Shaped, Threaded Metal Can

Abstract

A food or drink container kit includes a metal container including a round threaded neck having at least one integrally formed thread. The kit also includes a metal press-on, twist-off closure comprising a round skirt including a gasket material 5 located on at least a portion of the interior of the skirt, a seal forming between the neck and skirt when the closure is placed on the container and heated.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of prior U.S. application Ser. No. 11/811,362, filed Jun. 8, 2007 that is currently pending, which is incorporated herein by reference in its entirety.

BACKGROUND

The application generally relates to metal food containers. The application relates more specifically to shaped metal food containers with screw-top closures and methods of making the same.

SUMMARY

One embodiment relates to a two piece container. The two piece container includes a can end, can body, neck portion, body portion and a double seam. The can end has an outside diameter. The can body is formed from a single sheet of metal joined with a seam to form a cylinder having a top end and a bottom end. The seam extends from the top end to the bottom end. The can body includes a neck portion formed at the top end and a body portion. The neck portion defines the can opening surrounded by a curled portion of the sheet metal and a threaded portion including at least one thread formed from the sheet metal adjacent to the curled portion. The body portion has a variable-diameter side-wall that extends from the neck portion to the bottom end. The side-wall has a first lobe portion with a diameter between 100% and 120% of the end diameter, a second lobe portion with a diameter between 95% and 110% of the end diameter and a transition portion joining the lobed portions with a diameter between 80% and 95% of the end diameter. The double seam hermetically seals the can end to the body portion.

Another embodiment relates to a two piece container. The two piece container includes a can end, can body, neck portion, body portion and a double seam. The can end has an outside diameter. The can body is formed from a single sheet of metal joined with a seam to form a cylinder having a top end and a bottom end. The seam extends from the top end to the bottom end. The can body includes a neck portion formed at the top end and a body portion. The neck portion defines a can opening surrounded by a toroid formed from the sheet metal and a threaded portion including at least one thread from the sheet metal adjacent to the toroid. The body portion has a variable-diameter side-wall that extends from the neck portion to the bottom end. The side-wall has a first lobe portion with a diameter between 100% and 120% of the end diameter, a second lobe portion with a diameter between 95% and 110% of the end diameter and a transition portion joining the lobed portions with a diameter between 80% and 95% of the end diameter. The body portion has a length defined by the distance between the neck portion and the bottom end that is between 165% and 230% of the end diameter. The double seam hermetically seals the can end to the body portion.

Yet another embodiment relates to a two piece container. The two piece container includes a can end, can body, neck portion, side-wall and a double seam. The can end has an outside diameter. The can body is formed from a single sheet of metal joined with a seam to form a cylinder having a top end and a bottom end. The can body includes a neck portion formed at the top end and a body portion. The neck portion defines a can opening surrounded by a toroid formed from the sheet metal and a threaded portion including at least one thread which wraps at least 1½ times around the neck portion and is formed from the sheet metal adjacent to the toroid. The body portion has a variable-diameter side-wall that extends from the neck portion to the bottom end. The side-wall has a first lobe portion with a diameter between 100% and 120% of the end diameter, a second lobe portion with a diameter between 95% and 110% of the end diameter and a transition portion joining the lobed portions with a diameter between 80% and 95% of the end diameter. The body portion has a length defined by the distance between the neck portion and the bottom end that is between 165% and 230% of the end diameter. The double seam hermetically seals the can end to the body portion.

BRIEF DESCRIPTION OF THE FIGURES

The application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which:

FIG. 1 is a perspective view of a metal container having a threaded neck, according to an exemplary embodiment;

FIG. 2 is a side profile view of a metal container having a threaded neck, according to an exemplary embodiment;

FIG. 3 is a close-up side profile view of the threaded neck, according to an exemplary embodiment;

FIG. 4 is a close-up side profile view of the threaded neck having a press-on twistoff closure installed, according to an exemplary embodiment;

FIG. 5 is a partial sectional view of the container threading having the closure installed, according to an exemplary embodiment;

FIG. 6 is a partial sectional view of the container threading having the closure installed, according to an alternative embodiment;

FIG. 7A is a side profile view of a threaded neck, according to an alternative embodiment;

FIG. 7B is a side profile view of a threaded neck having a closure installed, according to an alternative embodiment;

FIG. 8 is a flow chart of a method of making the metal container, according to an exemplary embodiment.

FIG. 9 is a side profile view of a metal container during manufacturing, prior to forming threading into the container neck, according to an exemplary embodiment.

FIG. 10 is a side profile view of a metal container with the improved shaped having a threaded neck, according to an exemplary embodiment.

FIG. 11 is a side profile view of a metal container with the improved shaped having a threaded neck, according to an alternative embodiment.

FIG. 12 is a side profile view of a metal container with the improved shaped having a threaded neck, according to an alternative embodiment.

FIG. 13 is a side profile view of a metal container with the improved shaped having a threaded neck, according to an alternative embodiment.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

Before turning to the figures which illustrate the exemplary embodiments in detail, it should be understood that the application is not limited to the details or methodology set forth in the following description or illustrated in the figures. It should also be understood that the phraseology and terminology employed herein is for the purpose of description only and should not be regarded as limiting.

Referring generally to the figures, a metal container (i.e., a can) is shown having a threaded neck integrally formed from the metal of the container body. The threads are formed to fit a screw-top closure and the closure is a press-on, twist-off closure. The container is suitable for use with a thermal retort process with or without over-pressure. Referring still to the figures in general, a process of making a metal container is provided so that the integrally formed threads are formed from a relatively unworked or un-thinned portion of metal once the majority of the container body has been formed.

Referring to FIG. 1, a perspective view of metal container 1 is shown, according to an exemplary embodiment. Metal container 1 includes a top end 2, a body 4, and a bottom end 6. Container 1 and body 4 are shown as substantially cylindrical (i.e., the container walls or piece forming body 4 are curvilinear). According to various other embodiments, container 1 may take any number of other container shapes as may be desirable for different applications or aesthetic qualities. For example, container 1 may be formed to have one or more angles that create a polygonal cross-section such as a rectangular cross-section. Container 1 and body 4 could also be formed to have any number of edges, curves and/or beads as may be desirable for end-users and/or for structural integrity purposes. Metal container 1 may be sized to store about eight ounces of liquid contents or may be sized differently (e.g., less than eight ounces, more than eight ounces, twelve ounces, sixteen ounces, thirty-two ounces, etc.).

According to an exemplary embodiment, the metal of container 1 is about 0.008 inches thick and is primarily made of tin plated steel. According to various other exemplary embodiments, the metal of container 1 is formed from steel having a working gauge range from about 0.006 inches thick to about 0.013 inches thick, or other available working ranges. According to various other alternative embodiments, container 1 may be formed of aluminum, tin free steel and/or another metal material that may be used to form metal food containers. The material of container 1 may also be more or less thick along certain structures or locations of body 4. For example, in the middle of the side walls of container body 4, the material may be more thin than material closer to the top end or bottom end.

The top of container 1 and container body 4 angles inward to create a frusto-conical portion 8. A threaded neck 10 extends from the frusto-conical portion 8. According to an exemplary embodiment, frusto-conical portion 8 is angled around thirty-seven degrees from the vertical surfaces of body 4 and sized so that the diameter of the neck with a closure installed thereon is smaller than the diameter of body 4. According to various other embodiments, frusto-conical portion 8 is angled more or less than thirty-seven degrees from vertical. This sizing and structure may create an aesthetically pleasing container top, provide a user with increased leverage for opening the screw-top and/or prevent the container top, threads, and closure from experiencing some amount of the unavoidable contact that containers typically have with adjacent containers or other structures during manufacture, shipping and/or use. According to other various exemplary embodiments, frusto-conical portion 8 may not be present on the container, may be characterized as a cone-shaped shoulder area, or may take any other shape or size.

Referring to FIG. 2, a side view of metal container 1 is shown, according to an exemplary embodiment. At bottom end 6 of metal container 1, one or more bottom seal structures 21 may fixably seal a bottom end piece to container body 4. According to an exemplary embodiment, bottom seal structures 21 are a double seam including folds of metal adjoining a container flange (e.g., 92 shown in FIG. 9) and a bottom end piece (i.e., sanitary end) so that a substantially hermetic seal is created.

Referring to FIGS. 2 and 3, detail of threaded neck 10 is shown, according to an exemplary embodiment. Threaded neck 10 is integrally formed from the metal of container 1, container body 4 and/or frusto-conical portion 8. Threaded neck 10 extends upward from frusto-conical portion 8 along the vertical axis of container body 4. The radius and height of threaded neck 10 is generally determined based on the radius and depth of the closure with which the threaded neck will be used. A lower ring 12 and one or more threads 14 extend from threaded neck 10.

According to an exemplary embodiment, thread 14 is a single thread conforming to the Glass Packaging Institute's (GPI) glass finish designation number 465, last revised Feb. 5, 1999. According to other alternative embodiments, different thread designations or specifications may be used to create the container's threads (e.g., GPI glass finish designation number 2215, etc.). Furthermore, as shown in the Figures, thread 14 may wrap around the neck portion more than 1 time. Preferably between 1½ and 2½ times.

Neck edge 16 will generally be curled or rounded to provide a suitable sealing surface (e.g., uniform and having some substantial diameter relative to the gauge of the container walls). Neck edge 16 may also be curled or rounded to provide a suitable surface for mouth contact or drinking. For example, neck edge 16 is shown as a curled neck edge, curling to the exterior of threaded neck 10. The exterior diameter of the neck and structures of the neck may be appropriately sized to allow the closure to function properly. According to an exemplary embodiment, the neck is sized per certain threading specifications (e.g., GPI glass finish designation number 2215,465, etc.).

Referring to FIG. 4, a side view of metal container 1 is shown, metal container 1 having closure 40 (e.g., cap, cover, top, etc.) shown installed on a round threaded neck 10 of the previous FIGS., according to an exemplary embodiment. Closure 40 includes a closure top end 42, a round closure skirt portion 44 and a closure bottom rim 46. When closure 40 is installed onto threaded neck 10, closure bottom rim 46 is adjacent lower ring 12. Closure 40 may have a diameter of 40 millimeters (e.g., shown as diameter “D” on FIG. 4), but may be sized differently to fit differently sized or configured threaded necks. According to one alternative embodiment, closure 40 is a 48 millimeter diameter closure. According to an exemplary embodiment, relatively deep closures may be desirable for use with threaded necks having a single thread. According to an exemplary embodiment, closure 40 has a closure style of “40 DER” that may be described as having a diameter of 40 millimeters, a deep closure skirt, and a vacuum safety button that requires a 20 inch Hg vacuum to verify the seal is intact. According to various other exemplary embodiments, the closure may include other tamper evidencing features or no tamper evidencing features.

Referring to FIG. 5, a sectional view of threaded neck 10 and closure 40 are shown, according to an exemplary embodiment. Closure 40 is a press-on, twist-off type metal closure (i.e., push-on/twist-off cap, etc.). A press-on, twist-off closure refers to a closure that is initially coupled to a body by a press-on (i.e., push-on) movement, but then is later removed or reattached by a twisting motion. According to an exemplary embodiment, closure skirt portion 44 is smooth such that closure skirt portion does not have any threads or other metal structures that would prevent closure 40 from being pressed onto the threaded neck or threads of a container. According to various alternative embodiments, closure 40 may be a plastic closure or another closure other than metal.

According to an exemplary embodiment, the metal of closure 40 is between about 0.006 inches and 0.008 inches thick. Closure underside or interior surface 41, along at least some of the closure skirt portion 44, is coated with a gasket or gasket material 50. According to an exemplary embodiment, gasket 50 is a plastisol material or compound applied to the top and side surfaces of closure underside 41. Materials other than plastisol may serve as the gasket. Plastisol may provide sufficient resistance to acids of food products that may come into contact with the plastisol, may permit hot-fill processes to produce a vacuum seal, and may withstand a heat-based sterilization or cooking process. A sufficient amount of the gasket material coats closure underside 41 such that the outer diameter of thread 14 is larger than the inner diameter of gasket 50. The plastisol compound does not contain preformed thread indents or receiving structures. Rather, steam or another application of heat is used to soften the plastisol material prior to pushing the material onto the threaded neck of the container. The difference between the diameter of the gasket material and the structures of threaded neck 10 cause the softened gasket 50 to move and flow around thread 14 so that many portions of threaded neck 10 are surrounded by gasket 50 such that the interface(s) between threaded neck 10 and gasket 50 form a hermetic seal. Following cooling of the plastisol, the plastisol stiffens or hardens to create a resilient foam that may act to maintain the hermetic seal with threads 14. The cooled plastisol may have a semi-permanent or permanent impression of the structures of the threaded neck such that the closure may be removed and/or reclosed or resealed with a twist-off or twist-on motion.

According to an exemplary embodiment, gasket 50 specifically comprises a plastisol compound that may be characterized as a “508 compound” or similar material. Gasket 50 may be a liquid applied gasket or any other suitable gasket material.

Referring to FIG. 6, a sectional view of a threaded neck and closure 40 is shown, according to an alternative exemplary embodiment. In the embodiment shown in FIG. 6, neck edge 16 is curled to the interior of the threaded neck. Sealing compound 61 may prevent a raw metal edge from exposure to moisture that may rust and/or corrode the raw metal.

Referring to FIGS. 7A and 7B, a side view of a threaded container neck having multiple independent threads is shown, according to an alternative embodiment. Multiple independent threads may allow the height of a closure to be decreased.

Referring to FIG. 8, a flow chart of a process of making and using a metal container such as metal container 1 shown in the previous FIGS. is shown, according to an exemplary embodiment. Metal container 1 may be made using a variety of methods. For example, metal container 1 may be formed using a drawn and ironed manufacturing process, a drawn and redrawn manufacturing process and/or a variety of alternative manufacturing processes. According to the embodiment shown in FIG. 8, a drawn and ironed process is used to manufacture metal container 1. Raw material may come from a source in a variety of forms. For example, raw material may come from a metal supplier in a large coil. This coil may be upended or otherwise moved into a position to be unreeled by an unreeler. The unreeled metal from the unreeler may be fed into a lubricator. Lubricant may be applied to the unreeled metal by a series of rollers or otherwise. Lubricant improves the workability of the raw material later in the process.

A blank may be formed from the lubricated raw material or otherwise provided (step 802). The blank may be sized such that the blank may be fanned to create the container body. Blanks may be formed using a variety of processes including cutting processes. For example, the blanks may be fanned using a press cut-activity. A cupping press machine may cut a blank that is shaped like a disk. Once a blank has been formed or otherwise provided, the blank is formed into a cup (step 804). This cup forming activity may take place within the same machine and close-in-time to the blank cutting step. For example, a single machine may act in a double action; a first action may cut the blank and a second action may form the cup. A cup may then be ejected and advanced to the can handling system.

The cup fanned from the blank may be a relatively short or squat cup. The bottom of the cup will be approximately the same metal thickness as the original blank. The sides of the cup may be worked slightly and may be thinner than the original metal of the blank. Depending on the target height of the metal container, the cup will be subjected to a drawn and ironed process that forms the container body shape from the cup (step 806). The container body shape may be fanned using a machine generally referred to in the art as a “bodymaker.” This machine works or forms the cup with a punch and ironing rings in a progression to form the shape and size of the container's body walls. While this drawn and ironed process allows the container to be formed to a height taller than the cup, the ironing reduces the wall thickness and often results in the walls being too thin and/or brittle to reliably form fine and precise structures such as threads. The base of the formed container, however, is still approximately the same metal thickness as the original blank (i.e., the original cup base is still the base of the fanned container as of this step, and is relatively unworked and un-thinned). This relatively unworked or un-thinned container base may be reliably formed into the thread. So, the base of the formed container shape, or the cup bottom, becomes the top of the final container body and the container neck is fanned using the base of the formed container (step 808). During this step or another step, the container neck may be cut to create the primary container opening that the closure will cover. According to various exemplary embodiments, the primary container opening may be cut prior to forming the neck from the base of the formed container.

After the neck has been formed and the primary container opening has been cut, threading may be formed from the container neck (step 810). The threading may be formed using an interior press, an exterior press, and/or any other suitable thread forming process. The threads may be formed to fit a press-on, twist-off closure. According to an exemplary embodiment, the thread or threads may also be formed such that a threaded neck and thread metal thickness of about at least 0.007 inches is maintained. In addition to maintaining a certain thickness of the metal, it may be important to maintain a certain low percentage of thinning. For example, while the sides of the container may be thinned during the drawing process down to about 40 percent of the original thickness of the blank, the metal used to form the threaded neck and the threads should not be thinned by more than 10 percent of the original blank thickness. According to an exemplary embodiment, no portion of the threaded neck and/or threads are thinned more than 12 percent and maintain a thickness of about at least 0.007 inches. According to various alternative embodiments, greater thinning percentages (e.g., thread thinning of greater than 12 percent, thinning of up to 30 percent, etc.) may be used to create the threaded neck and/or threads. According to yet other various embodiments, container wall and/or thread thickness may be less than 0.007 inches.

According to various exemplary embodiments, the threading will be thick enough and resilient enough to withstand various typical thread forming and container handling processes. The threading should be prominent enough so that when human applied rotation of the closure relative to the container body occurs, the threads provide enough leverage in the plastisol to break the vacuum seal (e.g., around 20 in Hg) holding the closure onto the container body. The threading may thereby be configured to allow the consumer easy initial access to the container contents and thereafter allow the consumer to reclose the container with sufficient thread-provided leverage and threading accuracy to create a liquid-type seal (i.e., substantially watertight) upon reclosure.

The container end opposite the neck (i.e., the can bottom end) may be fixably enclosed (step 812) after a variety of steps in the process. According to an exemplary embodiment, a container bottom end part is attached to the container end opposite the neck (i.e., the can bottom end shown in FIGS. 1 and 2) such that a bottom most portion of the container body side walls and the edge of a bottom end are interfolded together to create a fixed and hermetic seal.

After both the top end and bottom end of the container are formed, the container may be filled (step 814). While the open container may be filled with any variety of materials or contents, the container is filled with food according to an exemplary embodiment. The food may be pre-cooked, partially pre-cooked, warmed or cool. According to an exemplary embodiment, the container is hot-filled.

Once the container has been filled, the closure may be pressed onto the threaded neck (step 816). Step 816 may include heating the closure prior to and/or during the activity of pressing the closure onto the threaded neck. According to an exemplary embodiment, the closure is a press-on, twist-off closure lined with a plastisol material. The plastisol may be partially fluid, softened and/or heated prior to pushing the closure onto the threads such that the friction between the plastisol material and the threaded structures is low enough to allow the closure to be fully applied (i.e., installed, slidably installed, rotatably installed) and/or formed around the threads (e.g., pressed onto the threads). According to an exemplary embodiment, steam or hot air may be applied to the closure to adequately soften the plastisol material prior to pressing the closure onto the threads. According to various exemplary embodiments, the steam temperature applied to the closure is around 190 degrees Fahrenheit to 210 degrees Fahrenheit.

The container may be subjected to a thermal retort process (step 818). A thermal retort process may generally be characterized as a process of subjecting the filled and closed container to a cooking or sterilization process having different heat, time and pressure variables sufficient to substantially sterilize the interior and contents of the food container. Some thermal retort processes may be overpressure thermal retort processes where pressure outside the container is substantially matched or slightly exceeded relative to the pressure that builds on the inside of the container due to heating a sealed container. Overpressure thermal retort processes may generally include inserting a filled and closed container (or group of containers) into a retort vessel that heats the container via steam, water or a combination of steam and water and provides overpressure to prevent container deformation or breakage due to pressure build-up inside the container.

During a thermal retort process, the container and the food inside the container will be brought to a temperature of about at least 200 degrees Fahrenheit. According to various exemplary embodiments, a thermal retort process may include bringing the container to a temperature of between 220 degrees Fahrenheit and 260 degrees Fahrenheit. According to yet other embodiments, a thermal retort process includes bringing the container to a temperature of at least 240 degrees Fahrenheit. According to a preferred embodiment, the container and closure should be able to withstand a thermal retort process of about 250 degrees Fahrenheit with about 32 pounds per square inch of overriding pressure for a period of about 45 minutes and 3 pounds per square inch differential between overriding pressure and internal pressure. Processing step 818 may also include steps of controllably ramping up temperature, cooking and then controllably bringing temperature down or dropping temperature so that a strong vacuum (e.g., 20 inHg to 25 inHg) is formed between the closure and container body that substantially holds the closure onto the neck and maintains the hermetic seal. According to various other exemplary embodiments, a weaker or stronger vacuum may be created and maintained.

The specifications of the thermal retort process will vary depending on the food being cooked, the machinery (e.g., retort vessel) being used, the amount of agitation used with the heat and any number of other variables. It maybe desirable to cook different types of food to certain different minimum temperatures for certain different minimum amounts of time to ensure sterilization. A container and closure of the present application should be able to withstand a variety of typical temperature, time and pressure levels such that the container may be considered suitable for use with a thermal retort process for a wide variety of foodstuffs, including, for example, adult nutritional drinks, to those skilled in the art of food sterilization using a retort process.

During the manufacturing process, the metal container may also be washed and coated as required for workability, cleanliness of the container and longevity of the container surfaces when subjected to container contents, liquids and/or air.

Referring to FIG. 9, a profile view of a container body prior to forming the threading is shown, according to an exemplary embodiment. As discussed above with reference to the process of FIG. 8, a container neck 90 will be formed using the base of the formed cup or container shape. Container neck 90 may be formed prior to or after cutting a primary container opening into the container. Unformed container neck 90 may be taller than a formed threaded neck as the forming process will generally shorten the neck as it bends or otherwise uses the material of the neck in shaping the thread or threads. Furthermore, excess material may be cut or otherwise removed from the top of container neck 90 and/or the edges may be rolled or folded over to create the outward or inward rolls of FIGS. 5 and 6. Referring still to FIG. 9, bottom end flanges 92 maybe formed or created by machinery of the container's manufacturing process to provide a beginning interface or structure that a bottom end part may be interfolded with to create a fixably attached and hermetically sealed (e.g., dry-sealed) bottom end.

Referring to FIGS. 10-13 generally, a container is shown which includes a top container end, a bottom container end and a can body. Cans of this type may include a shaped can body (as shown by examples), separately formed bottom container end and a separately formed top container end. The container ends may be fabricated all, or in part, from a metal (e.g., steel) and are joined to the can body with a rolled joint double-seam or soldered joint creating a hermetic seal. The container body can be formed from a rolled piece of metal with a seam or welded joint extending from the top end of the can body to the bottom end of the can body.

The relative dimensions, including angles, in FIGS. 10-13 are to scale. Actual measurements of FIGS. 10-13 will disclose the relative dimensions and angles of the preferred embodiments. Accordingly, actual dimensions not expressly set out in this description, can be determined by using the ratios of dimensions measured in FIGS. 10-13 in combination with the express dimensions set out in this description.

Referring to FIGS. 10-13, the container body includes a neck portion and a body portion. The neck portion is located at the top end of the body portion and includes a curled portion of sheet metal and a threaded portion. The threaded portion includes one or more threads formed from the metal adjacent to the curled portion. The curled portion may be formed by taking the end portion of the sheet metal and curling it inwardly in order to form a hollow toroid that surrounds the opening of the top can end. The hollow toroid that is formed is referred to as a torus. The hollow toroid, or torus, that is formed may have a generally circular cross-section. In alternative embodiments, the threaded portion may include at least one thread that wraps around the neck portion at least 1½ times. Alternative embodiments may further include a curled portion formed by taking the end portion of the sheet metal and curling it outwardly to form the hollow toroid surrounding the opening in order to form a torus. Additionally, the hollow toroid portion may have a generally elongated cross-section in various other embodiments.

Referring to FIGS. 10-13, the body portion has a length that includes a side wall that extends from the neck portion to the bottom end of the container. The side wall includes a first lobe portion, a second lobe portion and a transition portion located between the first and second lobes. Each portion of the side wall has a diameter. The first diameter is the diameter at the widest portion of the first lobe located between the transition portion and the bottom of the neck portion. The second diameter is the diameter at the widest point of the second lobe located between the transition portion and the bottom container end of the container body. The third diameter is located at the transition portion and is the diameter at the narrowest point of the container body.

Referring to FIG. 10, container 100 includes body portion 102, first lobe portion 104, second lobe portion 106, transition portion 108, bottom container end 110, length 112, first diameter D114, second diameter D116, third diameter D118 and end diameter D120.

The dimensions of container 100 are suitable with various diameters and lengths for various applications. Exemplary dimensions are illustrated in centimeters (cm). Exemplary dimensions with the diameters and length are between 6.0 cm and 12 cm in diameter and 10 cm and 20 cm in length. In one embodiment diameter D114 is 102% of diameter D120, diameter D114 is about 7.2 cm and diameter D120 is about 7.0 cm. In this same embodiment diameter D116 is 102% of diameter D120, diameter D116 is about 7.2 cm and diameter D120 is about 7.0 cm. Also, in this same embodiment, diameter D118 is 87% of diameter D120, diameter D118 is about 6.1 cm and diameter D120 is about 7.0 cm. This embodiment also includes length 112 that is 165% of diameter D120, length 112 is about 11.6 cm and D120 is about 7.0 cm. In additional embodiments diameter D114 can be substantially similar to or greater in length than diameter D120. Diameter D116 can be substantially similar, greater or lesser in length than diameter D120, diameter D118 can be substantially similar or less than the length of diameter D120 and length 112 is greater in length than diameter D120.

Referring to FIG. 11, container 200 includes body portion 202, first lobe portion 204, second lobe portion 206, transition portion 208, bottom container end 210, length 212, first diameter D214, second diameter D216, third diameter D218 and end diameter D220.

The dimensions of container 200 are suitable with various diameters and lengths for various applications. Exemplary dimensions are illustrated in centimeters (cm). Exemplary dimensions with the diameters and length are between 6.0 cm and 12 cm in diameter and 10 cm and 20 cm in length. In one embodiment diameter D214 is 101% of diameter D220, diameter D214 is about 7.5 cm and diameter D220 is about 7.4 cm. In this same embodiment diameter D216 is 99% of diameter D220, diameter D216 is about 7.3 cm and diameter D220 is about 7.4 cm. Also, in this same embodiment, diameter D218 is 86% of diameter D220, diameter D218 is about 6.4 cm and diameter D220 is about 7.4 cm. This embodiment also includes length 212 that is 218% of diameter D220, length 212 is about 16.1 cm and D220 is about 7.4 cm. In additional embodiments diameter D214 can be substantially similar to or greater in length than diameter D220. Diameter D216 can be substantially similar, greater or lesser in length than diameter D220, diameter D218 can be substantially similar or less than the length of diameter D220 and length 212 is greater in length than diameter D220.

Referring to FIG. 12, container 300 includes body portion 302, first lobe portion 304, second lobe portion 306, transition portion 308, bottom container end 310, length 312, first diameter D314, second diameter D316, third diameter D318 and end diameter D320.

The dimensions of container 300 are suitable with various diameters and lengths for various applications. Exemplary dimensions are illustrated in centimeters (cm). Exemplary dimensions with the diameters and length are between 6.0 cm and 12 cm in diameter and 10 cm and 20 cm in length. In one embodiment diameter D314 is 107% of diameter D320, diameter D314 is about 7.8 cm and diameter D320 is about 7.3 cm. In this same embodiment diameter D316 is 107% of diameter D320, diameter D316 is about 7.8 cm and diameter D320 is about 7.3 cm. Also, in this same embodiment, diameter D318 is 90% of diameter D320, diameter D318 is about 6.6 cm and diameter D320 is about 7.3 cm. This embodiment also includes length 312 that is 179% of diameter D320, length 312 is about 13.1 cm and D320 is about 7.3 cm. In additional embodiments diameter D314 can be substantially similar to or greater in length than diameter D320. Diameter D316 can be substantially similar, greater or lesser in length than diameter D320, diameter D318 can be substantially similar or less than the length of diameter D320 and length 312 is greater in length than diameter D320.

Referring to FIG. 13, container 400 includes body portion 402, first lobe portion 404, second lobe portion 406, transition portion 408, bottom container end 410, length 412, first diameter D414, second diameter D416, third diameter D418 and end diameter D420.

The dimensions of container 400 are suitable with various diameters and lengths for various applications. Exemplary dimensions are illustrated in centimeters (cm). Exemplary dimensions with the diameters and length are between 6.0 cm and 12 cm in diameter and 10 cm and 20 cm in length. In one embodiment diameter D414 is 116% of diameter D420, diameter D414 is about 8.0 cm and diameter D420 is about 6.9 cm. In this same embodiment diameter D416 is 106% of diameter D420, diameter D416 is about 7.3 cm and diameter D420 is about 6.9 cm. Also, in this same embodiment, diameter D418 is 94% of diameter D420, diameter D418 is about 6.5 cm and diameter D420 is about 6.9 cm. This embodiment also includes length 412 that is 174% of diameter D420, length 412 is about 12.0 cm and D420 is about 6.9 cm. In additional embodiments diameter D414 can be substantially similar to or greater in length than diameter D420. Diameter D416 can be substantially similar, greater or lesser in length than diameter D420, diameter D418 can be substantially similar or less than the length of diameter D420 and length 412 is greater in length than diameter D420.

According to one alternative embodiment, it may be desirable to pre-coat the interior of a metal food container to ensure that a thorough and even application of protective coating is applied to the interior of the container. Using pre-coated blanks of material, however, it may be desirable to form the container using a process other than a drawn and ironed process described above. In this process, a container may be formed using one or more steps to form the basic shape of the container. More particularly, a metal container using pre-coated material may be made by the process of forming a container body from a blank of pre-coated metal, forming a threaded neck from a top end of the container body to create an integrally formed thread configured to receive a closure, and filling the container body with foodstuffs. Once filled, the process may further include pushing a closure onto the threaded neck, the closure and the threaded neck creating a hermetic seal when subjected to a heating and cooling process such that a plastisol material lining the interior of the closure resiliently engages the threads and a vacuum provides a physical force to hold the closure onto the container top end.

According to various other exemplary embodiments, the interior and/or exterior of the container are coated with a preservative coating after the container is formed or substantially formed. According to yet other exemplary embodiments, the container is precoated and then coated with one or more post-forming coats. Coating may be applied via spraying or any other suitable method. Different coatings may be provided for different food applications. The coating material may be a vinyl, polyester, epoxy and/or other suitable preservative spray. The coating, for example, may be a spray epoxy such as PPG Z12215L, sold by PPG Industries, Inc. According to other embodiments, the coating may be a coating such as sold by Valspar Coatings (e.g., coating number 6256-069, etc.).

According to various exemplary embodiments, a user of various embodiments of a metal container described throughout this application may open the container by applying an opening torque to the closure, container body and/or other structures of the container to rotatably remove the closure. Using the thread indents or molds created in the plastisol, the thread surfaces should be able to slide along the interfacing plastisol such that the closure is directed upward by the spiral or helix nature of the threads. With enough twisting, the closure will be directed upward until the hermetic seal between the closure and the container will be broken and the vacuum inside the container will be released. If the closure has a safety-button type incorporated, a safety-button formerly depressed when the vacuum was maintained will pop-up to indicate to the user that the seal has been broken.

According to any preferred embodiment, although the container includes a closure at the top end, and a bottom end part at the bottom end, the container embodies a 2-piece can in that one continuous blank of material forms the container body, neck, and threads and a vertical seam or weld line does not run down the side wall of the container. According to various alternative embodiments, the container may be a three-piece can wherein a flat blank or sheet of material is shaped or bent until a first side and a second side of the shaped sheet may be welded together.

As the container and the food inside the container are heated, the inside of the container is sterilized so that the food does not spoil. When the container begins cooling, the closure is fixed to the threads by the plastisol cooling and a negative pressure relationship or a vacuum that develops on the container interior. As the plastisol cools, it hardens and forms around the threads of the container and resembles a resilient foam. As the container interior cools, a vacuum creates a physical force that provides a seal between the closure and the rest of the container interior.

It should be understood that the phrase “food” used to describe various embodiments of this disclosure may refer to dry food, moist food, liquid, or any other drinkable or edible material, regardless of nutritional value.

According to various other embodiments, a container kit may be provided utilizing various containers and closures described herein.

While the exemplary embodiments illustrated in the figures and described herein are presently preferred, it should be understood that these embodiments are offered by way of example only. Accordingly, the present application is not limited to a particular embodiment, but extends to various modifications that nevertheless fall within the scope of the appended claims. The order or sequence of any processes or method steps may be varied or re-sequenced according to alternative embodiments.

The construction and arrangement of the container as shown in the various exemplary embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present application. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the scope of the present application.

It should be noted that although the figures herein may show a specific order of method steps, it is understood that the order of these steps may differ from what is depicted. Also, two or more steps may be performed concurrently or with partial concurrence. It is understood that all such variations are within the scope of the application.

Claims

1. A two piece container, comprising:

a can end having an outside end diameter;

a can body formed from single sheet of metal joined with a seam to form a cylinder having a top end and a bottom end, the seam extending from the top end to the bottom end, the can body including a neck portion formed at the top end and a body portion;

the neck portion defining a can opening surrounded by a curled portion of the sheet metal and a threaded portion including at least one thread formed from the sheet metal adjacent to the curled portion;

the body portion having a variable-diameter side-wall extending from the neck portion to the bottom end, the side wall including a first lobe portion, a second lobe portion and a transition portion joining the lobed portions wherein the side-wall has a first diameter at the first lobe portion which is between 100 and 120% of the end diameter, a second diameter at the second lobe portion which is between 95 and 110% of the end diameter, and a third diameter at the transition portion which is between 80 and 95% of the end diameter; and

a double seam which hermetically seals the can end to the body portion.

2. The container of claim 1, wherein the body portion has a length defined by the distance between the neck portion and the bottom end, the length being between 165 and 230% of the end diameter.

3. The container of claim 2, wherein the curled portion is formed by curling an end portion of the sheet metal outwardly.

4. The container of claim 2, wherein the curled portion is formed by curling an end portion of the sheet metal inwardly.

5. The container of claim 3, wherein the curled portion forms a hollow toroid surrounding the opening.

6. The container of claim 4, wherein the curled portion forms a hollow toroid surrounding the opening.

7. The container of claim 5, wherein the toroid is a torus.

8. The container of claim 2, wherein the thread wraps around the neck portion at least 1½ times.

9. The container of claim 8, including a metal closure having a generally cylindrical side wall integrally formed with an end wall and integrally formed with a rim at the end of the side wall opposite the end wall, the closure further including a gasket material disposed within the closure to form a hermetic seal between the neck and closure when the closure is joined to the threaded portion, heated and then cooled.

10. The container of claim 9, wherein the gasket material is disposed within the closure to permit the closure to be pressed onto the threaded portion to form a vacuum or hermetic seal between the closure and the neck portion when the container wall and closure are heated.

11. The container of claim 10, wherein the gasket material hardens and forms around the first end when it is heated and then cooled.

12. A two piece container, comprising:

a can end having an outside end diameter;

a can body formed from single sheet of metal joined with a seam to form a cylinder having a top end and a bottom end, the seam extending from the top end to the bottom end, the can body including a neck portion formed at the top end and a body portion;

the neck portion defining a can opening surrounded by a toroid formed from the sheet metal and a threaded portion including at least one thread from the sheet metal adjacent to the toroid;

the body portion having a variable-diameter side-wall extending from the neck portion to the bottom end, the side wall including a first lobe portion, a second lobe portion and a transition portion joining the lobed portions wherein the side-wall has a first diameter at the first lobe portion which is between 100 and 120% of the end diameter, a second diameter at the second lobe portion which is between 95 and 110% of the end diameter, and a third diameter at the transition portion which is between 80 and 95% of the end diameter; wherein the body portion has a length defined by the distance between the neck portion and the bottom end, the length being between 165 and 230% of the end diameter; and

a double seam which hermetically seals the can end to the body portion.

13. The container of claim 12, wherein the toroid is hollow and has a generally circular cross-section.

14. The container of claim 12, wherein the toroid is hollow and has a generally elongated cross-section.

15. The container of claim 12, wherein the threaded portion is a single thread which wraps around the neck portion at least 1½ times.

16. The container of claim 12, including a metal closure having a generally cylindrical side wall integrally formed with an end wall and integrally formed with a rim at the end of the side wall opposite the end wall, the closure further including a gasket material disposed within the closure to form a hermetic seal between the neck and closure when the closure is joined to the threaded portion, heated and then cooled.

17. The container of claim 16, wherein the gasket material is disposed within the closure to permit the closure to be pressed onto the threaded portion to form a vacuum or hermetic seal between the closure and the neck portion when the container wall and closure are heated.

18. The container of claim 17, wherein the gasket material hardens and forms around the first end when it is heated and then cooled.

19. A two piece container, comprising:

a can end having an outside end diameter;

a can body formed from single sheet of metal joined with a seam to form a cylinder having a top end and a bottom end, the seam extending from the top end to the bottom end, the can body including a neck portion formed at the top end and a body portion;

the neck portion defining a can opening surrounded by a toroid formed from the sheet metal and a threaded portion including at least one thread formed from the sheet metal adjacent to the toroid which wraps around the neck portion at least 1½ times, the body portion having a variable-diameter side-wall extending from the neck portion to the bottom end;

the side wall including a first lobe portion, a second lobe portion and a transition portion joining the lobed portions wherein the side-wall has a first diameter at the first lobe portion which is between 100 and 120% of the end diameter, a second diameter at the second lobe portion which is between 95 and 110% of the end diameter, and a third diameter at the transition portion which is between 80 and 95% of the end diameter; wherein the body portion has a length defined by the distance between the neck portion and the bottom end, the length being between 165 and 230% of the end diameter; and

a double seam which hermetically seals the can end to the body portion.

20. The container of claim 19, wherein the toroid is hollow and has a generally circular cross-section.