LOW SPREAD METAL ELONGATED BOTTLE AND PRODUCTION METHOD

Abstract

A low-spread metal elongated bottle and its production method are described for reducing rejection rates associated with the production of metal bottles at high speeds. The elongated bottle includes a sheet metal formed body. The sheet metal has a low spread between a yield state corresponding to the yield stress of the sheet metal and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal. The body further includes a concave bottom portion having a circular perimeter. A cylindrical portion extends from the circular perimeter of the bottom portion and has a uniform diameter. A neck portion extends from the cylindrical portion and has a tapered profile. The neck portion may include a threaded portion including threads exposed on the outer surface of the neck portion or an area for crimping of a crown.

Description

FIELD

This disclosure relates to a metal elongated bottle and its method of production, and, in particular, to an elongated low-spread aluminum bottle and its method of production.

BACKGROUND

Beverage containers are often made from a metal sheet due to the robust structure, light weight, and good thermal conductivity of metal sheet materials. For example, aluminum cans are prevalent in the beverage industry and are made from aluminum sheet coils that are cut, drawn, formed, trimmed and coated to form cylindrical containers. The cylindrical containers are then filled with a beverage and sealed with a single-use lid.

Recently, metal sheet material has also been used to create aluminum, bottle-shaped containers that have a narrow neck and an open end that is either threaded to receive a cap or includes a crimped crown. The narrow neck and slender shape of aluminum bottles provide more comfort for drinkers holding the bottle and also provide an appealing visual appearance. However, the elongate shaped body and the narrow neck of aluminum bottles require increased plastic deformation of the original aluminum sheet material when the bottle is formed. The increased deformation of the aluminum sheet has resulted in increased manufacturing defects and higher rejection rates when compared with aluminum can manufacturing.

SUMMARY

This disclosure presents a low-spread metal elongated bottle and its production method. As described in more detail below, the low-spread metal bottle and production method result in reduced rejection rates as compared with rejection rates when aluminum bottles are made using traditional aluminum can materials and manufacturing methods. The low-spread metal elongated bottle is formed from a low-spread metal and includes an elongated body shape and a narrow neck. The low-spread metal has a low spread between a yield state corresponding to the yield stress of the sheet metal and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal.

In a specific aspect, the spread of the sheet metal equals to the arithmetic difference between the yield stress and the ultimate tensile stress. For example, in some embodiments, the difference between the yield stress and ultimate tensile stress of the low-spread sheet metal is about 22.4 MPa or 3.25 ksi. In some embodiments, the yield stress of the low-spread sheet metal is about 200 MPa or 29 ksi.

In another aspect, there is described a method for manufacturing an elongated bottle that includes providing a piece of sheet metal having a low spread between a yield state and an ultimate tensile state. The yield state corresponds to the yield stress of the sheet metal and the ultimate tensile state corresponds to the ultimate tensile stress of the sheet metal. The piece of sheet metal is formed into a circular cup. The circular cup is drawn into a cylindrical container having an open end and a closed end. The closed end of the cylindrical container is formed into a concave bottom portion. The open end of the cylindrical container is narrowed into a neck portion.

In one specific aspect, the method further includes trimming the open end for a straight edge prior to narrowing the open end into the neck portion.

In another specific aspect, narrowing the open end of the cylindrical container into a neck portion further includes applying a pressure perpendicular to the cylindrical axis of the central container near the open end.

In yet another specific aspect, the method further includes applying a layer of paint onto the outer surface of the elongated bottle. The layer of transparent seal is further applied onto the layer of paint.

In one specific aspect, the method further includes applying a film of seal onto the inner surface of the elongated bottle.

In another specific aspect, the spread of the sheet metal is the arithmetic difference between the yield stress and the ultimate tensile stress of the sheet metal. In some embodiments, the spread is within about 22.4 MPa or 3.25 ksi.

In another aspect, there is described an elongated bottle that includes a sheet metal formed body, wherein the sheet metal of the sheet metal formed body has a low spread between a yield state corresponding to the yield stress of the sheet metal and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal. The body also includes a concave bottom portion that has a circular perimeter and a cylindrical portion that extends from the circular perimeter of the bottom portion. In some embodiments, the cylindrical portion has a uniform diameter. The bottle also includes a neck portion that has a varying diameter reduced from the uniform diameter of the cylindrical portion to form a tapered profile. The bottle also includes an opening.

In some embodiments, the arithmetic difference between the yield stress and the ultimate tensile stress of the sheet metal is between about 21 MPa or 3.05 ksi and about 23.1 MPa or 3.35 ksi.

In other embodiments, the arithmetic difference between the yield stress and the ultimate tensile stress of the sheet metal is between about 21.4 MPa or 3.1 ksi and about 22.8 MPa or 3.3 ksi.

In yet other embodiments, the arithmetic difference between the yield stress and the ultimate tensile stress of the sheet metal is about 22.1 MPa or 3.2 ksi.

In still other embodiments, the yield stress of the sheet metal is between about 196.5 MPa or 28.5 ksi and about 217.2 MPa or 31.5 ksi.

In another embodiment, the yield stress of the sheet metal is between about 29 ksi and about 31 ksi.

In still another embodiment, the yield stress is about 29.8 ksi.

In some embodiments, the cylindrical portion of the bottle has a length between about 114 mm or 4.490″ and about 162 mm or 6.381″.

In other embodiments, the cylindrical portion has a length of about 162 mm.

In still other embodiments, the bottle has a total length between about 190 mm and about 238 mm.

In another embodiment, the bottle has a total length of about 238 mm.

In certain embodiments, the neck portion of the bottle includes a threaded portion.

In other embodiments, the threaded portion of the neck portion includes a folded flange.

In some embodiments, the bottle includes a threaded cap that is couplable with the threaded portion.

In another aspect, there is described a method for manufacturing an elongated bottle that includes providing sheet metal having a low spread between a yield state corresponding to the yield stress of the sheet metal and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal. The method includes forming the sheet metal into a circular cup and drawing and ironing the circular cup into a cylindrical container having an open end and a closed end. The method also includes forming the closed end of the cylindrical container into a concave bottom portion and cutting the open end of the cylindrical container. The method also includes forming the open end of the cylindrical container into a neck portion.

In some embodiments, the method includes forming the container to have a total length between about 127 mm or 5″ and about 254 mm or 10″.

In other embodiments, the method includes forming the container to have a total length of about 238 mm.

In some other embodiments, an arithmetic difference between the yield stress and the ultimate tensile stress is about 22.4 MPa or 3.2 ksi.

In another aspect, there is provided a method for manufacturing a beverage bottle that includes forming sheet metal into a circular cup, wherein the sheet metal has a low spread between a yield state corresponding to the yield stress of the sheet metal and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal. The arithmetic difference between the yield stress and the ultimate tensile stress of the sheet metal is about 22 MPa or 3.2 ksi and the yield stress is about 205.5 MPa or 29.8 ksi. The method also includes drawing and ironing the circular cup into a cylindrical container that has an open end and a closed end. The method also includes forming the closed end of the cylindrical container into a concave bottom portion and cutting the open end of the cylindrical container. The method also includes narrowing the open end of the cylindrical container into a neck portion and folding an edge of the open end outward to form a flange. In some embodiments, the bottle has a total length of about 238 mm.

In other embodiments, the method includes forming a shoulder portion at an angle of about 45 degrees to a body portion of the container.

Other aspects, features, and advantages will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are part of this disclosure and which illustrate, by way of example, principles of the disclosure.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 is a schematic of an embodiment of an elongated bottle made of a low-spread metal in accordance with this disclosure.

FIGS. 2A and 2B are graphs showing a stress-strain relationship of the low-spread metal used to make the elongated bottle shown in FIG. 1.

FIG. 3 is a schematic of a cap for sealing the elongated bottle of FIG. 1.

FIG. 4 is a flow chart illustrating an embodiment of a method for producing the elongated bottle of FIG. 1.

DETAILED DESCRIPTION

Metal elongated bottles have many advantages over traditional can-shaped containers (as briefly discussed in the background). However, during manufacturing, rejection rates for elongated bottles may be higher than rejection rates of traditional cans due to the more complicated geometry of the bottle and the higher plastic deformation required for the elongated shape and narrower neck of the bottle. For example, rejections rates in the production of metal bottles may range from about 5% to about 95% due to defects such as excessive metal expansion and brim roll splitting.

It was previously thought that a wide spread between the yield stress and the ultimate tensile stress of the sheet aluminum used to form aluminum containers would provide lower rejection rates by allowing for increased operating latitude for metal forming properties. It has been found, however, that a low spread, i.e., a low difference between the yield stress and the ultimate tensile stress, of the sheet aluminum, such as the 3104 series aluminum, provides for lower rejection rates at high production speeds. In addition, it has been found that special post-forming thermal treatment of the metal, in conjunction with low spread metal, also helps to reduce manufacturing defects. For example, in some embodiments, a cup formed from a low spread metal is heat treated after a decorative printing coat is applied to the cup to dry the decorative printing. The cup is then necked and threaded, and a brim roll is applied to the bottle opening. In some embodiments, the heat treating of the metal, in conjunction with the low spread metal, removes a sufficient amount of work hardening to allow for necking, threading and brim rolling at high production speeds with low defect rates.

This disclosure presents a low-spread metal elongated bottle and a production method for reducing rejection rates associated with the production of aluminum bottles. In some embodiments, the production method described herein also allows for the production of an elongated bottle that is taller than previously available aluminum bottles. In some embodiments, the production method described herein also allows for a thinner side wall thickness and thus a lower aluminum material usage than previously available. Further, the disclosed processes and apparatuses may be used to form complicated bottle shapes that are less feasible with non-low-spread metals.

FIG. 1 is a schematic of an elongated bottle 100 made of a low-spread sheet metal 101. The elongated bottle 100 can be mass-produced from coils of the low-spread sheet metal 101 using “drawing and ironing” manufacturing methods. In some embodiments, for a thicker wall thickness, impact extrusion methods may also be used with slugs of similar physical properties. The low-spread sheet metal 101 is a heat treated and chemical treated aluminum alloy that has a low spread (i.e., arithmetic difference) between a yield state corresponding to the yield stress of the sheet metal 101 and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal 101.

The elongated bottle 100 shown in FIG. 1 is an example of a bottle 100 made using low spread metal and other geometries, designs, and variations are possible. The elongated bottle 100 includes a concave bottom portion 115, a cylindrical portion 110 and a neck portion 105 that includes a threaded portion 120. The bottom portion 115 includes a circular perimeter 117. The concave shape of the bottom portion 115 provides structural support for pressurized beverage fluids contained therein. The bottom portion 115 is created from the center portion of the sheet metal 101 and forms a closed end. The cylindrical portion 110 extends from the circular perimeter 117 and has a uniform diameter 112. During production, the cylindrical portion 110 is drawn and ironed to a length slightly exceeding the height of the bottle 100. In some embodiments, the cylindrical portion 110 has a wall thickness of between about 0.213 mm or 0.0084″ and about 0.239 mm or 0.0094″. In other embodiments, the cylindrical portion 110 has a wall thickness of about 0.165 mm or 0.0065″.

The neck portion 105 is formed near the open end 191 of the bottle 100. The neck portion 105 has a varying diameter reduced from the uniform diameter 112 of the cylindrical portion 110. The varying diameter forms a tapered profile 107 that gradually constricts the neck portion 105 toward the opening 123. In some embodiments, a shoulder portion 111 of the neck portion 105 extends at an angle of about 45 degrees from the cylindrical portion 110. In some embodiments, a top neck portion 113 of the neck portion 105 extends at an angle of about 6 degrees from a center line 103 of the bottle 100. In some embodiments, the top neck portion 113 of the neck portion 105 extends at an angle of about 5.75 degrees from the center line 103 of the bottle 100.

The neck portion 105 includes a threaded portion 120 that has one or more threads 122 exposed on the outer surface of the threaded portion 120. The threads 122 enables a threaded cap 300 (FIG. 3) to close and seal the opening 123. In some embodiments, the threaded portion 120 further includes a folded flange 125 that is folded outwardly from the opening 123 for safe contact when a beverage is consumed from the bottle 100.

In some embodiments, a printed indicia 118 is applied onto the outer surface of the bottle 100. The print indicia 118 may be further sealed with a clear or transparent coat 119 applied to the outer surface of the bottle 100. An inner coating 130 may be applied to an inner surface of the elongated bottle 100 for separating a beverage from the sheet metal 101.

In some embodiments, the cylindrical portion 110 of the bottle 100 has a height of between about 114 mm or 4.490″ and about 162 mm or 6.381″. In some embodiments, the cylindrical portion 110 has a height of between about 120 mm or 4.7244″ and about 155 mm or 6.1024″. In other embodiments, the cylindrical portion 110 has a height of about 162 mm or 6.3779″. In some embodiments, the bottle 100 has an overall height of between about 190 mm or 7.48″ and about 238 mm or 9.37″. In other embodiments, the bottle 100 has an overall height of between about 200 mm or 7.874″ and about 220 mm or 8.661″. In other embodiments, the bottle 100 can have an overall height up to about 762 mm or 30″. As described in more detail below, bottles of this height were previously difficult to form on a consistent basis at high production rates due to high defect rates. For example, the increased amount of cold working of metal involved in forming a taller container caused the metal to become more brittle, leading to an increased rate of manufacturing defects. It has been found that the use of low spread metal in conjunction with heat treating allows for the creation of bottle-shaped containers at high speeds with low defect rates. The present disclosure allows for consistent, low-defect-rate production of bottles 100 with an overall height of about 238 mm (9.37″) or taller at high production speeds.

FIGS. 2A and 2B show embodiments of an example stress-strain relationship of a low-spread sheet metal 210 and a non-low-spread sheet metal 220. FIGS. 2A and 2B are for illustration purposes and other materials with other stress-strain relationships are within the scope of this disclosure. Referring now specifically to FIG. 2A, a stress-strain curve of a low-spread sheet metal is shown at 210 and a stress-strain curve of a non-low-spread sheet metal is shown at 220. The horizontal axis of the FIG. 2A shows the strain variable (ε) and the vertical axis shows the stress variable (σ). The two different metals represented by curves 210 and 220 have the same elasticity modulus (E) shown at numeral 215 and the same yield stress (σ_y) shown at numeral 202. As shown by the curves 210 and 220, the yield stress 202 corresponds to the strain 222 and a (yield stress, strain), or (σ_y, ε₁), is defined at the intersection between the stress-strain relationship and the straight line extending at a slope of the elasticity modulus (E) 215 from (ε_0.2, 0), where ε_0.2=0.002. The ultimate tensile stress of the low-spread metal 210 is represented by σ_uL, shown at numeral 204, and the ultimate tensile stress of the non-low-spread metal 220 is represented by σ_uN, shown at numeral 206. In this example, σ_uL and σ_uN both correspond to the same ultimate tensile strain ε_T shown at numeral 224. In the example illustrated in FIG. 2A, σ_yL=σ_yN=σ_y for ease of comparison. Actual values of σ_yL and σ_yN may be different. Similarly, the ultimate tensile strain ε_T may also have respective values for the low-spread metal 210 and the non-low-spread metal 220. For the same alloy, σ_uL and σ_uN may vary depending on heat treatment, variations in the alloy elements, chemical treatment, or other alternations to the structure of the metal crystals.

As shown in FIG. 2A, the difference between the yield stress and the ultimate tensile stress of the low-spread metal 210 is less than the difference between the yield stress and the ultimate tensile stress of the non-low-spread metal, such that σ_uL−σ_yL<σ_uN−σ_yN. In some embodiments, the difference (i.e., spread) between the ultimate tensile stress σ_uL and the yield stress σ_yL of the low-spread sheet metal 210 is significantly smaller than the difference between the ultimate tensile stress σ_uN and the yield stress σ_yN of the non-low-spread sheet metal 220. In some embodiments, for example, the low-spread sheet metal 210 has an ultimate tensile stress of about 227.53 MPa or 33 ksi and a yield stress of about 205.46 MPa or 29.8 ksi, and a typical non-low-spread sheet metal has an ultimate tensile stress of about 268.9-317.2 MPa or 39-46 ksi and a yield stress of about 241-289.6 MPa or 35-42 ksi.

In some embodiments, the ultimate tensile stress of the low-spread aluminum sheet material is between about 213.7 MPa or 31 ksi and about 241.3 MPa or 35 ksi. In some embodiments, the ultimate tensile stress of the aluminum sheet material is about 227.5 MPa or 33 ksi. In some embodiments, the yield stress of the aluminum sheet material is between about 196.5 MPa or 28.5 ksi and about 217.2 MPa or 31.5 ksi. In other embodiments, the yield stress is about 205.5 MPa or 29.8 ksi. It has been found that yield stress below about 193 MPa or 28 ksi may result in a loss of buckle strength of the bottle 100. In some embodiments, the arithmetic difference between the yield stress and the ultimate tensile stress of the low-spread metal is between about 21 MPa or 3.05 ksi and about 23.1 MPa or 3.35 ksi. In other embodiments, the arithmetic difference between the yield stress and the ultimate tensile stress in the low-spread metal is between about 21.4 MPa or 3.1 ksi and about 22.1 MPa or 3.2 ksi. In some embodiments, the arithmetic difference between the yield stress and the ultimate tensile stress in the low-spread metal is about 22.4 MPa or 3.25 ksi. In some embodiments, for example, the low-spread metal 210 may have a yield stress σ_y=200 MPa (or 29 ksi) and a tensile stress σ_uL=222.4 MPa (or 32.25 ksi). The low spread σ_uL−σ_Y is therefore within about 22.4 MPa (or 3.25 ksi). As explained above, the arithmetic difference in non-low-spread metal between the yield stress and the ultimate tensile stress is typically about 255.1 MPa or 37 ksi.

During deformation, the achievable maximum plastic deformation of the low-spread sheet metal 210 is ε_L shown at numeral 233, wherein ε_T−ε_L is the elastic strain. Similarly, the maximum plastic deformation of the non-low-spread sheet metal 220 is ε_N shown at numeral 231, wherein ε_T−ε_N is the elastic strain. Because σ_uN is greater than σ_uL, and both metals 210 and 220 have the same elasticity modulus E 215, the achievable plastic deformation ε_L 233 is greater than ε_N 231. Therefore, it has been found that the low-spread metal 210 can withstand greater plastic deformation during high speed metal bottle production than non-low-spread metal 220. In addition, it has been found that the difference between ε_L 233 and ε_N 231 in low-spread metal reduces the rejection rates during production by reducing tearing and defects in the bottles. In some embodiments, for example, low spread metal having a spread of about 3.2 ksi has produced bottles 100 at a rate of about 1,200 bottles per minute with a defect rate of about 3%, as compared with defect rates from about 10% to about 60% with non-low-spread material.

It was previously thought that a low spread between the yield stress and the ultimate tensile stress of metal sheets used to form cans and bottles would increase defect rates and slow production. Specifically, it was previously thought that a wide spread was necessary to provide increased operating latitude for metal forming properties. However, it has been found that using sheet metal with a low spread between the yield stress and the ultimate tensile stress is well suited to form elongated aluminum bottles at high speeds.

FIG. 2B shows a second example set of stress-strain curves comparing a low-spread sheet metal 260 and a non-low-spread sheet metal 270. Similar to FIG. 2A, the horizontal axis of FIG. 2B shows the strain variable (ε) and the vertical axis shows the stress variable (σ). The two different metals 260 and 270 have the same elasticity modulus E 215 and the same yield stress σ_y 252. σ_y 252 corresponds to the strain ε₁ 272, wherein (ε₁, σ_y) is defined at the intersection between the stress-strain relationship and the straight line extending at a slope of E 265 from (ε_0.2, 0), where ε_0.2=0.002. The ultimate tensile stress of the low-spread metal 260 is σ_uL 254, and the ultimate tensile stress of the non-low-spread metal 270 is σ_uN 256. σ_uL 254 corresponds to the ultimate tensile strain ε_uL 275 and σ_uN 256 corresponds to the ultimate tensile strain ε_uN 285. In the example illustrated in FIG. 2B. σ_yL=σ_yN=σ_y, although, as explained above, these values may vary.

As described above, the low-spread sheet metal 260 has a lower spread than the non-low-spread sheet metal 270, or, in other words, σ_uL−σ_yL<σ_uN−σ_yN. In the example illustrated in FIG. 2B, the lower ultimate tensile strength σ_uL 254 corresponds to a greater ultimate tensile strain ε_uL 275 than ε_uN 285, i.e., ε_uL>ε_uN. During deformation, the achievable maximum plastic deformation of the low-spread sheet metal 260 is ε_L 273, wherein ε_uL−ε_L is the elastic strain. Similarly, the maximum plastic deformation of the non-low-spread sheet metal 270 is ε_N 283, wherein ε_uN−ε_N is the elastic strain. Because σ_uN is greater than σ_uL, and the both metals 210 and 220 has the same elasticity modulus E 215, the elastic deformation portion (ε_uN−ε_N) is greater than (ε_uL−ε_L). Furthermore, ε_L is greater than ε_N. Therefore, it has been found that the low-spread metal 260 can withstand much greater plastic deformation than the non-low-spread metal 270 at high production rates. It has also been found that the difference between ε_L 273 and ε_N 283 can help reduction of rejection rates during production by providing a higher strain value ε_L for plastic deformation. It has been found that a wide spread is not necessary because the pre-form container can be consistently formed without manufacturing defects. In fact, it has been found that a wide spread increases the rate of manufacturing defects related to neck and thread formation.

FIG. 3 is a schematic of a cap 300 for sealing the elongated bottle 100 of FIG. 1. The cap 300 includes a spiral thread 310 that corresponds to the spiral thread 122 of the bottle 100. The spiral thread 310 can engage the threaded portion 120 to seal the elongated bottle 100. In some implementations, the cap 300 may be made of metal, plastic, or other suitable materials. The cap 300 may also include a component indicating the cap 300 has been opened once, such as a breakable band at the bottom edge of the cap 300.

FIG. 4 is a flow chart 400 of a method for producing the elongated bottle 100 of FIG. 1. At step 402, low-spread sheet metal is provided for making the elongated bottle 100. The low-spread sheet metal has a low spread between a yield state corresponding to the yield stress of the sheet metal and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal. In some embodiments, the low spread of the sheet metal equals to the arithmetic difference between the yield stress and the ultimate tensile stress. For example, in some embodiments, the arithmetic difference between the yield stress and ultimate tensile stress of the low-spread metal is about 22.4 MPa or 3.25 ksi.

At step 404, the sheet metal is formed into a cup. The cup is then drawn into a cylindrical container at step 406. The cylindrical container has an open end and a closed end. At step 408, a concave bottom portion is formed at the closed end of the cylindrical container. In some embodiments, the open end is trimmed for a straight edge prior to narrowing the open end into the neck portion. At step 410, a decorative coating and sealer are applied to the cup. In some embodiments, a layer of paint is applied onto the outer surface of the elongated bottle 100 and a layer of transparent sealer 119 may further be applied onto the layer of paint. A film of sealer 130 may be applied onto the inner surface of the elongated bottle 100 for separating the drink from the sheet metal. At step 412, the cylindrical container may be heat treated to remove some or all of the work hardening effect incurred at previous steps and to dry the decorative coating or sealer applied to the cup. At step 4114, a neck portion is formed near the opening 123 of the cylindrical container 100. The neck portion 105 may be formed in a necking operation and may have a varying diameter forming a narrowing tapered profile 107.

At step 416, a threaded portion 120 is formed on the neck portion 105 by deforming or indenting a portion of the neck portion 105 to form one or more threads 122. The threads 122 are exposed on the outer surface of the elongated bottle 100. At 418, a flange 125 at the edge of the opening 123 is folded outwardly to provide a rounded rim.

In some embodiments, the temperature set points and cycle duration during step 412 are configured to cure any decorative coating applied to the bottle and to thermally recover the metal. For example, the coated bottle 100 may pass through a washer dry-off oven, a pin oven, and a bake oven. In some embodiments, the coated bottle 100 may travel at about 5-17 ft/min through the washer dry-off oven at about 275-500° F. Then the coated bottle 100 may travel at the rate of about 200-1500 cans/min through the pin oven at about 390-500 F. And finally the coated bottle 100 may travel through the bake oven at a maximum speed of about 12-22 ft/min. The inside oven temperature can be about 290-340° F. in a first zone, 410-500° F. in a second zone, and 400-500° F. in a third zone.

In a different embodiment, the coated bottle 100 may travel at about 6-14 ft/min through the washer dry-off oven at about 280-350° F. Then the coated bottle 100 may travel at the rate of about 400-1300 cans/min through the pin oven at about 425-485° F. And finally the coated bottle 100 may travel through the bake oven at a maximum speed of about 14-20 ft/min. The inside oven temperature can be about 300-330° F. in a first zone, about 450-490° F. in a second zone, and about 440-490° F. in a third zone.

In some other embodiments, the coated bottle 100 may travel at about 7-12 ft/min through the washer dry-off oven at about 300-320° F. Then the coated bottle 100 may travel at the rate of about 600-1200 cans/min through the pin oven at about 460-470° F. And finally the coated bottle 100 may travel through the bake oven at a maximum speed of about 16-18 ft/min. The inside oven temperature can be about 310-320° F. in a first zone, about 465-475° F. in a second zone, and about 460-470° F. in a third zone. It has been found that, in some embodiments, the above temperatures and travel rates recover at least some of the work hardening of the material to allow the low spread metal to be formed into the shape of a bottle with a neck-shaped portion, as described above.

In the foregoing description of certain embodiments, specific terminology has been chosen for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. In this specification, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.

In addition, the foregoing describes some embodiments of the disclosure, and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.

Furthermore, the disclosure is not to be limited to the illustrated implementations, but to the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the disclosure. Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.

Claims

1. An elongated bottle, comprising:

a body formed of sheet metal, wherein the sheet metal has a low spread between a yield state corresponding to the yield stress of the sheet metal and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal, the body further comprising: a concave bottom portion having a circular perimeter; a cylindrical portion extending from the circular perimeter of the bottom portion, the cylindrical portion having a uniform diameter; a neck portion having a varying diameter reduced from the uniform diameter of the cylindrical portion, the varying diameter forming a tapered profile; and an opening.

2. The elongated bottle of claim 1, wherein the arithmetic difference between the yield stress and the ultimate tensile stress of the sheet metal is between about 21 MPa or 3.05 ksi and about 23.1 MPa or 3.35 ksi.

3. The elongated bottle of claim 1, wherein the arithmetic difference between the yield stress and the ultimate tensile stress of the sheet metal is between about 21.4 MPa or 3.1 ksi and about 22.75 MPa or 3.3 ksi.

4. The elongated bottle of claim 1, wherein the arithmetic difference between the yield stress and the ultimate tensile stress of the sheet metal is about 22 MPa or 3.2 ksi.

5. The elongated bottle of claim 1, wherein the yield stress of the sheet metal is between about 196.5 MPa or 28.5 ksi and about 217.2 MPa or 31.5 ksi.

6. The elongated bottle of claim 1, wherein the yield stress of the sheet metal is between about 213.7 MPa or 31 ksi and about 268.9 MPa or 39 ksi.

7. The elongated bottle of claim 3, wherein the yield stress of the sheet metal is about 205.5 MPa or 29.8 ksi.

8. The elongated bottle of claim 1, wherein the cylindrical portion has a length between about 114 mm or 4.490″ and about 162 mm or 6.381″.

9. The elongated bottle of claim 8, wherein the cylindrical portion has a length of about 162 mm.

10. The elongated bottle of claim 1, wherein the bottle has a total length between about 190 mm and about 238 mm.

11. The elongated bottle of claim 1, wherein the bottle has a total length of about 238 mm.

12. The elongated bottle of claim 1, wherein the neck portion comprises a threaded portion.

13. The elongated bottle of claim 12, wherein the threaded portion further comprises a folded flange.

14. The elongated bottle of claim 12, further comprises a threaded cap that is couplable with the threaded portion.

15. A method for manufacturing an elongated bottle, the method comprising:

providing sheet metal having a low spread between a yield state corresponding to the yield stress of the sheet metal and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal;

forming the sheet metal into a circular cup;

drawing and ironing the circular cup into a cylindrical container having an open end and a closed end;

forming the closed end of the cylindrical container into a concave bottom portion;

cutting the open end of the cylindrical container; and

forming the open end of the cylindrical container into a neck portion.

16. The method of claim 15, wherein the bottle has a total length between about 190 mm and about 238 mm.

17. The method of claim 15, wherein the bottle has a total length of about 238 mm.

18. The method of claim 15, wherein an arithmetic difference between the yield stress and the ultimate tensile stress of the sheet metal is about 3.2 ksi.

19. A method for manufacturing a beverage bottle, the method comprising:

forming sheet metal into a circular cup, the sheet metal having a low spread between a yield stress of the sheet metal and an ultimate tensile stress of the sheet metal, wherein an arithmetic difference between the yield stress and the ultimate tensile stress of the sheet metal is about 22.4 MPa and wherein the yield stress is about 200 MPa;

drawing and ironing the circular cup into a cylindrical container having an open end and a closed end;

forming the closed end of the cylindrical container into a concave bottom portion;

cutting the open end of the cylindrical container;

narrowing the open end of the cylindrical container into a neck portion; and

folding an edge of the open end outwardly to form a flange;

wherein the bottle has a total length of about 238 mm.

20. The method of claim 19, further comprising forming a shoulder portion at an angle of about 45 degrees to a body portion of the container.