Power unit for jumping rope

An apparatus that moves a jumping element. The apparatus includes a motorized hub that is attached to a housing. The hub can rotate a jumping element, such as a jump rope, about a horizontal axis and/or a vertical axis. The hub is connected to a motor. The speed of the motor is controlled by a variable speed regulator. A player can select a motor speed through activation of a button on the apparatus. The apparatus includes one or more indicators that provide an indication of the selected motor speed.

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Description
REFERENCE TO CROSS-RELATED APPLICATION

This application is a continuation-in-part of application Ser. No. 10/627,529, filed Jul. 25, 2003, pending.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an apparatus that can automatically rotate a jump rope.

2. Prior Art

U.S. Pat. No. 4,739,985 issued to Rudell et al., discloses a motorized unit that can automatically rotate a jump rope. The motorized unit includes a motorized rotating hub that can be coupled to one end of a jump rope. The hub can be coupled to a pedestal so that the jump rope can rotate about a horizontal axis. The other end of the jump rope can be attached to a post or other stationary object. The apparatus allows the players to “jump rope” without manually swinging the rope. The apparatus also has a vertical mode wherein a hub platform is laid on the ground and the rope swings about a vertical axis. A player(s) then jumps over the swinging rope.

The Rudell motorized unit has an on/off switch located on the hub platform. Unfortunately, it is difficult to reach the platform and turn off the switch while jumping rope. Additionally, when in the vertical mode, it is difficult to turn on the motorized hub without getting whipped by the rope and adjoining crank arm. The patent addresses this issue by describing a wireless transmitter that can be worn by the user to turn the motorized hub on and off. Wireless transmitters add to the cost of the product and are susceptible to damage, thereby rending the apparatus inoperative. The patent also describes the use of a pull string, but the string may become entangled with the rope.

The owner of the '985 patent had developed a product that included a timer. The timer would control the time interval at which the motorized hub would be active. Unfortunately, the user had no indication of when the motor was to start or end. Additionally, there is not indication of the speed of the motor.

There have been marketed a number of jump rope games such as SKIP-IT, TWIRL N JUMP, SKIP STICK and STICK-N-ROPE that all required manual activation of the rope.

BRIEF SUMMARY OF THE INVENTION

An apparatus that can move a jumping element. The apparatus includes a motor that is attached to a housing and coupled to a hub. The hub is adapted to be coupled to the jumping element. The apparatus includes an indicator that provides an indication of a characteristic of the motor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing players using an apparatus that swings a jump rope;

FIG. 2 is a perspective view showing a motorized rotating hub of the apparatus;

FIG. 3 is a side view showing the coupling of a jump rope to a crank arm;

FIG. 4 is a side view of a spring biased hub;

FIG. 5 is an exploded view of the spring biased hub;

FIG. 6 is a sectional view showing a motor and gear assembly of the apparatus;

FIG. 7 is a schematic of an electrical system of the apparatus;

FIG. 8 is a perspective view of an alternate embodiment of the apparatus;

FIG. 9 is a perspective view of an alternate embodiment of an apparatus that operates in a vertical mode;

FIG. 10 is a perspective view of an alternate embodiment of an apparatus that can operate in both a horizontal mode and a vertical mode;

FIG. 11 is a perspective view showing a hub platform being coupled to a vertical mode base;

FIG. 12 is a schematic of an alternate embodiment of the apparatus.

DETAILED DESCRIPTION

Disclosed is an apparatus that moves a jumping element. The apparatus includes a motorized hub that is attached to a housing. The hub can rotate a jumping element, such as a jump rope, about a horizontal axis and/or a vertical axis. The hub is connected to a motor. The speed of the motor is controlled by a variable speed regulator. A player can select a motor speed through activation of a button on the apparatus. The apparatus includes one or more indicators that provide an indication of the selected motor speed.

Referring to the drawings more particularly by reference numbers, FIGS. 1 and 2 show an apparatus 10 that can swing a jumping element 12. The jumping element 12 may be constructed as a jump rope. The apparatus 10 includes a hub platform 14 that is coupled to a horizontal base 16 by a pedestal 18. The horizontal base 16 may have a port 20 that allows the base 16 to be filled with water or sand to weigh down the apparatus 10.

The apparatus 10 may further include a crank arm 22 that is coupled to a rotating hub 24. The crank arm 22 may be attached to one end of the jump rope 12. The other end of the rope 12 may be attached to a post 26 or other stationary structure. The crank arm 22 may have a protective sleeve 28 constructed from an impact absorbing material such as a soft foam.

The hub 24 may rotate about a horizontal axis 30 to swing the rope 12 in an automated manner. The hub platform 14 may include buttons 32, 34, 36 and 38 that can be depressed by a user to set the time interval for rotation of the hub 24. Each button 32, 34, 36 and 38 has a corresponding indicator 40, 42, 44 and 46 that provides an indication of the time interval selected by the user. The indicators 40, 42, 44 and 46 may be light emitting diodes (LEDs).

By way of example, button 32 and indicator 40 may be associated with a 1 minute interval, button 34 and indicator 42 may correspond to a 3 minute interval, button 36 and indicator 44 a 5 minute interval, and button 38 and indicator 46 a 10 minute interval. The platform surface may have indicia adjacent to the indicators that provide the corresponding numerical value. By way of example, depressing button 36 will cause the hub 24 to rotate for 5 minutes. Illumination of the indicator 46 will allow the user to determine which interval was selected. Alternatively, one of the buttons may be an on/off switch and the other buttons may be used to select the speed of hub rotation.

As shown in FIG. 3 the jump rope 12 may have a ball 50 that can snap into a corresponding slot 52 in the crank arm 22. This allows the user to easily attach and detach the rope 12 form the arm 22. Likewise, as shown in FIG. 4, the hub 24 may have a corresponding slot 54 that receives the crank arm 22. As shown in FIG. 5, the hub 24 may be assembled from two half pieces 56 coupled together by springs 58. The springs 58 may bias the pieces 56 into a closed position and exert a spring force that retains the crank arm 22 within the hub slot 54.

FIG. 6 shows an embodiment of a hub platform 14 that contains a motor 60 coupled to the hub 22 by a gear assembly 62. FIG. 7 shows an embodiment of an electrical circuit for the apparatus. The circuit may include a timer 64 that controls activation of the motor 60. The timer 64 may be a controller circuit that receives input from buttons 32, 34, 36 or 38 and can illuminate indicators 40, 42, 44 or 46. The timer 64 may also drive a speaker 66 or other sound generating device (see also FIG. 2). All of the electrical circuits and devices may be powered by a battery 68.

In operation, the user depresses one of the buttons 32, 34, 36 or 38 to set the time interval of operation. Alternatively, the buttons 32, 34, 36 or 38 may set the speed of the motor 60. Upon selecting a button the timer 64 begins a count until the motor 60 is activated. The timer 64 may drive the speaker 66 to emit a sound such as a beeping sound to indicate that the motor 60 is about to be activated. The timer 64 also illuminates an indicator that corresponds to the selected button.

At the end of the count the timer 64 activates the motor 60. The timer 64 may begin another count that corresponds to the selected time interval. At the end of the time interval the timer 64 deactivates the motor 60. The timer 64 may cause the indicator to flash to indicate to the user that the motor is about to be deactivated.

FIG. 8 shows an alternate embodiment of an apparatus that has a mechanical switch 70 for setting the time interval of the motor. The switch 70 may have discrete settings with corresponding light indicators 72 that are illuminated to indicate the selected time interval. The apparatus may also have a separate on/off switch 74.

FIG. 9 is an alternate embodiment of an apparatus that can be operated in a vertical mode. A hub platform 76 is placed on a surface so that a hub 78 rotates a crank arm 80 and a jumping element 82 about a vertical axis 84.

In operation the user can select a time interval or speed by depressing one of the buttons 88, 90, 92 or 94, which causes an illumination of an indicator 96, 98, 100 or 102. An internal timer counts down a certain time interval, providing an audible indication of the impending activation of the motor. This allows the user to position themselves to jump over the rope when the motor is activated. The motor is then activated for the selected time interval. The automatic deactivation of the motor at the end of the time intervals allows the player to discontinue play without having to reach the hub platform 76. Ball 86, attached to jumping element 82, provides both a visual indication as to the position of the rotating jumping element, and also provides a weight mass to stabilize the jumping element as it rotates.

FIGS. 10 and 11 show an embodiment wherein the hub platform 14 can be located in a horizontal mode or placed in a horizontal position for use in a vertical mode. The base 16′ may have a cavity 104 that receives the hub platform 14 for use in the vertical mode.

FIG. 12 is an alternate embodiment wherein the motor 60 is controlled by a variable speed regulator 110. The regulator 110 is connected to buttons 32, 34, 36 and 38, and indicators 40, 42, 44 or 46. The user can change the speed of the motor 60 by depressing one of the buttons 32, 34, 36 or 38. The selected speed is indicated by the illumination of one or more of the indicators 40, 42, 44 and 46. The indicators 40, 42, 44 and 46 may also have indicia that allows the user to read the selected speed. For example, the indicia may be “slow”, “medium”, “fast” and “very fast” associated with the buttons 32, 34, 36 and 38, and indicators 40, 42, 44 and 46, respectively.

While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those ordinarily skilled in the art.

Claims

1. A method of forming a metal container of defined shape and lateral dimensions, comprising

(a) disposing a hollow metal preform having a closed end in a die cavity laterally enclosed by a die wall defining said shape and lateral dimensions, with only a single, movable punch, said punch being located at one end of the cavity and translatable into the cavity, the preform closed end being positioned in proximate facing relation to the punch and at least a portion of the preform being initially spaced inwardly from the die wall;
(b) subjecting the preform to internal fluid pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said fluid pressure exerting force, on said closed end, directed toward said one end of the cavity; and
(c) translating the punch into the cavity to engage and displace the closed end of the preform in a direction opposite to the direction of force exerted by fluid pressure thereon, deforming the closed end of the preform.

2. (canceled)

3. A method according to claim 1, wherein the punch is moved into contact with the closed end of the preform before commencing expansion of the preform and the contact is maintained throughout the expansion of the preform.

4. A method according to claim 1, wherein said punch has a contoured surface, the closed end of the preform being deformed so as to conform to said contoured surface.

5. A method according to claim 1, wherein said defined shape is a bottle shape including a neck portion and a body portion larger in lateral dimensions than the neck portion, said die cavity having a long axis, said preform having a long axis and being disposed substantially coaxially with said cavity in step (a), and said punch being translatable along the long axis of the cavity.

6. A method according to claim 5, wherein said punch has a domed contour, and wherein step (c) deforms said closed end of said preform into said domed contour.

7. A method according to claim 5, wherein said die wall comprises a split die separable for removal of the formed container following step (c).

8. A method according to claim 7, wherein said defined shape is asymmetric about said long axis of said cavity.

9. A method according to claim 5, wherein said punch is initially positioned, at the start of step (b), to limit axial lengthening of the preform by said fluid pressure.

10. (canceled)

11. A method according to claim 5, wherein workpiece having an open end opposite said closed end and is substantially equal in diameter to said neck portion of said bottle shape.

12. A method according to claim 11, wherein said workpiece has sufficient formability to be expandable to said defined shape in a single pressure forming operation.

13. A method according to claim 11, including a preliminary steps of placing the workpiece in a die cavity smaller than the first-mentioned die cavity and subjecting the workpiece therein to internal fluid pressure to expand the workpiece to an intermediate size and shape smaller than said defined shape and lateral dimensions, before performing steps (a), (b) and (c).

14. (canceled)

15. A method according to claim 1, wherein said preform is an aluminum preform.

16-19. (canceled)

20. A method according to claim 1, wherein step (b) comprises simultaneously applying internal positive fluid pressure and external positive fluid pressure to the preform in the cavity, said internal positive fluid pressure being higher than said external positive fluid pressure.

21. (canceled)

22. A method according to claim 3, wherein heat is applied to the preform by way of heating means in the punch to thereby induce a temperature gradient to the preform commencing at the closed bottom and extending upwardly.

23. (canceled)

24. A method according to claim 22, wherein heat is applied to the preform by way of heating means in the side walls of the die.

25-31. (canceled)

32. A method according to claim 1, wherein the die wall comprises die structure having upper and lower portions and wherein heat is applied to the preform by two groups of heating elements respectively incorporated in the upper and lower portions of the die structure and under independent temperature control for controlling temperature gradient in the preform.

33. A method according to claim 1, wherein heat is applied to the preform by a heating element disposed within the preform substantially coaxially therewith.

34. A method according to claim 33 wherein heat is further supplied to the preform by heating the punch.

35-45. (canceled)

46. A method according to claim 1, wherein said fluid pressure is provided by gas.

47. A method of forming a metal container of defined shape and lateral dimensions, comprising

(a) disposing a hollow metal preform having a closed end in a die cavity laterally enclosed by a die wall defining said shape and lateral dimensions, with a punch located at one end of the cavity and translatable into the cavity, the preform closed end being positioned in proximate facing relation to the punch and at least a portion of the preform being initially spaced inwardly from the die wall;
(b) subjecting the preform to internal gas pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said gas pressure exerting force, on said closed end, directed toward said one end of the cavity; and
(c) translating the punch into the cavity to engage and displace the closed end of the preform in a direction opposite to the direction of force exerted by gas pressure thereon, deforming the closed end of the preform.

48. A method of forming a metal container of defined shape and lateral dimensions, comprising the steps of

(a) disposing a hollow metal preform having a closed end in a die cavity laterally enclosed by a die wall defining said shape and lateral dimensions, the preform closed end being positioned in facing relation to one end of the cavity and at least a portion of the preform being initially spaced inwardly from the die wall, and
(b) subjecting the preform to internal fluid pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said fluid pressure exerting force, on said closed end, directed toward said one end of the cavity,
wherein step (b) comprises simultaneously applying internal positive fluid pressure and external positive fluid pressure to the preform in the cavity, said internal positive fluid pressure being higher than said external positive fluid pressure,
and including controlling strain rate in the preform by independently controlling the internal and external positive fluid pressures to which the preform is simultaneously subjected for varying the differential between said internal positive fluid pressure and said external positive fluid pressure.

49. A method of forming a metal container of defined shape and lateral dimensions, comprising

(a) disposing a hollow metal preform having a closed end in a die cavity laterally enclosed by a die wall defining said shape and lateral dimensions, with a punch located at one end of the cavity and translatable into the cavity, the preform closed end being positioned in proximate facing relation to the punch and at least a portion of the preform being initially spaced inwardly from the die wall;
(b) subjecting the preform to internal fluid pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said fluid pressure exerting force, on said closed end, directed toward said one end of the cavity; and
(c) translating the punch into the cavity to engage and displace the closed end of the preform in a direction opposite to the direction of force exerted by fluid pressure thereon, deforming the closed end of the preform,
wherein step (b) comprises simultaneously applying internal positive fluid pressure and external positive fluid pressure to the preform in the cavity, said internal positive fluid pressure being higher than said external positive fluid pressure, and wherein said metal is aluminum.

50. A method according to claim 49, wherein said fluid pressure is provided by gas.

51. A method according to claim 50, wherein steps (b) and (c) are performed at a temperature higher than 100° C.

52. A method according to claim 47, wherein steps (b) and (c) are performed at a temperature higher than 100° C.

53. A method according to claim 47, wherein steps (b) and (c) are performed at a temperature of about 300° C.

54. A method according to claim 49, including controlling strain rate in the preform by independently controlling the internal and external positive fluid pressures to which the preform is simultaneously subjected for varying the differential between said internal positive fluid pressure and said external positive fluid pressure.

55. A method according to claim 54, wherein said internal positive fluid pressure is provided by gas.

56. A method according to claim 55, wherein both said internal and external positive fluid pressures are provided by gas.

57. A method according to claim 55, wherein steps (b) and (c) are performed at a temperature higher than 100° C.

58. A method of forming an aluminum container of defined shape and lateral dimensions, comprising

(a) disposing a hollow aluminum preform having a closed end in a die cavity laterally enclosed by a die wall defining said shape and lateral dimensions, with a punch located at one end of the cavity and translatable into the cavity, the preform closed end being positioned in proximate facing relation to the punch and at least a portion of the preform being initially spaced inwardly from the die wall;
(b) subjecting the preform to internal gas pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said gas pressure exerting force, on said closed end, directed toward said one end of the cavity; and
(c) translating the punch into the cavity to engage and displace the closed end of the preform in a direction opposite to the direction of force exerted by gas pressure thereon, deforming the closed end of the preform,
further including the step of making the preform from aluminum sheet having a recrystallized or recovered microstructure with a gauge in a range of about 0.25 to about 1.5 mm, prior to performance of step (a).

59. A method according to claim 58, wherein steps (b) and (c) are performed at a temperature higher than 100° C.

60. A method according to claim 58, wherein step (b) comprises simultaneously applying internal positive fluid pressure and external positive fluid pressure to the preform in the cavity, said internal positive fluid pressure being higher than said external positive fluid pressure,

and including controlling strain rate in the preform by independently controlling the internal and external positive fluid pressures to which the preform is simultaneously subjected for varying the differential between said internal positive fluid pressure and said external positive fluid pressure.

61. A method according to claim 47, wherein said gas is selected from the group consisting of nitrogen, air and argon.

62. A method according to claim 51, wherein said gas is selected from the group consisting of nitrogen, air and argon.

63. A method according to claim 55, wherein said gas is selected from the group consisting of nitrogen, air and argon.

64. A method according to claim 59, wherein said gas is selected from the group consisting of nitrogen, air and argon.

65. A method of forming an aluminum container of defined shape and lateral dimensions, comprising

(a) disposing a hollow aluminum preform having a closed end in a die cavity laterally enclosed by a die wall defining said shape and lateral dimensions, the preform closed end being positioned in facing relation to one end of the cavity and at least a portion of the preform being initially spaced inwardly from the die wall; and
(b) subjecting the preform to internal fluid pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said fluid pressure exerting force, on said closed end, directed toward said one end of the cavity;
further including the step of making the preform from aluminum sheet having a recrystallized or recovered microstructure with a gauge in a range of about 0.25 to about 1.5 mm, prior to performance of step (a).

66. A method of forming an aluminum container of defined shape and lateral dimensions, comprising

(a) disposing a hollow aluminum preform having a closed end in a die cavity laterally enclosed by a die wall defining said shape and lateral dimensions, the preform closed end being positioned in facing relation to one end of the cavity and at least a portion of the preform being initially spaced inwardly from the die wall; and
(b) subjecting the preform to internal fluid pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said fluid pressure exerting force, on said closed end, directed toward said one end of the cavity;
wherein said defined shape is a bottle shape including a neck portion and a body portion larger in lateral dimensions than the neck portion, said die cavity having a long axis, said preform having a long axis and being disposed substantially coaxially with said cavity in step (a);
wherein said preform is an elongated and initially generally cylindrical workpiece having an open end opposite said closed end and is substantially equal in diameter to said neck portion of said bottle shape; and
including preliminary steps of placing the workpiece in a die cavity smaller than the first-mentioned die cavity and subjecting the workpiece therein to internal fluid pressure to expand the workpiece to an intermediate size and shape smaller than said defined shape and lateral dimensions, before performing steps (a) and (b).

67. A method according to claim 66, further including the step of making the preform from aluminum sheet having a recrystallized or recovered microstructure with a gauge in a range of about 0.25 to about 1.5 mm, prior to performance of step (a).

68. Apparatus for forming a metal container of defined shape and lateral dimensions from a hollow metal preform having a closed end, comprising

(a) die structure providing a die cavity for receiving the preform therein with at least a portion of the preform being initially spaced inwardly from the die wall and the preform closed end facing one end of the cavity, said cavity having a die wall defining said shape and lateral dimensions;
(b) a fluid pressure supply for subjecting a preform within the cavity to internal fluid pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said fluid pressure exerting force, on said closed end, directed toward said one end of the cavity;
(c) the die cavity having a second end opposed to said one end and an axis extending therebetween;
(d) the die wall comprising a split die including a plurality of split inserts disposed in tandem along said axis for defining successive portions of said shape and separable for removal of the formed container from the cavity.

69. Apparatus as defined in claim 68, wherein the die structure comprises a split holder within which the split inserts are removably and replaceably received, for maintaining the inserts in fixed die-cavity-defining position during expansion of a preform within the cavity.

70. Apparatus as defined in claim 69, wherein at least one of said inserts has an inner surface bearing a relief feature for imparting a corresponding relief feature to the container.

71. Apparatus as defined in claim 70, further comprising a group of interchangeable inserts having inner surfaces respectively bearing different relief features, from which one or more split inserts are selected for insertion in said holder.

72. Apparatus as defined in claim 68, further including separate gas-feeding channels for respectively feeding gas to the interior of the preform and to the die cavity externally of the preform, to apply internal and external positive fluid pressures to a preform within the die cavity.

73. Apparatus as defined in claim 68, wherein the die structure has upper and lower portions and two groups of heating elements respectively incorporated in the upper and lower portions of the die structure and under independent temperature control for controlling temperature gradient in the preform.

74. Apparatus as defined in claim 68, further including a heating element insertable within a preform in the die cavity substantially coaxially therewith.

75. Apparatus as defined in claim 68, wherein the neck portion of the defined shape includes a screw thread or lug for securing a screw closure to the formed container and wherein the die wall has a neck portion with a thread or lug formed therein for imparting a thread or lug to a preform disposed in the die cavity.

76. A method of forming a hollow metal article of defined shape and lateral dimensions, comprising

(a) disposing a hollow metal preform having a closed end in a die cavity laterally enclosed by a die wall defining said shape and lateral dimensions, with only a single, movable punch, said punch being located at one end of the cavity and translatable into the cavity, the preform closed end being positioned in proximate facing relation to the punch and at least a portion of the preform being initially spaced inwardly from the die wall;
(b) subjecting the preform to internal fluid pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said fluid pressure exerting force, on said closed end, directed toward said one end of the cavity; and
(c) translating the punch into the cavity to engage and displace the closed end of the preform in a direction opposite to the direction of force exerted by fluid pressure thereon, deforming the closed end of the preform.

77. A method of forming a hollow metal article of defined shape and lateral dimensions, comprising

(a) disposing a hollow metal preform having a closed end in a die cavity laterally enclosed by a die wall defining said shape and lateral dimensions, with a punch located at one end of the cavity and translatable into the cavity, the preform closed end being positioned in proximate facing relation to the punch and at least a portion of the preform being initially spaced inwardly from the die wall;
(b) subjecting the preform to internal gas pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said gas pressure exerting force, on said closed end, directed toward said one end of the cavity; and
(c) translating the punch into the cavity to engage and displace the closed end of the preform in a direction opposite to the direction of force exerted by gas pressure thereon, deforming the closed end of the preform.

78. A method of forming a hollow metal article of defined shape and lateral dimensions, comprising the steps of

(a) disposing a hollow metal preform having a closed end in a die cavity laterally enclosed by a die wall defining said shape and lateral dimensions, the preform closed end being positioned in facing relation to one end of the cavity and at least a portion of the preform being initially spaced inwardly from the die wall, and
(b) subjecting the preform to internal fluid pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said fluid pressure exerting force, on said closed end, directed toward said one end of the cavity,
wherein step (b) comprises simultaneously applying internal positive fluid pressure and external positive fluid pressure to the preform in the cavity, said internal positive fluid pressure being higher than said external positive fluid pressure,
and including controlling strain rate in the preform by independently controlling the internal and external positive fluid pressures to which the preform is simultaneously subjected for varying the differential between said internal positive fluid pressure and said external positive fluid pressure.

79. A method of forming a hollow metal article of defined shape and lateral dimensions, comprising

(a) disposing a hollow metal preform having a closed end in a die cavity laterally enclosed by a die wall defining said shape and lateral dimensions, with a punch located at one end of the cavity and translatable into the cavity, the preform closed end being positioned in proximate facing relation to the punch and at least a portion of the preform being initially spaced inwardly from the die wall;
(b) subjecting the preform to internal fluid pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said fluid pressure exerting force, on said closed end, directed toward said one end of the cavity; and
(c) translating the punch into the cavity to engage and displace the closed end of the preform in a direction opposite to the direction of force exerted by fluid pressure thereon, deforming the closed end of the preform,
wherein step (b) comprises simultaneously applying internal positive fluid pressure and external positive fluid pressure to the preform in the cavity, said internal positive fluid pressure being higher than said external positive fluid pressure, and wherein said metal is aluminum.

80. A method of forming a hollow aluminum article of defined shape and lateral dimensions, comprising

(a) disposing a hollow aluminum preform having a closed end in a die cavity laterally enclosed by a die wall defining said shape and lateral dimensions, with a punch located at one end of the cavity and translatable into the cavity, the preform closed end being positioned in proximate facing relation to the punch and at least a portion of the preform being initially spaced inwardly from the die wall;
(b) subjecting the preform to internal gas pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said gas pressure exerting force, on said closed end, directed toward said one end of the cavity; and
(c) translating the punch into the cavity to engage and displace the closed end of the preform in a direction opposite to the direction of force exerted by gas pressure thereon, deforming the closed end of the preform,
further including the step of making the preform from aluminum sheet having a recrystallized or recovered microstructure with a gauge in a range of about 0.25 to about 1.5 mm, prior to performance of step (a).

81. A method of forming a hollow aluminum article of defined shape and lateral dimensions, comprising

(a) disposing a hollow aluminum preform having a closed end in a die cavity laterally enclosed by a die wall defining said shape and lateral dimensions, the preform closed end being positioned in facing relation to one end of the cavity and at least a portion of the preform being initially spaced inwardly from the die wall; and
(b) subjecting the preform to internal fluid pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said fluid pressure exerting force, on said closed end, directed toward said one end of the cavity;
further including the step of making the preform from aluminum sheet having a recrystallized or recovered microstructure with a gauge in a range of about 0.25 to about 1.5 mm, prior to performance of step (a).

82. A method of forming a hollow aluminum article of defined shape and lateral dimensions, comprising

(a) disposing a hollow aluminum preform having a closed end in a die cavity laterally enclosed by a die wall defining said shape and lateral dimensions, the preform closed end being positioned in facing relation to one end of the cavity and at least a portion of the preform being initially spaced inwardly from the die wall; and
(b) subjecting the preform to internal fluid pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said fluid pressure exerting force, on said closed end, directed toward said one end of the cavity;
wherein said defined shape is a bottle shape including a neck portion and a body portion larger in lateral dimensions than the neck portion, said die cavity having a long axis, said preform having a long axis and being disposed substantially coaxially with said cavity in step (a);
wherein said preform is an elongated and initially generally cylindrical workpiece having an open end opposite said closed end and is substantially equal in diameter to said neck portion of said bottle shape; and
including preliminary steps of placing the workpiece in a die cavity smaller than the first-mentioned die cavity and subjecting the workpiece therein to internal fluid pressure to expand the workpiece to an intermediate size and shape smaller than said defined shape and lateral dimensions, before performing steps (a) and (b).

83. Apparatus for forming a hollow metal article of defined shape and lateral dimensions from a hollow metal preform having a closed end, comprising

(a) die structure providing a die cavity for receiving the preform therein with at least a portion of the preform being initially spaced inwardly from the die wall and the preform closed end facing one end of the cavity, said cavity having a die wall defining said shape and lateral dimensions;
(b) a fluid pressure supply for subjecting a preform within the cavity to internal fluid pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said fluid pressure exerting force, on said closed end, directed toward said one end of the cavity;
(c) the die cavity having a second end opposed to said one end and an axis extending therebetween;
(d) the die wall comprising a split die including a plurality of split inserts disposed in tandem along said axis for defining successive portions of said shape and separable for removal of the formed container from the cavity.

84. Apparatus for forming a hollow metal article of defined shape and lateral dimensions from a hollow metal preform having a closed end, comprising

(a) die structure providing a die cavity for receiving the preform therein with at least a portion of the preform being initially spaced inwardly from the die wall and the preform closed end facing one end of the cavity, said cavity having a die wall defining said shape and lateral dimensions;
(b) a punch located at one end of the cavity and translatable into the cavity such that the closed end of a preform received within the cavity is positioned in proximate facing relation to the punch;
(c) a fluid pressure supply for subjecting a preform within the cavity to internal fluid pressure to expand the preform outwardly into substantially full contact with the die wall, thereby to impart said defined shape and lateral dimensions to the preform, said fluid pressure exerting force, on said closed end, directed toward said one end of the cavity;
(d) the die cavity having a second end opposed to said one end and an axis extending therebetween;
(e) the die wall comprising a split die including a plurality of split inserts disposed in tandem along said axis for defining successive portions of said shape and separable for removal of the formed container from the cavity.
Patent History
Publication number: 20050020414
Type: Application
Filed: Oct 16, 2003
Publication Date: Jan 27, 2005
Inventors: Elliot Rudell (Torrance, CA), George Foster (Long Beach, CA), Joseph Cernansky (Palos Verdes Estates, CA)
Application Number: 10/688,636
Classifications
Current U.S. Class: 482/81.000