METHOD FOR FORMING CUT FOR TAB AND END MANUFACTURE

A process is described for producing substantially continuous cuts or coils for tab or shell manufacture. A coil of aluminum alloy is split into at least first and second cut coils, each of the first and second cut coils having a cut strip width less than a width of the aluminum alloy coil, and the free ends of the cut strip coiled on the first and second coils are connected to form a continuous cut strip having a length longer than a length of the strip on the aluminum alloy coil.

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Description
CROSS REFERENCE TO RELATED APPLICATION

The present application claims the benefits of U.S. Provisional Application Ser. No. 61/933,155, filed Jan. 29, 2014, having the same title, which is incorporated herein by this reference in its entirety.

FIELD

The disclosure relates generally to aluminum alloy manufacture and particularly to aluminum alloy cuts for container end manufacture.

BACKGROUND

A conventional finished end manufacturing process is shown in FIG. 1. Aluminum alloy cut is placed on a rotatable turntable 100 to provide aluminum alloy sheet 104, or tab stock, to a conversion press 108. Conventional tab stock is made at the rolling mill by taking the full width product and running through a slitter (not shown) to achieve the desired width for the conversion press to be supplied. Those individual cuts are removed from a mandrel and placed on a pallet with the cuts stacked upright. That same pallet of metal is shipped to the end plant and placed on a “Lazy Susan” revolving table or turntable. The turntable will turn as fast as needed to supply strip to the conversion press 108. The speed is controlled by an “arm” that controls the table speed and slack in the strip. An electric eye sensor is placed near the entry of the press and will stop when it does not see a strip.

Shells 112 (which are blank with no score or markings on the face) are stamped by a shell stamping press 116 out of a second aluminum alloy cut (not shown), transferred to a tube (not shown), and stored in balancer units (not shown) for introduction by tubes (not shown) into the conversion press 108. The conversion press 108 can accept simultaneously one to four shells in individual lanes.

The shells 112 are fed to the conversion press 108 simultaneously with the aluminum alloy sheet 104 (i.e., tab stock). Tab stock is supplied in cut form at the appropriate width needed to support how many ends are being introduced into the conversion press 108 (which is known as 1-out, 2-out, 3-out or 4-out). Cuts of tab stock are supplied in a cut form (known as pancakes or mullets) and stacked one-on-top-of-the-other. The tab stock is fed into one end of the conversion press 108 with one single cut at a time. As the ends progress through the conversion press 108, the conversion press 108 adds, to the shells 112, the score, design of writing, and the rivet. At the same time, the tabs are fabricated in a progression strip from the flat tab stock sheet to make the tab design. The conversion press normally runs at 650-750 strokes per minute. At the end of the conversion process, the tab is removed from the progression strip and staked to the end rivet to form a complete end.

The conversion press 108 outputs finished ends 120 to be provided to a beverage manufacturer to seal aluminum alloy cups containing the beverage, thereby forming beverage-containing aluminum alloy cans. As will be appreciated, the can is held tightly against the seat of a filling machine and a beverage is poured in. The finished end is added. The upper flange, formed when the can was given its neck, is then bent around the lid and seamed shut. At this point, the can is ready for sale.

Each time a tab pancake/cut is completed, the conversion press is shut down and cleaned out, and a new strip is started. The press is run in jog mode until the first complete tab is formed on the new progression. As this is being done, ends are being scrapped as they have no tabs. Once the first tab is affixed, the conversion press is stopped and then started again in run mode. The next 20-40 ends are discarded to insure that the ends are made in run mode. This tab strip change-over operation takes about 15-20 minutes and will be done for each cut. On a 4-out conversion press, this translates into 750 ends×4 out×20 minutes or 60,000 ends per press that will be scrapped.

The outer diameter (“OD”) size of the tab stock cut will determine how frequently a cut must be introduced. A 92″ OD on a 16″ inner diameter (“ID”) cut will run on a 750-stroke conversion press for about 8 hours. Thus, in a 24-hour period this change-over would be done 3 times. So the potential scrapped end volume is 60,000 ends×3 or 180,000 in 24 hours for each conversion press or 65,700,000 ends per year for each conversion press. Normal end plants have 3 to 6 conversion presses.

SUMMARY

These and other needs are addressed by the various aspects, embodiments, and configurations of the present disclosure. A process and system are described for joining split cuts to form a substantially continuous cut for tab or shell manufacture. This can reduce down time between cut change over (thereby reducing the amount of scrapped ends) and have the conversion press run longer.

A process can include the steps:

    • (a) splitting a coil of aluminum alloy into at least first and second cut coils, each of the first and second cut coils having a cut strip width less than a width of the aluminum alloy coil; and
    • (b) connecting free ends of the cut strip coiled on the first and second coils to form a continuous cut strip having a length longer than a length of the strip on the aluminum alloy coil.

The width of the aluminum alloy coil commonly ranges from about 10 to about 75 inches, and the width of each of the first and second cut coils from about 1 to about 10 inches. The widths of each of the first and second cut coils are normally substantially the same.

The length of the continuous cut strip is commonly at least about 150% and more commonly at least about 175% of the length of the strip on the aluminum alloy coil.

The free end of the first cut coil can be an inner diameter end of the first cut coil, and the free end of the second cut coil can be an outer diameter end of the second cut coil.

The continuous cut coil can be marked in spatial proximity to a weld line connecting the free ends to enable sensor at a can plant to detect the weld.

The connecting step can include the sub-steps of:

    • (b1) placing the first and second cut coils on an entry mandrel; and
    • (b2) welding the free end of the first cut coil to the free end of the second cut coil.

The continuous cut strip can be coiled on the first and second coils, and the first and second coils stacked one-on-top-of-the-other and separated by a spacer.

The continuous cut strip can be coiled on a common coil. The coil is commonly staggered back-and-forth across a face of a rewind mandrel to form the common coil.

The connecting step can include the sub-steps:

    • (b1) positioning the first and second cut coils on an entry mandrel;
    • (b2) locating the first cut coil at a selected point along a length of the entry mandrel;
    • (b3) unwinding the first cut coil from the entry mandrel and rewinding the first cut coil on a rewind mandrel;
    • (b4) when the first cut coil is unwound and rewound on the rewind mandrel, locating the second cut coil at the selected point; and
    • (b5) connecting the free end of the first cut coil to the free end of the second cut coil to form the continuous cut strip.

The process can further include the step:

    • (c) unwinding the second cut coil from the entry mandrel and rewinding the second cut coil on a rewind mandrel.

The rewind mandrel can reciprocate back-and-forth while the first and second cut coils are rewound on the rewind mandrel to form the stagger wind of the continuous cut coil on the rewind mandrel.

The continuous cut coil can be tab stock, and the process include the further step:

    • (d) passing the continuous cut coil and can end shells through a conversion press to form a finished can end having a tab positioned on a can end.

A continuous cut strip can have first and second strip ends welded together, be coiled on first and second coils, with the first and second coils being stacked one-on-top-of-the-other and separated by a spacer.

A continuous cut strip can have first and second strip ends welded together and be coiled on a common coil. The coil is commonly staggered back-and-forth across a face of a rewind mandrel.

A system for manufacturing can ends can include:

    • (a) a splitter to cut an aluminum alloy coil into first and second cut coils, each of the first and second cut coils having a width less than a width of the aluminum alloy coil;
    • (b) an entry mandrel to receive the first and second cut coils; and
    • (c) a welder to connect an inner diameter end of the first cut coil to an outer diameter end of the second cut coil.

The system can further include one or more of:

    • (d) a lift to lift each of the first and second cut coils onto the entry mandrel;
    • (e) a lift to lift each of the first and second cut coils onto the entry mandrel; and
    • (f) a reciprocating rewind mandrel to unwind the first and second cut coils and stagger wind the continuous cut strip into a common coil; and
    • (g) an upender unit to remove the first and second cut coils from the entry mandrel or the common coil from the rewind mandrel, as appropriate.

The present disclosure can provide a number of advantages depending on the particular configuration. The use of a substantially continuous cut formed by connecting or joining cuts can enable longer plant run times between cut replacement, thereby reducing the number of shells discarded or scrapped during any shift. By using a larger capacity cut on the turntable, cut replacement is required less frequently and fewer shells discarded each shift.

These and other advantages will be apparent from the disclosure of the aspects, embodiments, and configurations contained herein.

As used herein, “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together. When each one of A, B, and C in the above expressions refers to an element, such as X, Y, and Z, or class of elements, such as X1-Xn, Y1-Ym, and Z1-Zo, the phrase is intended to refer to a single element selected from X, Y, and Z, a combination of elements selected from the same class (e.g., X1 and X2) as well as a combination of elements selected from two or more classes (e.g., Y1 and Zo).

It is to be noted that the term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.

“Aluminum alloys” are alloys in which aluminum (Al) is the predominant metal. The typical alloying elements are copper, magnesium, manganese, silicon, and zinc.

A can “end” refers to an end of the can that is engaged with the can body after the can body is filled with a liquid, such as a beverage.

The term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112, Paragraph 6. Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials or acts and the equivalents thereof shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.

A “tab” refers to a projection, flap, or short strip attached to a can end to facilitate or otherwise enable opening the can for consumption of its contents.

Unless otherwise noted, all component or composition levels are in reference to the active portion of that component or composition and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources of such components or compositions.

All percentages and ratios are calculated by total composition weight, unless indicated otherwise.

It should be understood that every maximum numerical limitation given throughout this disclosure is deemed to include each and every lower numerical limitation as an alternative, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this disclosure is deemed to include each and every higher numerical limitation as an alternative, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this disclosure is deemed to include each and every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein. By way of example, the phrase from about 2 to about 4 includes the whole number and/or integer ranges from about 2 to about 3, from about 3 to about 4 and each possible range based on real (e.g., irrational and/or rational) numbers, such as from about 2.1 to about 4.9, from about 2.1 to about 3.4, and so on.

The preceding is a simplified summary of the disclosure to provide an understanding of some aspects of the disclosure. This summary is neither an extensive nor exhaustive overview of the disclosure and its various aspects, embodiments, and configurations. It is intended neither to identify key or critical elements of the disclosure nor to delineate the scope of the disclosure but to present selected concepts of the disclosure in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other aspects, embodiments, and configurations of the disclosure are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below. Also, while the disclosure is presented in terms of exemplary embodiments, it should be appreciated that individual aspects of the disclosure can be separately claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are incorporated into and form a part of the specification to illustrate several examples of the present disclosure. These drawings, together with the description, explain the principles of the disclosure. The drawings simply illustrate preferred and alternative examples of how the disclosure can be made and used and are not to be construed as limiting the disclosure to only the illustrated and described examples. Further features and advantages will become apparent from the following, more detailed, description of the various aspects, embodiments, and configurations of the disclosure, as illustrated by the drawings referenced below.

FIG. 1 depicts a prior art finished end manufacturing process;

FIG. 2 depicts a process according to a first embodiment of this disclosure;

FIG. 3 depicts a process according to a second embodiment of this disclosure;

FIG. 4 is a perspective view of cuts connected according to an embodiment of this disclosure;

FIG. 5 is a perspective view of cuts connected according to an embodiment of this disclosure; and

FIG. 6 is a perspective view of cuts connected according to an embodiment of this disclosure.

 DETAILED DESCRIPTION

In one system and process configuration, a pallet supporting the cuts is transferred to a welding system off line and separate from the normal slitting line. The welding system would have an entry mandrel, and the cuts would be removed from the pallet and placed on the mandrel with the cuts standing up vertically. The ID end from a first cut is welded to the OD end of a second cut, and a spacer is placed between the cuts. The spacer thickness can be slightly wider than the actual metal cut width so that the spacer can support adjacent cuts when the cuts are laid back down on the pallet without warping or otherwise bending the strip of alloy sheet passing between the cuts (or the “cut length”). This welding process continues until all of the cuts have been welded together. The welding unit is placed conveniently so the operator can take both ends and make the weld easily. Once all of the cuts are welded and spacers in place, the cuts are moved to the opposite end of the mandrel and down loaded on to a pallet with an upender unit. The coil would then be packed and sent to the final customer. This continuous coil formed by the connected cuts can run one continuous long strip though the conversion press without having to shut down until the last cut has run through. This can be the equivalent to 24-36 hours off running time versus 8 hours.

This configuration is illustrated by FIG. 2. A coil of aluminum alloy tab and/or end feedstock 200 (or master coil) is fed to a splitter 204, which cuts the cut into plural cuts 208a-c of the same diameter as the master coil but having a narrower width. The width of each of the cuts is selected to maximize the number of tabs that can be manufactured from each cut 208. The cumulative width of the plural cuts is less than the width of the master coil of aluminum alloy tab and/or end feedstock 200 before being fed to the splitter (due to the widths of the cutting blades). Typically, the width of the master coil ranges from about 10 to about 75 inches, more typically from about 25 to about 72.5 inches, and more typically from about 35 to about 70 inches. Typically, the width of each cut 208 ranges typically from about 1 to about 10 inches, more typically from about 1.5 to about 7.5 inches, and even more typically from about 2 to about 5 inches.

A lift (not shown) lifts each of the cuts 208a-c onto an entry mandrel 212 and positions the cuts at selected spaced-apart intervals along its length. A welder 216 then joins an end of the cut at an inner diameter of a first cut 208a to an opposing end of the cut at an outer diameter of a second cut 208b, an end of the cut at an inner diameter of a second cut 208b to an opposing end of the cut at an outer diameter of a third cut 208c, and so on until a selected number of cuts are joined together to form a continuous cut. The connection of the adjacent cuts is shown by cut lengths 220 extending between adjacent cuts 208. At each weld location, a mark or other indicator, such as a black mark extending at least part of the length of the weld, is placed on or near the weld so that any tabs manufactured that incorporate the weld can be rejected readily by human or machine (e.g., camera and robotic) inspection.

The continuously connected cuts can then be placed, by an upender unit (not shown), on a pallet 224 for shipment to the can making plant. The cuts 208a-c are separated by spacers 228 to prevent the continuous cut from kinking The width of each of the spacers 228 is at least as wide as, and commonly wider than, the width of the cut. The spacer width typically ranges from about 1.5 to about 10 inches, more typically from about 2 to about 7.5 inches, and even more typically from about 2.5 to about 6.5 inches.

FIGS. 4-6 show the cuts 208a-c stacked on the pallet 224. The welded lengths of each cut, or cut lengths 220, can alternatively form a loop positioned outside the spacer 228 and outer diameter of the stacked cuts. Looping the welded lengths of cut in this manner provide ease of use by the can manufacturer and inhibit kinking in the cut. The markings on the weld joining the two lengths can be seen. As shown in FIG. 4, the cuts typically have an open diameter or open center 400; that is, they are not coiled about a mandrel.

At the can plant, the cuts 208a-c are placed on the turntable 100. As each cut is used, the spacer formerly separating the now consumed cut and new cut is removed.

The cuts 208a-c can be stacked one-on-top-of-the-other on a pallet (not shown) for delivery to the entry mandrel 212.

Another system and process configuration uses the same entry mandrel configuration. Again, the master coil is slit at the conventional slitter and brought over to the welding system. The cuts are again placed on the entry mandrel with the cuts oriented vertically. A first cut is moved to a selected or fixed point on the entry mandrel to be in a straight line with a rewind mandrel. The rewind mandrel is configured to reciprocate left-to-right and right-to-left at a high speed. This can be done by moving the rewind mandrel itself rather than the entire rewind unit mandrel and motor. A first cut is run off (or unwound) and would be rewound, typically on a 48″ aluminum core, in a “stagger wind”, with the strip moving left to right back and forth. The mandrel would move at the same time to allow full coverage (stagger) of the 48″ core length but the mandrel movement would keep the straight line effect so the strip does not fold over or kink. When the first cut has been completely unwound, the inner diameter end would be joined (or welded) to the outer diameter end of a second cut, and the same process goes on until all of the cuts are welded to each other and stagger wound on the core. The core then would be taken off the rewind mandrel and placed standing up vertically on a pallet. The upright core and pallet would be shipped to the end plant and placed on the “lazy Susan” or turntable and, as in the prior configuration, have a continuous strip to run.

This configuration is illustrated by FIG. 3. A master coil of aluminum alloy tab and/or end feedstock 200 is fed to a splitter 204, which cuts the cut into plural cuts 208a-c of narrower width. The cuts 208a-c can be stacked one-on-top-of-the-other on a pallet (not shown) for delivery to the entry mandrel 304. The cuts can have an open or closed diameter.

The cuts 208a-c are placed by lift 300 at spaced apart intervals on the entry mandrel 304. A first cut 208a is moved to a selected position 308 on the entry mandrel 304. The selected position can be marked by cut stops 312 so that each cut is located at or near the same location during the process of unwinding and rewinding.

A length 316 of the first cut 208a is threaded onto a rewind mandrel 320 to commence the process. A motor 324 causes the rewind mandrel 320 to rotate and reciprocate back-and-forth along its longitudinal axis as shown by double arrow 328 to cause the cut length to wind in a zig-zag pattern 332. The zig-zag pattern inhibits the cut from kinking as it is rewound on the rewind mandrel 320. As the rewind mandrel 320 oscillates or reciprocates back and forth, the zig-zag pattern moves back and forth along a selected length 336 of the rewind mandrel 320. While this process is occurring, the entry mandrel can rotate but is maintained at a fixed location; that is, it does not oscillate or reciprocate back-and-forth along its longitudinal axis.

When the first cut 208a is fully unwound, the inner diameter end of the first cut 208a is welded to an outer diameter end of the second cut 208b, which has been lifted and repositioned at the selected position 308 so that the inner diameter end of the first cut 208a is completely aligned, and not offset from, the outer diameter end of the second cut 208b. Then welder 216 then joins, by welding, the two ends together, and the weld is marked as noted above. During welding, the motor is in neutral and is neither causing rotation nor reciprocation/oscillation of the rewind mandrel 320.

When welding is completed and the weld marked, the motor is engaged to repeat the unwind and rewind process discussed above with reference to the first cut 208a.

These steps are completed until the desired number of cuts have been connected to one another and rewound on the rewind mandrel 320.

When completed, the continuously connected cuts can be lifted and placed vertically onto a pallet 224. While paper can be placed between the cuts, no spacer is normally required to be positioned between adjacent cuts. This is so because of the zig-zag rewind pattern.

In either of the configurations of FIGS. 2-3, the weld line would be marked with a bold line, most likely a marker, to identify the weld (which can be a weak point in the strip). The same marking would be on the finished tab and “kicked out” by the finished end camera system looking for marks on the tab/end. Even if any tab incorporating the weld were to be missed, the weld has been shown to make a good functional tab if needed.

A number of variations and modifications of the disclosure can be used. It would be possible to provide for some features of the disclosure without providing others.

For example in one alternative embodiment, the entry mandrel in the process of FIG. 3 moves or reciprocates/oscillates back-and-forth while the rewind mandrel does not. In other words, the rewind mandrel is not displaced along its longitudinal axis but, as in the case of the entry mandrel, rotates.

In another alternative embodiment, the rewind mandrel in the process of FIG. 3 is moved to index with each cut positioned along the length of the entry mandrel 304. In other words, the cuts are not moved sequentially to a selected position along the entry mandrel but remain stationary.

In another alternative embodiment, the process of either FIG. 2 or 3 is used to manufacture end stock for shell fabrication. Rather than cuts being connected, end stock coils are connected or welded to one another.

The present disclosure, in various aspects, embodiments, and configurations, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various aspects, embodiments, configurations, subcombinations, and subsets thereof. Those of skill in the art will understand how to make and use the various aspects, aspects, embodiments, and configurations, after understanding the present disclosure. The present disclosure, in various aspects, embodiments, and configurations, includes providing devices and processes in the absence of items not depicted and/or described herein or in various aspects, embodiments, and configurations hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and\or reducing cost of implementation.

The foregoing discussion of the disclosure has been presented for purposes of illustration and description. The foregoing is not intended to limit the disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the disclosure are grouped together in one or more, aspects, embodiments, and configurations for the purpose of streamlining the disclosure. The features of the aspects, embodiments, and configurations of the disclosure may be combined in alternate aspects, embodiments, and configurations other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed aspects, embodiments, and configurations. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the disclosure.

Moreover, though the description of the disclosure has included description of one or more aspects, embodiments, or configurations and certain variations and modifications, other variations, combinations, and modifications are within the scope of the disclosure, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative aspects, embodiments, and configurations to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.

Claims

1. A process, comprising:

splitting a coil of aluminum alloy into at least first and second cut coils, each of the first and second cut coils having a cut strip width less than a width of the aluminum alloy coil; and
connecting free ends of the cut strip coiled on the first and second coils to form a continuous cut strip having a length longer than a length of the strip on the aluminum alloy coil.

2. The process of claim 1, wherein the continuous cut strip is coiled on the first and second coils, wherein the first and second coils are stacked one-on-top-of-the-other and separated by a spacer, and wherein the length of the continuous cut strip is at least about 150% of the length of the strip on the aluminum alloy coil.

3. The process of claim 1, wherein the splitting step is performed by a splitter, wherein the free ends are connected by a welder, and wherein the connecting step comprises:

placing the first and second cut coils on an entry mandrel; and
welding the free end of the first cut coil to the free end of the second cut coil.

4. The process of claim 1, wherein the continuous cut strip is coiled on a common coil, wherein the coil is staggered back-and-forth across a face of a rewind mandrel, and wherein the length of the continuous cut strip is at least about 150% of the length of the strip on the aluminum alloy coil.

5. The process of claim 1, wherein the splitting step is performed by a splitter, wherein the free ends are connected by a welder, and wherein the connecting step comprises:

positioning the first and second cut coils on an entry mandrel;
locating the first cut coil at a selected point along a length of the entry mandrel;
unwinding the first cut coil from the entry mandrel and rewinding the first cut coil on a rewind mandrel;
when the first cut coil is unwound and rewound on the rewind mandrel, locating the second cut coil at the selected point; and
connecting the free end of the first cut coil to the free end of the second cut coil to form the continuous cut strip; and further comprising:
unwinding the second cut coil from the entry mandrel and rewinding the second cut coil on a rewind mandrel.

6. The process of claim 5, wherein the rewind mandrel reciprocates back-and-forth while the first and second cut coils are rewound on the rewind mandrel to form a stagger wind of the continuous cut coil on the rewind mandrel.

7. The process of claim 1, wherein the free end of the first cut coil is an inner diameter end of the first cut coil and the free end of the second cut coil is an outer diameter end of the second cut coil.

8. The process of claim 1, wherein the continuous cut coil is marked in spatial proximity to a weld line connecting the free ends to enable sensor at a can plant to detect the weld.

9. The process of claim 1, wherein the continuous cut coil is tab stock and further comprising:

passing the continuous cut coil and can end shells through a conversion press to form a finished can end having a tab positioned on a can end.

10. The process of claim 1, wherein the width of the aluminum alloy coil ranges from about 10 to about 75 inches and the width of each of the first and second cut coils ranges from about 1 to about 10 inches.

11. A continuous cut strip having first and second strip ends welded together and being coiled on first and second coils, wherein the first and second coils are stacked one-on-top-of-the-other and separated by a spacer, and wherein the length of the continuous cut strip is at least about 150% of the length of the strip on the aluminum alloy coil.

12. The continuous cut strip of claim 10, wherein the width of each of the first and second cut coils ranges from about 1 to about 10 inches and wherein the widths of the first and second cut coils are substantially the same.

13. The continuous cut strip of claim 10, wherein the continuous cut strip is tab stock and wherein the first strip end is an inner diameter end of the first cut coil and the second strip end is an outer diameter end of the second cut coil.

14. A continuous cut strip having first and second strip ends welded together, wherein the continuous cut strip is coiled on a common coil, wherein the coil is staggered back-and-forth across a face of a rewind mandrel, and wherein the length of the continuous cut strip is at least about 150% of the length of the strip on the aluminum alloy coil.

15. The continuous cut strip of claim 14, wherein the width of each of the first and second cut coils ranges from about 1 to about 10 inches and wherein the widths of the first and second cut coils are substantially the same.

16. The continuous cut strip of claim 14, wherein the continuous cut strip is tab stock and wherein the first strip end is an inner diameter end of the first cut coil and the second strip end is an outer diameter end of the second cut coil.

17. A system for manufacturing can ends, comprising

a splitter to cut an aluminum alloy coil into first and second cut coils, each of the first and second cut coils having a width less than a width of the aluminum alloy coil;
an entry mandrel to receive the first and second cut coils; and
a welder to connect an inner diameter end of the first cut coil to an outer diameter end of the second cut coil.

18. The system of claim 17, further comprising:

a lift to lift each of the first and second cut coils onto the entry mandrel; and
an upender unit to remove the first and second cut coils from the entry mandrel.

19. The system of claim 17, further comprising:

a lift to lift each of the first and second cut coils onto the entry mandrel.

20. The system of claim 19, further comprising:

a reciprocating rewind mandrel to unwind the first and second cut coils and stagger wind the continuous cut strip into a common coil; and
an upender unit to remove the common coil from the rewind mandrel.

21. The system of claim 19, wherein each of the first and second cut coils is unwound from a common location on the entry mandrel.

Patent History
Publication number: 20150209854
Type: Application
Filed: Jan 29, 2015
Publication Date: Jul 30, 2015
Inventor: Mark Selepack (Longmont, CO)
Application Number: 14/608,873
Classifications
International Classification: B21D 51/38 (20060101);