMF-operations on metal containers.
  • EMF methods include: trimming, curling, threading, installing earner ring, imprinting, and/or combinations thereof.
  • workpiece means: a object being worked on with a tool or machine.
  • a workpiece include a metal container being worked on by an electromagnetic forming device (e.g. pulsed EMF device).
  • the metal container is configured as a bottle, [0065] In some embodiments, the metal container is configured as a cars.
  • the metal container is configured as an aerosol can.
  • the metal container is configured with a. finish feature (e.g. mechanical configuration, threading, lugs, or the like) such that the metal container is configured to accept a clos re (e.g. lid, cover, cap, crown).
  • a finish feature e.g. mechanical configuration, threading, lugs, or the like
  • a clos re e.g. lid, cover, cap, crown
  • the metal container is configured to hold food, beverages, aerosols, wet and/or dry goods, pressurized contents, non-pressurized contents, hermetically sealed goods, and combinations thereof.
  • metals (making up the metal container) include: aluminum, aluminum alloys, steel, steel alloys, and combinations thereof.
  • on-Umiting examples of aluminum or aluminum alloys include: lxxx; 1060; 1070; 3xxx; 3104; 5xxx; 5182; 5052; 5042; 5352; and combinations thereof.
  • the average thickness range of the workpiece is at least ⁇ . oos ' ".
  • the thickness range of the workpiece for EMF- eatures and/or EMF-operations are on thin gauge cans.
  • the thickness range for imparting EMF-features or operations on the workpiece at least 0.003" up to 0.039".
  • the thickness for imparting EMF-features or EMF-operations to the workpiece is at least 0.0084".
  • the thickness for imparting EMF-features or EMF-operations to the workpiece is at least 0.015 s '.
  • the workplace comprises a container with the sidewall at least 0.003" thick and is made from a sheet at least 0.006" thick.
  • the sheet is at least 0.009"- 0.030" thick.
  • Figure 1 provides a embodiment of a metal container having an EMF feature including a roll-on pilfer proof (R.OPP) thread and cur!, in accordance with one or more embodiments in accordance with the instant disclosure.
  • R.OPP roll-on pilfer proof
  • Figure 2 provides an embodiment of a metal container having an EMF ⁇ .feat.ure including a PET-style integral thread formed on a metal container, in accordance with one or more embodiments of the instant disclosure.
  • Figure 3 depicts an illustration of an embodiment of an EMF-feature of a twist-off crown type thread integrally formed, on a metal container thereon, in accordance with the instant disclosure.
  • Figure 4 depicts an illustration of an embodiment, of an EMF-feature on a metal container having a PET-style thread integrally formed thereon, in accordance with the instant disclosure.
  • Figure 5 depicts a computer simulation of an embodiment of an EMF-feature being formed on the workpiece, with the inductor configured inside the workpiece and generally configured, in the center of the die and workpiece and the die configured outside the workpiece, in accordance with one or more embodiments of the instant disclosure.
  • the inductor is a one-piece inductor that has a fixed height.
  • Figure 6 depicts a computer simulation of an embodiment of an EMF-feature being formed on the workpiece, with, the inductor configured inside the workpiece and generally configured in the center of the die and workpiece and the die configured outside the workpiece, in accordance with one or more embodiments of the instant disclosure.
  • die inductor is a coiled-configuralion that is capable of being adjusted in height (e.g. made taller, variable heigh etc).
  • Figure 7 depicts a computer simulation of an embodiment of an. EMF-feature integrally formed in the workpiece (e.g. aluminum bottle), wherein the EMF-feature includes an asymmetrical thread finish (e.g. PET-style thread showing a vent slot ⁇ , i accordance with one or more embodiments of the instant disclosure.
  • the workpiece e.g. aluminum bottle
  • the EMF-feature includes an asymmetrical thread finish (e.g. PET-style thread showing a vent slot ⁇ , i accordance with one or more embodiments of the instant disclosure.
  • Figures 8, 9, and 10 are a die system and workpiece (depicted in. position in a portion of the die of Figure 8), in accordance with one or more embodiments of the instant disclosure.
  • the die system of Figures 8-10 includes a OPP type thread configured in a two-piece thread forming tool (with the inductor positioned inside the botde), in accordance with various embodiments of the instant disclosure.
  • Figures 1.1 and 12 depicts a perspective view of two die halves, the die providing a PET-style thread for integral EMF-forming of this type feature onto the workpiece, in accordance with various embodiments of the instant disclosure (with inductor positioned inside the workpiece).
  • Figures 13-15 depict various views of a segmented tooling design for thread forming (with inductor positioned outside the bottle and die inside the bottle) in accordance with various aspects of the instant disclosure.
  • ihe workpiece having an integrally formed thread is depicted, in accordance with the embodiments of the instant disclosure.
  • Figure 16 -19 and 22- 24 depict the segmented dies of Figures 13-15 in conjunction with a spacer, rod, and the like, configured to retain the die in place, in accordance with one or more aspects of the instant disclosure.
  • Figures 20 and 21 depict, yet another embodiment in which an EMF-fearure of a PET- style thread is integrally formed on a metal container, in accordance with one o more embodim ents of the instan t disclosure.
  • Figure 25 and 26 depict yet another embodiment of the instant disclosure, a tooling for asymmetric sidewali imprinting utilizing pulsed EMF (with the inductor positioned inside the workpiece), in accordance with one or more embodiments of the instant disclosure.
  • Figure 27 is a photograph of Ihe incising apparatus securing a workpiece, in accordance with one or more embodiments of the instaxit disclosure.
  • Figure 28 - 30 are photographs of experimental data illustrating EMF-features on the dome of a workpiece, on the sidewall of a workpiece, and on the upper end of the workpiece, in accordance with one or more embodiments of the instant disclosure.
  • Figure 31 is a schematic cut away side view of an embodiment of an EMF-feature including carrier ring having an outsert (e.g. plastic or metal ring), in accordance with one or more embodiments of the instant disclosure, in some embodiments, the ring ontsert is mechanically secured, via the BMP-forming of the carrier ring fea ture adjacent to the position of the carrier ring insert, in accordance with aspects of the instant disclosure.
  • outsert e.g. plastic or metal ring
  • Figures 32 and 33 depict yet another embodiment for forming an EMF-feature including a carrier ring, including dies and the positioning of the inductor within the workpiece, in accordance with various embodiments of the instant disclosure.
  • Figure 34 and Figure 35 depict still another embodiment for forming an EMF-feature including a carrier ring, including dies and the positioning of the inductor within the workpiece, in accordance with various embodiments of the instant disclosure,
  • Figure 36 depicts an embodiment for creating an EMF-feature on the bottom of a workpiece/metal container, including an incising step, in accordance with one or more methods of the instant disclosure.
  • Figure 37 depicts an embodiment of a functional diagram the pulse-magnetic device of Example 7, in accordance with the instant disclosure.
  • Figure 38 depicts a graph outlining the functional relationship between current and voltage of the pulsed magnetic installation, in accordance with one or more embodiments of the instant disclosure.
  • Figures 39A-C depict an embodiment of a configuration of the clamp, die, and inductor positioning to impart a logo on the sidewail of a workpiece, in. accordance with one or more embodiments of the instant disclosure.
  • Figure 40 depicts a schematic of an. embodiment of the clamp and corresponding configuration of the workpiece in Example 8 for imprinting the bottom of a container, in accordance with one or more embodiments of the instant disclosure.
  • Figures 41 A and 41B depict an embodiment of a trimming die and inductor configuration (41 A.) and the die with inductor, depicting an adjustable clamping device for securing the workpiece to the clamp to complete a trimming operation via EMF, in accordance with one or more embodiments of the instant disclosure.
  • Example 1 EMF ' Feature - Threading by . Expansion:
  • EMF-feature (Thread) onto the sidewail (threading by expansion).
  • the samples/ workpieces were metal container preforms of aluminum alloy 3104 having a package diameter of 59 mm and a sheet thickness of approximately 0.0212".
  • the workpieces (e.g. neck completed) were configured with closed bottoms and a perimetrical sidewall extending up from the bottom of the metal container,
  • the samples were secured (e.g. clamped) in the auxiliary support with the inductor positioned inside the opening along the upper end of the container and the inductor configured proximate/adjacent to the inner sidewall of the workpiece/sample.
  • a die having a thread feature or profile e.g. PET style- thread of Figure 4
  • the voltage was varied: the highest voltage was 8kV, and the lowest was 4kV.
  • the segmented die was removed from the inside of the workpiece via a puller device. Although the EMF forming worked to impart a thread configuration on the pper portion of the metal container, when visually observed, it was determined that the part would not meet commercial specifications for rigid packaging materials (e.g. aesthetics).
  • [001 15] Utilizing the pulse magnetic device described in Example 7, approximately 12 samples underwent EMF-forming to impart an EMF-feature onto the sidewalL
  • the samples had a preform diameter of 59 mm and a sidewall thickness (e.g. in straightwall portion of preform) of 0,00765" to 0.00785" di'awn and ironed from sheet of approximately 0.0176" thick.
  • the samples were metal container preforms (e.g. aluminum alloy 3104), configured with closed bottoms and a perimetrical sidewall extending up from the bottom of the metal container.
  • the preform was configured as a closed-bottom cylinder.
  • a workpiece e.g. dome, having a 59 um package diameter, made of aluminum alloy 3104.
  • a workpiece e.g. dome, having a 59 um package diameter, made of aluminum alloy 3104
  • an EMF-puIse with a voltage sufficient to imprint a logo "ALCOA” onto the dome.
  • An image of the resulting imprinted dome is depicted in Figure 28.
  • Example 7 Utilizing the pulse magnetic device described in Example 7. approximately 30 samples underwent .EMF-fomiing to impart an EMF-feature (e.g. curl) onto the upper end (opening) of the workpiece, The samples were taken from metal container preforms (e.g. aluminum alloy 3104, configured as open ended cylinders necked into an aluminum bottle chimney and then cut''removed from the bottom closed end of the workpiece (e.g. having no closed lower end). The removal of the lower portion of the aluminum bottle perform was only for expediency to fit the top chimney portion into existing holding fixtures.
  • metal container preforms e.g. aluminum alloy 3104, configured as open ended cylinders necked into an aluminum bottle chimney and then cut''removed from the bottom closed end of the workpiece (e.g. having no closed lower end).
  • the removal of the lower portion of the aluminum bottle perform was only for expediency to fit the top chimney portion into existing holding fixtures.
  • a hase tool was positioned between the lower portion o the workpiece chimney and the inductor coil.
  • the base tool was configured as an actuator to undergo displacement in the EMF field (created via the inductor) and press the workpiece chimney onto the curling die/tool (positioned on the opposite end of the workpiece chimney), imparting a curl on the upper portion of the sample,
  • the inductor was operated at 9kV.
  • one open ended cylinder was iteratively trimmed via EMF (e.g. utilizing a voltage of 6.5 k.V) on alternating ends with dies shown in Figure 41 A-B In order to evaluate utilizing EMF to achieve a trimming operation.
  • EMF e.g. utilizing a voltage of 6.5 k.V
  • the sample was a 3104 aluminum alloy with a package diameter of 59 mm and thickness (in straightwall. portion of preform) of 0.0082" to 0.0087".
  • the workpiece was configured as an open ended cylinders necked into an aluminum bottle chimney then removed from the straight, lower portion of the preform (e.g. having no closed lower end). The removal of the lower portion of the aluminum bottle perform was only for expediency to fit the top chimney portion into existing holding fixtures. As trimming was completed, each trimming operation resulted in multiple shreds of metal collecting in the bottom of the apparatus/auxiliary assembly.
  • a lab-scale pulse-magnetic device was configured as follows: Maximum Accumulated Energy: lOkJ; Output Voltage Range: 1-1 7kV; Short-Circuit Current: up to 800 kA; Capacity of the energy storage -- 68 ⁇ ' ⁇ ; Frequency: variable, up to 109 kHz; inductance: 31 nil; Supply Voltage: 460-480 V AC, 60 Hz; and Peak Line Currents (2s): 60A.
  • a pulse of electromagnetic frequency lasted for a duration of a few to several microseconds (e.g. 2 microseconds (ps) to 10 microseconds long).
  • the pulse-magnetic device consists of four modules of energy storage. Each module contains a pulse capacitor (C1...C4) with the built-in vacuum discharger (SV1...SV4). The modules are connected in parallel to output terminals of the pulse- magnetic device via a system of plane sheet, bus bars.
  • the charging operation is sufficient to charge the energy stores to a predetermined level Uo and synchronously discharging into the inductor Li in automatic mode.
  • the characteristic discharge into the inductive load is a single, a periodic or oscillating pulse with the discharging current frequency determined by parameters of the inductor.
  • the Charging unit transforms the main voltage AC of 460...480 V to high voltage DC of 20 kV. Charging is performed via the charging current controller which uses the method of pulse-phase regulation of the voltage of the high- voltage transformer, m the process of charging, the opening angle of the ihyristor Ql in the power circuit changes smoothly. Charging of capacitors C1...C4 is completed in accordance with the linear law which ensures efficiency and high resource of the pulse capacitors.
  • the capacitors CL ..C4 are charged by high, voltage in the range of L ..17 kV through ballast resistors R1...R4.
  • the Energy dosing unit stops charging by the command “Stop” and simultaneously starts the Trigger-pulse generator by the command "Discharge 5" ,
  • the initiating pulse of 6 kV from the Trigger-pulse generator is configured to start dischargers SV1...SV4 which synchronously discharge the energy storages into a common load -the working inductor LL
  • the pulse current flows through the inductor. Amplitude of this current is 10 to 500 kA, its duration is 10...1000 ⁇ $ depending on the level of the stored energy and parameters of the working inductor. [00133]
  • the energy which is stored by the Energy storage is smoothly dosed by varying the charge voltage: Wo €r*UV ' )/2, where (1 ⁇ 2 ⁇ total capacity of the energy storage. Uo - charge voltage.
  • the pulse magnetic device is comprised of the basic power unit the remote control station, the technological table, and protective box,
  • the power unit includes: the high- voltage rectifier, the charging transformer, the power transformer for the Trigger-pulse generator and the ballast resistors of the charging unit, with the capacitors of the energy storage configured and the Trigger-pulse generator also located in the unit.
  • the following elements of external connections are placed on the side surface of the pedestal of the housing: the iead-in of the supply network cable, the plug-and-socket for connection of the cable of the remote-control station, terminals for grounding wires of the power unit and discharging rod.
  • the discharging rod is set close to the pulse magnetic device and is configured to connect to the power unit.
  • the clamping device with output terminals for connection of the inductor is placed on the front panel of the housing,
  • the teclmological table for placement of the inductor and working tooling is mounted on the front panel of the power unit.
  • the Energy dosing block - ⁇ A5 and Voltage display- A6 are located in the remote- control station. Controls, signal indicators, the kilovolrmeter of the current value of charge voltage are placed on the panel of the remote-control station.
  • the pulse-magnetic device utilized in one or more aspects of the instant disclosure is configured to convert electrical energy, accumulated by the capacitive energy storage, to the electromagnetic field, arising in the inductor during discharge of the energy storage.
  • the electromagnetic field of the inductor induces eddy currents in the processed material (e.g. portion of the workpiece undergoing EMF forming). Interaction of the electromagnetic field of the inductor with eddy currents in the processed material (e.g. portion of the workpiece adjacent to the inductor) leads to strain work and pulse heating of the material.
  • the lab-scale EMF forming device described herein was utilized in the examples (experimental section) described herein.
  • a flyer tool was positioned between the workpiece and the inductor coil and configured as an actuator to undergo displacement in the EMF field (created via the inductor) and press the tool with lettering secured therein into the bottom of the workpiece/alum.inum bottle (e.g. bottom, outer surface of the workpiece),
  • the resulting incised logo was visually inspected for quality. It was found that all letters imprinted against the workpiece, leaving a legible message, "ALCOA ALUMINUM MADE IN THE USA" on the bottom of the sample.
  • the logo was visually inspected and confirmed to have an acceptable definition incised upon it (e.g. all letters were fully visible, fracture free).
  • Container e.g. closed-bottom, metal container, shaped can, bottle
  • Open end (e.g. configured at top) 14
  • Thread (e.g. thread configuration/lug pattern) 36
  • Carrier ring hp (e.g. formed via EMF and configured to hold/secure carrier ring insert) 90
  • Imprint feature (e.g. on bottom/dome vs. on sidewa!l/body) 42
  • Vent slots e.g. channels, grooves configured generally axially
  • individual thread/lug e.g. individual raised ridges interspaced with/defined by valleys
  • individual valleys e.g. configured between threads, to define individual thread(s)/liig(s) and thread/lug depth
  • Pilfer band (configured to accommodate pilfer ring) 52
  • Curl e.g. or flange, or flare
  • Mechanical attachment area on die(s) (e.g. configured on outer sidewail of upper portion of container) 76
  • Attachment components e.g. screws

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Containers Having Bodies Formed In One Piece (AREA)

Abstract

La présente invention concerne de manière générale divers procédés de formage électromagnétique de pièces ainsi que les pièces ainsi obtenues. Plus particulièrement, la présente invention concerne divers modes de réalisation pour conférer des caractéristiques de formage électromagnétique à des pièces ; des pièces présentant des caractéristiques de formage électromagnétique obtenues se présentant sous forme de récipients métalliques.
PCT/US2016/065793 2015-12-09 2016-12-09 Produits métalliques et procédés de formation de composants comprenant lesdits produits WO2017100548A1 (fr)

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US62/265,180 2015-12-09

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CN110421089A (zh) * 2019-08-12 2019-11-08 吴振飞 一种五金制品卷边冲压模具
EP3684524A4 (fr) * 2017-09-18 2021-06-09 Ball Corporation Procédé et appareil pour gaufrer et dégaufrer des récipients métalliques

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CA2947167C (fr) 2014-05-04 2022-06-21 Belvac Production Machinery, Inc. Systemes et procedes de formation electromagnetique de recipients
EP3184188B1 (fr) * 2015-12-23 2024-04-24 Guala Closures S.p.A. Procédé de formage d'un élément de fermeture

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US20090235715A1 (en) * 2008-03-15 2009-09-24 Elringklinger Ag Method for selectively forming (plastic working) at least one region of a sheet metal layer made from a sheet of spring steel, and a device for carrying out this method
US20100147043A1 (en) * 2008-12-12 2010-06-17 Tung-Chen Cheng Device for Producing Patterns
WO2015054284A2 (fr) * 2013-10-08 2015-04-16 The Coca-Cola Company Récipient métallique façonné, microstructure, procédé pour fabriquer un récipient métallique façonné
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EP3684524A4 (fr) * 2017-09-18 2021-06-09 Ball Corporation Procédé et appareil pour gaufrer et dégaufrer des récipients métalliques
CN110421089A (zh) * 2019-08-12 2019-11-08 吴振飞 一种五金制品卷边冲压模具
CN110421089B (zh) * 2019-08-12 2020-12-11 武汉普泰金属制造技术有限公司 一种五金制品卷边冲压模具

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