Method and Apparatus for Reforming an Inside Dome Wall Portion of a Container

Info

Publication number: 20170361971
Type: Application
Filed: Jun 16, 2017
Publication Date: Dec 21, 2017
Applicant: Ball Corporation (Broomfield, CO)
Inventors: Kevin R. Jentzsch (Arvada, CO), Mark A. Jacober (Arvada, CO)
Application Number: 15/625,518

Abstract

A reform apparatus for reforming a bottom portion of a metallic beverage container is provided. The reform apparatus generally includes a pair of reform rollers interconnected to pivot arms. Spring are operably interconnected to the reform rollers such that the reform rollers a biased radially inwardly in an unactuated state. The springs at least one of spring bushings and compression springs. The reform rollers rotate radially outwardly when a wedge member pushes axially between the two pivot arms. The wedge member engages and imparts rotation to the pivot arms. An annular edge of each of the reform rollers contacts an inner wall portion of the bottom portion of the beverage container to form a groove of a predetermined size and shape.

Description

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 62/351,510 filed Jun. 17, 2016, which is incorporated herein in its entirety by reference.

FIELD OF THE INVENTION

The present invention relates generally to the manufacture of containers. More specifically, the present invention relates to a method and apparatus for reforming the bottom portion of a metallic container to enhance strength characteristics.

BACKGROUND

Metallic beverage containers offer distributors and consumers many benefits. The metallic body of a beverage container provides optimal protection properties for products. For example, the metallic body prevents CO₂migration and transmission of UV radiation which may damage beverages, negatively influencing the flavor, appearance, or color of the product. Metallic beverage containers also offer an impermeable barrier to light, water vapor, oils and fats, oxygen, and micro-organisms and keep the contents of the container fresh and protected from external influences, thereby guaranteeing a long shelf-life. The surfaces of metallic containers are also ideal for decorating with brand names, logos, designs, product information, and/or other preferred indicia for identifying, marketing, and distinguishing the metallic container and its contents from other products and competitors. Thus, metallic containers offer bottlers, distributors, and retailers an ability to stand out at the point of sale.

Additionally, many consumers prefer metallic containers compared to containers made of glass or plastic. Metallic containers are particularly attractive to consumers because of the convenience they offer. The light weight of metallic containers makes them easier to carry than glass containers. Metallic containers are particularly suitable for use in public places and outdoors because they are more durable than glass containers. Further, some consumers avoid plastic containers due to concerns that the plastic may leach chemicals into consumable products.

As a result of these benefits, sales of metallic containers were valued at approximately $53 billion globally in 2014. A large percentage of the metallic container market is driven by beverage containers. According to one report, approximately 290 billion metallic beverage containers were shipped globally in 2012. One U.S. trade group reported that 126 billion metallic containers were shipped in the U.S. alone in 2014. To meet this demand, metallic container manufacturing facilities operate some of the fastest, if not the fastest, production lines in the container industry. Accordingly, specialized equipment is required for many of the operations performed to form the metallic beverage containers.

Metallic beverage containers come in a variety of shapes and sizes. Common sizes range from about 6 ounces to about 32 ounces or larger. Exemplary diameter sizes for beverage containers are 2 2/16 inches, 2 4/16 inches, and 2 11/16 inches, which are commonly known as 202, 204, and 211 containers, respectively. Numerous other diameter sizes exist and are well known in the art. Metallic beverage containers are typically cylindrical, although other shapes are known.

Beverage containers are generally formed of two separate pieces, a container body and a container end closure. The container body is formed from a single piece of metal and includes a bottom dome portion, a sidewall portion, and a neck portion with a decreased diameter extending upwardly from the sidewall portion. The neck portion is adapted to receive an end closure after the container body is filled with a beverage. An example of a known process of forming a container body is generally illustrated and described in “Inside a Ball Beverage Can Plant,” available at: http://www.ball.com/Ball/media/Ball/Global/Downloads/How_a_Ball_Metal_Beverage_Can_Is_Made.pdf?ext=.pdf (last visited Mar. 28, 2017) which is incorporated herein by reference in its entirety.

An important consideration in designing and fabricating such beverage containers involves providing a desirable balance between minimizing material requirements (such as providing relatively thin-gauge metal) while achieving a beverage container that will maintain its integrity and/or form, despite shipping and handling impacts or forces and impacts arising from dropped beverage containers and shipping mishaps. Moreover, it is critical to provide beverage containers which maintain integrity and/or form even when the contents are under pressure due to carbonated or otherwise gas-pressurized contents and/or arising from high internal temperatures, including, in some cases, pasteurization temperatures.

Typical beverage container forming processes include subjecting a thin sheet of metal alloy to a series of drawing, ironing, and/or forming operations. One of the first steps performed on such a metal sheet is a cupping process where the sheet is drawn into a seamless cup to establish an initial shape and inside diameter of the beverage container. Subsequently, the cup is pushed through a series of ironing rings to thin the outer wall of the container to a selected thickness. During these ironing processes, performed with equipment commonly referred to as bodymaker tooling, the diameter of the container is typically maintained while the outer wall length is substantially increased to establish the fluid capacity of the beverage container. The bottom portion of the beverage container is generally formed to define a recessed or concave dome surface to resist deformation due to internal fluid pressures. The pressure at which the recessed surface is deformed or reversed is often called the “static dome reversal pressure” of the beverage container. The bottom portion of the beverage container also includes an annular support member which will contact a supporting surface to maintain the beverage container in a vertical position during stacking, consumer use, and the like.

The annular support member generally contains outer and inner surfaces that join the outer wall to the annular support member and that join the annular support member to the domed surface, respectively. These outer and inner surfaces have profiles which are shaped during the manufacture of the container to provide an outside dome profile and an inside dome profile.

The configuration of the bottom portion of the beverage container is important for a variety of reasons. The outside dome profile is often configured for purposes of stacking beverage containers. The outside and inside dome profiles are also important in facilitating material usage reductions, since various geometric configurations can be utilized to enhance strength characteristics. For example, the bottom portion may be configured to enhance the static dome reversal pressure characteristics and to reduce the risk of damage caused when a filled beverage container is dropped onto a hard surface during shipping, storage, and use. This drop resistance may be described as the cumulative drop height at which the bottom portion is damaged sufficiently to preclude the beverage container from standing upright on a flat surface.

One method of improving the strength characteristics of beverage containers is known as “reforming.” During reforming, the inside dome profile of the bottom portion of a beverage container is formed to create a geometric configuration with improved strength characteristics. Reforming results in increased buckle and drop strength for beverage containers. Methods and apparatus, known as “reformers,” used in reforming the inside dome profile of beverage containers are disclosed in U.S. Pat. No. 5,105,973, U.S. Pat. No. 5,222,385, U.S. Pat. No. 5,355,709, U.S. Pat. No. 5,524,468, U.S. Pat. No. 5,540,352, U.S. Pat. No. 5,697,242, U.S. Pat. No. 5,704,241, U.S. Pat. No. 5,706,686, U.S. Pat. No. 5,934,127, U.S. Pat. No. 6,616,393, U.S. Pat. No. 6,837,089, and U.S. Pat. No. 6,959,577 which are each incorporated herein in their entirety.

Typical beverage container manufacturing facilities contain expensive capital equipment and often produce hundreds of millions of beverage containers per year. The wear of components of reformers is inherent in such a container manufacturing facility based of the tremendous speed and output of product. The wear rings and bushings of known reformers are especially susceptible to wear and failure. In some reformers, wear rings and bushings typically last only a few months between rebuilds or before other substantial maintenance is required. For example, some known reformers typically only operate for about 3 to 4 months before requiring maintenance. During this period, the reformer may reform the interior dome of only about 315 million beverage containers.

Additionally, as the reformer components wear, there is frequently a deterioration in the precision with which the reform roller is positioned. Variations in the positioning of the reform rollers cause a departure of the container bottom shape from the intended shape or profile. Such departures can reduce the beverage container's strength, durability, or resistance to damage or failure. However, replacement of parts and other maintenance performed on reformers typically requires shutting down a production line with disadvantageous economic consequences. It is highly desirable to reduce such maintenance, as performing the maintenance results in the machine being out of service for manufacturing use, and also requires personnel to service the machine and replacement parts, all of which add to the total cost of producing beverage containers.

Further, some prior art reformers include a reform roller that is activated in response to a force applied by a metallic container contacting the reformer. For example, one known reformer requires the metallic container to apply a force to the reformer to move the reform roller outwardly into contact with the dome of the metallic container. As one of skill in the art will appreciate, the force applied by the metallic container may damage the metallic container, such as causing the body portion of the metallic container to buckle or otherwise deform.

Accordingly, it would be beneficial to have a reformer with components that last longer and which operate according to specifications for longer periods without maintenance or replacement to reduce overall maintenance in a manufacturing facility, and to reduce the inherent wear of machinery and the tooling associated therewith.

SUMMARY OF THE INVENTION

The present invention provides systems and methods for reforming a container dome wall in a cost-effective, fast, and reliable manner. One aspect of the present invention is a reforming apparatus which forms a consistent reform bead or groove in an inner wall portion of a dome portion of a beverage container while operating for extended time periods without excessive wear or failure. More specifically, the reforming apparatus of one embodiment of the present invention can operate for up to at least 1 year without significant maintenance or rebuilding. Stated differently, the reforming apparatus of the present invention can operate up to at least 400 percent longer than known reformers. In another embodiment, the reforming apparatus of the present invention can reform the bottom dome portion of approximately 1.26 billion metallic containers without significant maintenance. Accordingly, the reforming apparatus of the present invention can significantly reduce downtime and associated loss of a beverage container production line.

Another aspect of the present invention is a reform apparatus that includes a novel sliding wedge. The sliding wedge transfers axial and rotational motion to pivot arms and to reform rollers. Biasing elements bias the pivot arms inwardly toward a longitudinal axis of the reform apparatus. In one embodiment, the sliding wedge includes two slots adapted to selectively capture the pivot arms that hold the reform rollers. In this manner, the sliding wedge causes the pivot arms to rotate axially around the longitudinal axis and the reform rollers to move outwardly away from the longitudinal axis. In one embodiment, the biasing elements include at least one of spring bushings and compression springs. The spring bushings and the compression springs bias the pivot arms inwardly toward the longitudinal axis when the sliding wedge is withdrawn at least partially from a space between the pivot arms. In one embodiment, the compression springs are interconnected to a set screw that may be rotated to alter the biasing force applied by the compression springs. In another embodiment, the reform apparatus uses some of the parts of known single roller reformers.

Yet another aspect of the present invention is to provide a reform apparatus that includes two reform rollers. The two rollers balance the forming load and improve the performance and longevity of components of the reform apparatus. Said otherwise, each of the two reform rollers is configured to apply less force to an interior dome portion of a metallic container compared to known reform apparatus that only include a single reform roller. Accordingly, the reform apparatus of the present invention may reform the interior dome portion of a metallic container while applying a lower load to the metallic container than known reforming apparatus.

Another aspect of the present invention is a reform apparatus which includes reform rollers interconnected to pivot arms. The reform rollers pivot outwardly in response to movement of a wedge member between the pivot arms. Thus, the reform rollers move outwardly to engage an inner wall portion of a metallic container due to movement of the wedge member. In one embodiment, the movement of the reform rollers and the wedge is not in response to contact of the metallic container with the reform apparatus. In this manner, the reform apparatus of the present invention does not require contact of the metallic container to move the reform rollers to an engaged position. Thus, the reform apparatus of the present invention applies a lower load to the metallic container during reforming of the metallic container dome wall compared to known reforming apparatus.

Still another aspect of the present invention is a novel sliding wedge. The sliding wedge includes grooves to selectively capture pivot arms of a reform apparatus. In one embodiment, the grooves are tapered. Optionally, the tapered grooves may include a first portion with a first slope and a second portion with a second different slope. In one embodiment, the sliding wedge is made of an engineered plastic. In another embodiment, the sliding wedge is made of an organic thermoplastic polymer. In still another embodiment, the sliding wedge is made of polyether ether ketone. In one embodiment, the sliding wedge is formed from a single piece of material.

It is another aspect of the present invention to provide a sliding wedge comprising a first portion interconnected to a second portion. The sliding wedge includes two grooves. Optionally, the grooves have a depth that varies along a length of the grooves. The grooves are generally parallel to a longitudinal axis of the wedge and positioned on substantially opposite sides of the wedge. In one embodiment, the sliding wedge includes rollers. The rollers may be arranged generally transverse to the longitudinal axis of the wedge. In one embodiment, the sliding wedge includes two rollers with one roller associated with each of the grooves. At least a portion of each roller projects through an aperture in the groove with which the roller is associated. In this manner, each roller contacts and rolls up an inclined surface of a pivot arm of the reform apparatus when the sliding wedge is advance axially between the pivot arms.

Another novel aspect of the present invention is a compression spring aligned to apply a biasing force to a pivot arm of a reform apparatus. The compression spring is configured to bias the pivot arm radially inwardly toward a longitudinal axis of the reform apparatus. In this manner, a reform roller associated with the pivot arm is biased in an unactuated state such that the pivot arm is positioned proximate to the longitudinal axis. In one embodiment, the compression spring is generally radially aligned with the longitudinal axis of the reforming apparatus. Said another way, the compression spring is substantially perpendicular to the longitudinal axis.

Yet another aspect of the present invention is a reforming apparatus which has fewer moving parts and requires less lubrication and maintenance than prior art reforming apparatus. In one embodiment, the reforming apparatus includes spring bushings that generate little or no friction.

It is one aspect of the present invention to provide a reforming apparatus for shaping an inner wall portion of a closed end of a metallic container. The apparatus includes, but is not limited to, one or more of: (1) a tooling support element; (2) a dome receptacle interconnected to a distal end of the tooling support element and including a surface portion adapted to support the closed end of the metallic container; (3) pivot arms positioned within the tooling support element; (4) a biasing element to provide an inward biasing force to the pivot arms; (5) a track roller interconnected to a distal end of each of the pivot arms; (6) a reform roller interconnected to a distal end of each track roller, each reform roller including an annular edge with a predetermined shape; (7) a wedge member positioned between the pivot arms and in operable contact to travel between the pivot arms; and (8) a shaft interconnected to a proximal end of the wedge member to selectively supply axial movement to the wedge member, wherein when the wedge member is advanced toward the dome receptacle between the pivot arms by the shaft, the pivot arms extend outwardly and the annular edges of the reform rollers engage the inner wall portion of the metallic container. The biasing element biases the distal end of each of the pivot arms inwardly toward a longitudinal axis of the reforming apparatus. In one embodiment, the biasing element is at least one of a spring bushing and a compression spring. In another embodiment, a spring bushing is positioned at least partially within each of the pivot arms. Optionally, a compression spring is interconnected to each of the pivot arms. In another embodiment, the compression spring is interconnected to an exterior side of each of the pivot arms to apply an inward biasing force to each of the pivot arms.

In one embodiment, an exterior distance between the annular edges of the reform rollers increases by at least about 0.08 inches when the pivot arms extend outwardly. Optionally, an angle between the reform rollers and a longitudinal axis of the reforming apparatus increases by at least about 0.9° when the pivot arms extend outwardly. In one embodiment, each track roller has a roller axis that is oblique to the longitudinal axis when the pivot arms extend outwardly.

In another embodiment, each of the pivot arms includes a projection to be received by the wedge member. Optionally, each of the pivot arms includes an interior side which slopes inwardly proximate to the distal end.

In one embodiment, the wedge member is configured to selectively engage a portion of each of the pivot arms. In another embodiment, the wedge member includes grooves to engage an interior side of each of the pivot arms. In one embodiment, the grooves engage the interior side when the wedge member is advanced axially between the pivot arms by the shaft. Optionally, the grooves of the wedge member include a first portion with a first slope and a second portion with a second slope. In another embodiment, the grooves of the wedge member have a first depth proximate to the shaft which is less than a second depth of the grooves proximate to the reform rollers. In still another embodiment, the wedge member comprises at least one of an engineered plastic and an organic thermoplastic polymer. In one embodiment, the wedge member supplies rotational movement to the pivot arms. Further, the wedge member supplies an outwardly oriented force to the pivot arms when the wedge member is advanced toward the dome receptacle.

In one embodiment, the spring bushings include an outer portion with a central bore. In another embodiment, the spring bushings include an inner portion positioned within the central bore of the outer portion. Optionally, the inner portion includes a peripheral gap along a length of the inner portion. In another embodiment, the inner portion includes two peripheral gaps. Optionally the two peripheral gaps are substantially diametrically aligned. In one embodiment, the spring bushings are aligned with a plane that is substantially perpendicular to an axis of rotation of the shaft. In another embodiment, longitudinal axes of the spring bushings define a plane that is substantially perpendicular to the axis of rotation of the shaft.

Another aspect of the present invention is a tool adapted to shape an inner wall of a metallic container dome. The tool comprises at least one of: (1) a tool assembly with an upper end (or first end) and a lower end (or second end), the first end having a substantially flat upper surface adapted to engage the dome of the metallic container; (2) two pivot arms positioned within the tool assembly; (3) a reform roller associated with a first end of each pivot arm; (4) a wedge member positioned between the two pivot arms and having a tapered geometric profile between a first end and a second end to engage an inward portion of each of the two pivot arms; and (5) a shaft operably engaged to the second end of the wedge member, wherein when force is applied to the second end of the wedge member, the pivot arms extend outwardly and annular edges of the reform rollers engage the inner wall of the metallic container dome. In one embodiment, the wedge member has an exterior surface configured to engage an interior portion of each of the two pivot arms. In another embodiment, the wedge member includes two outwardly facing grooves to engage the interior portion of each of the two pivot arms. Optionally, the grooves have a first depth proximate to the first end that is greater than a second depth proximate to the second end. In another embodiment, at least a portion of each of the reform rollers extends at least partially above (or beyond) the substantially flat upper surface of the tool assembly. In one embodiment, the shaft is operable to rotate around a longitudinal axis. In this manner, the shaft rotates the wedge member around the longitudinal axis.

Optionally, the tool further includes biasing elements interconnected to the tool assembly to bias each of the two pivot arms inwardly toward the longitudinal axis. In one embodiment, the biasing elements comprise at least one of a spring bushing associated with each of the two pivot arms and a compression spring interconnected to each of the two pivot arms. In another embodiment, a spring bushing is positioned at least partially within each of the two pivot arms. Optionally, the spring bushings include spring axes that define a spring plane, the spring plane substantially perpendicular to the longitudinal axis of the shaft. Additionally, or alternatively, a compression spring may be interconnected to an exterior side of each of the pivot arms.

Another aspect of the present invention is a method of reforming an inner wall portion of a metallic container. The method includes one or more of, but is not limited to: (1) positioning a lower dome portion of the metallic container on a reforming apparatus, comprising: (i) a tooling housing element with a first end and a second end; (ii) a dome receptacle interconnected to the first end of the tooling housing element and including a support surface configured to support the lower dome portion of the metallic container; (iii) pivot arms located within the tooling housing element; (iv) a reform roller associated with each pivot arm, each reform roller including an annular edge; and (v) a wedge member arranged between the pivot arms and operable to travel between the pivot arms toward the dome receptacle, the wedge member adapted to extend the pivot arms outwardly when the wedge member travels toward the dome receptacle; (2) moving the wedge member toward the dome receptacle; (3) engaging the inner wall portion of the metallic container with the annular edges of the reform rollers to form a predetermined geometry in the inner wall portion of the metallic container; and (4) moving the wedge member away from the dome receptacle to disengage the reform rollers from the inner wall portion of the metallic container. In one embodiment, the wedge member has an exterior surface configured to selectively engage a portion of each of the pivot arms. In one embodiment, the wedge member engages the pivot arms when the wedge member is moved toward the dome receptacle. In another embodiment, the annular edge of each reform roller extends beyond the support surface of the dome receptacle.

In one embodiment, the reforming apparatus further comprises a shaft interconnected to an end of the wedge member that is distal to the dome receptacle. The shaft is operable to rotate the wedge member around a longitudinal axis of the reforming apparatus. In one embodiment, the when the wedge member engages each of the pivot arms, the pivot arms rotate around the longitudinal axis.

Optionally, the reforming apparatus may include a bias element to bias the pivot arms inwardly toward the longitudinal axis. In one embodiment, the bias element includes at least one of a spring bushing and a compression spring. Optionally, a spring bushing is positioned at least partially within each of the pivot arms.

Although generally referred to herein as “metallic container,” “beverage container,” “can,” and “container,” it should be appreciated that the current invention may be used with containers of any size or shape including, without limitation, beverage cans and beverage bottles. Accordingly, the term “container” is intended to cover containers of any type. Further, as will be appreciated by one of skill in the art, the methods and apparatus of the present invention may be used for any type of metallic container and are not specifically limited to a beverage container such as a soft drink or beer can.

The terms “metal” or “metallic” as used hereinto refer to any metallic material that may be used to form a container, including without limitation aluminum, steel, tin, and any combination thereof.

The phrases “at least one,” “one or more,” and “and/or,” as used herein, 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.

Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.”

The term “a” or “an” entity, as used herein, 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.

The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein.

It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112(f). 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.

The Summary of the Invention is neither intended, nor should it be construed, as being representative of the full extent and scope of the present invention. Moreover, references made herein to “the present invention” or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to a particular description. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements or components. Additional aspects of the present invention will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying drawings, which are incorporated herein and constitute a part of the specification, illustrate embodiments of the invention and together with the Summary of the Invention given above and the Detailed Description of the drawings given below serve to explain the principles of these embodiments. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the present invention is not necessarily limited to the particular embodiments illustrated herein. Additionally, it should be understood that the drawings are not necessarily to scale.

FIG. 1A is a partial cross-sectional front elevation view of a beverage container illustrating a domed bottom portion before an inner wall portion of the domed bottom portion has been reformed;

FIG. 1B is another partial cross-sectional front elevation view of the beverage container of FIG. 1A after the inner wall portion has been reformed following a reform operation of one embodiment of the present invention;

FIG. 1C is an expanded cross-sectional front elevation view of the domed bottom portion of the beverage container of FIG. 1B;

FIG. 2 is a top plan view of a reform apparatus of one embodiment of the present invention with reform rollers illustrated in an unactuated state;

FIG. 3 is a cross-sectional front elevation view of the reform apparatus of FIG. 2 taken along line 3-3 with a retaining ring of the reform apparatus removed for clarity;

FIG. 4 is a cross-sectional front perspective view of the reform apparatus of FIG. 2 with the retaining ring of the reform apparatus removed for clarity;

FIG. 5 is another cross-sectional front elevation view of the reform apparatus of FIG. 2 taken along line 5-5 and showing the retaining ring;

FIG. 6 is a cross-sectional front perspective view of the reform apparatus of FIG. 2 with the retaining ring again removed for clarity;

FIG. 7 to a top cross-sectional perspective view of the reform apparatus of FIG. 2 taken along line 7-7 of FIG. 5 with the retaining ring removed for clarity;

FIG. 8 is a cross-sectional side elevation view of the reform apparatus of FIG. 2 taken along line 8-8;

FIGS. 9A-9C are cross-sectional views illustrating a beverage container being moved into a predetermined position with respect to the reform apparatus of FIG. 2;

FIG. 10 is a top plan view of the reform apparatus of FIG. 2 with the reform rollers illustrated in an actuated state;

FIG. 11 is a cross-sectional front elevation view of the reform apparatus of FIG. 10 taken along line 11-11 and showing the reform apparatus with the retaining ring removed for clarity;

FIG. 12 is a cross-sectional front perspective view of the reform apparatus of FIG. 10 that is taken along a line similar to the front elevation view of FIG. 11 with the retaining ring of the reform apparatus removed for clarity;

FIG. 13 is a cross-sectional side elevation view of the reform apparatus of FIG. 10 taken along line 13-13;

FIG. 14 is a cross-sectional view of the reform apparatus of FIG. 10 taken along line 14-14 of FIG. 11;

FIG. 15 is a cross-sectional front perspective view similar to the perspective view of FIG. 12 and illustrating an inner wall portion of a bottom dome portion of a beverage container being reformed by reform rollers of the reform apparatus of FIG. 10,

FIGS. 16-17 are views of a carrier element of a reform apparatus of one embodiment of the present invention with a tooling element and the retaining ring of the reform apparatus removed for clarity and showing a wedge member of the present invention;

FIGS. 18A-18B are cross-sectional perspective views of a spring bushing of one embodiment of the present invention;

FIGS. 19A-19B are exploded perspective views of a wedge member of another embodiment of the present invention comprising two pieces that are interconnectable and positionable within the reforming apparatus; and

FIG. 19C is a cross-sectional front elevation view of a portion of the reform apparatus showing the wedge member of FIGS. 19A-19B movable axially between pivot arms of the present invention.

Similar components and/or features may have the same reference number. Components of the same type may be distinguished by a letter following the reference number. If only the reference number is used, the description is applicable to any one of the similar components having the same reference number.

To assist in the understanding of one embodiment of the present invention the following list of components and associated numbering found in the drawings is provided herein:

Number Component 2 Beverage container 4 Container body 6 Container sidewall 8 Outer wall portion 10 Annular support member 12 Inner wall portion 14 Domed bottom portion 16 Groove or crease of reformed inner wall portion 17 Diameter of annular groove 18 Hook portion of inner wall portion 20 Reform apparatus 21 Longitudinal axis of reform apparatus 22 Housing 23 Housing end portion 24 Tooting support element 26 Retaining ring 27 Die cushion 27A Die cushion 28 Ram 29 Ram end portion 30 Shaft 31 Distance between housing end and ram end 32 Bearing 34 Retaining ring 36 Dome receptacle 38 Annular bead of dome receptacle 39 Bearings 40 Reform roller 41 Annular edge of reform roller 42 Track Roller 43 Longitudinal axis of track roller 44A Internal retaining ring 44B External retaining ring 45 Angle between track roller axis and reform apparatus longitudinal axis 46 Pivot arm 47 Ramp of pivot arm 48 Carrier element 50 Spring bushings 51 Threaded fasteners 51A Threaded fasteners 52 Wedge member 52A Wedge member 54 Driver element 56 Threaded fasteners 58 Cap of threaded fastener 60 Grooves of wedge member 61 Sloped grooves of wedge member 62 Distal portion of wedge member 64 Proximal portion of wedge member 65 Shims 66 Shims 67 Distance between dome receptacle and reform roller 68 Exterior distance between roller annular edges 69 Distance between interior of the roller annular edges. 70 Mandrel 72 Aperture for spring bushing 82 Compression springs 84 Set screw 86 Fixed sleeve of spring bushing 88 Load bearing sleeve of spring bushing 90 Core 92 First springs 94 Second springs 96 First portion of core 98 Second portion of core 100 Axial gap 102 First portion of wedge member 104 Second portion of wedge member 106 Rollers 108 Apertures

DETAILED DESCRIPTION

The present invention has significant benefits across a broad spectrum of endeavors. It is the Applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed. To acquaint persons skilled in the pertinent arts most closely related to the present invention, a preferred embodiment that illustrates the best mode now contemplated for putting the invention into practice is described herein by, and with reference to, the annexed drawings that form a part of the specification. The exemplary embodiment is described in detail without attempting to describe all of the various forms and modifications in which the invention might be embodied. As such, the embodiments described herein are illustrative, and as will become apparent to those skilled in the arts, may be modified in numerous ways within the scope and spirit of the invention.

Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term by limited, by implication or otherwise, to that single meaning.

Referring now to FIG. 1A, before describing certain features of the present invention, some general aspects of reforming a beverage container 2 will be described. A beverage container 2 is illustrated after initial forming but before dome reforming. The beverage container 2 includes a container body 4 with a generally cylindrical sidewall 6, an outer wall portion 8 with a reduced diameter, a generally annular support member 10, and an inner wall portion 12 coupling the annular support member 10 to a domed bottom portion 14 which defines a closed end-wall of the beverage container. The inner wall portion 12 of the dome portion 14 is substantially linear in a vertical direction before being reformed by a reform apparatus. By reforming the domed bottom portion 14 of the beverage container 2, enhanced strength characteristics can be achieved.

Reforming the beverage container 2 involves changing the shape of the inner wall portion 12. In one embodiment of the present invention, the inner wall portion 12 is reformed substantially as depicted in FIG. 1B to include a radially outwardly extending groove or crease 16. Typically, the groove or crease 16 extends substantially the entire circumferential extent of the inner wall portion 12. The position, magnitude, and shape of the groove 16 can affect the strength, durability, and/or damage-resistance of the beverage container 2. Accordingly, it is critical to provide accurate control of the reforming apparatus to obtain the proper geometry of the groove 16.

Referring now to FIG. 1C, an expanded view of the inner wall portion 12 of the beverage container 2 is illustrated after having been reformed by a reform apparatus according to one embodiment of the present invention. Following a reform process performed by a reform apparatus of an embodiment of the present invention, the inner wall portion 12 of the annular support member 10 may include a portion 18 having a relatively pronounced “hook” shape. The annular support member 10 has a radius R2 which is smaller than either of radii R1 and R3, which defines this hook portion 18. The hook portion 18 helps to enhance the strength characteristics of the domed bottom portion 14 of the beverage container 2. Further, the hook portion 18 substantially locks the inner wall portion 12 and the domed bottom portion 14 in place. The hook portion 18 also resists rollout because the hook radius R2 is smaller than either radii R1 and R3. By reforming the inner wall portion 12 in such a manner, the inner wall portion 12 resists plastic unrolling, or rollout, which may occur when the container 2 is pressurized, and is associated with a change in one or more of radii R1, R2, and R3.

The diameter 17 of the groove or crease 16 is larger than the interior surface diameter of the inner wall portion 12. Accordingly, it is more difficult to pass through the smaller opening of the inner wall portion 12. Said another way, the dome portion 14 cannot roll out or move downward past the inner wall portion 12 because the diameter 17 of the groove 16 is larger than the diameter of the inner wall portion 12. Further, the groove or crease 16 helps prevent unwinding and the resultant increased container length during any pasteurizing process. When pressure is applied to the domed bottom portion 14 from inside the container 2, the domed bottom portion 14 is forced toward the bottom portion of the beverage container 2. The geometric shape of the domed bottom portion 14 results in pressure applied to the inner wall portion 12 in a direction toward the bottom of the container 2 and toward the outer wall portion 8. When such pressure is applied, because of the geometry of the inner wall portion 12, it is unlikely that any of the radii R1, R2, and R3 will increase, thus reducing the likelihood of rollout and/or buckle. Examples of the dimensions and geometry of the groove 16 that may be formed with the reform apparatus 20 of the present invention are described in U.S. Pat. No. 5,836,473 which is incorporated herein in its entirety.

Referring now to FIGS. 2-8, one embodiment of a reform apparatus 20 of the present invention is illustrated. As shown in FIG. 3, the reform apparatus 20 generally includes a housing 22 interconnected to a tooling support element 24 by a first retaining ring 26. In one embodiment, a die cushion 27 is positioned between a portion of the tooling element 24 and the first retaining ring 26.

The housing 22 includes a ram 28 and a shaft 30 substantially concentrically aligned. The ram 28 and the shaft 30 can move axially generally parallel to a longitudinal axis 21 of the reform apparatus. The shaft 30 may also rotate around the longitudinal axis 21 within the housing 22. In one embodiment, when the reform apparatus 20 is in an open position in which the tooling of the reform apparatus 20 is in an unactuated state (as illustrated in FIGS. 2-9) a distance 31 between an end portion 23 of the housing 22 and an end portion 29 of the ram 28 is greater than approximately 0.3 inches. In a more preferred embodiment, the distance 31 is greater than approximately 0.33 inches. In a still more preferred embodiment, the distance is greater than approximately 0.34 inches.

The shaft 30 is supported by bearings 32 such that the shaft 30 can rotate with respect to the ram 28 while the ram 28 does not rotate. Any suitable bearings 32 may be used with the reform apparatus 20. In one embodiment, the bearings have a bore diameter of approximately 17 mm and an outer diameter of approximately 40 mm.

The tooling support element 24 generally includes a second retaining ring 34 (illustrated in FIGS. 2 and 5), a dome receptacle 36, and reform rollers 40. Optionally, a second die cushion 27A is positioned between a portion of the second retaining ring 34 and the dome receptacle 36. In one embodiment, the second die cushion 27A is the same as, or similar to, die cushion 27.

The dome receptacle 36 includes an annular bead 38 adapted to receive an annular support member 10 of a beverage container 2 (as illustrated in FIGS. 9B-9C). Different dome receptacles 36 may be used with the reform apparatus 20 with annular beads 38 of diameters sized to fit beverage containers 2 of any diameter. For example, the annular bead 38 of the dome receptacle 36 may have a diameter selected to receive the annular support member 10 of a 202 diameter beverage container (a beverage container with a diameter of 2 2/16 inches), a 204 diameter beverage container (a beverage container with a diameter of 2 4/16 inches), a 211 diameter beverage container (a beverage container with a diameter of 2 11/16 inches), or a beverage container of any other diameter.

Each reform roller 40 is rotationally interconnected to a head portion of a track roller 42 by a retaining ring 44A. The track rollers 42 include internal bearings (not illustrated). In one embodiment, the bearings of the track rollers 42 are needle rollers. It will be appreciated by one of skill in the art that the needle rollers of the track rollers 42 provide a longer service life than other bearings. The retaining rings 44A enable the reform rollers 40 to rotate axially about a longitudinal axis 43 of each track roller 42. In one embodiment, the head or cylindrical roller of the track rollers 42 has a diameter of approximately ⅝ inches and a width of approximately 7/16 inches.

An annular edge 41 of each reform roller 40 is adapted to contact and apply a compressive force to an inner wall portion 12 of a beverage container 2 when the annular support member 10 of the beverage container 2 is received in the annular bead 38. The annular edge 41 has a predetermined profile adapted to form the groove or crease 16 on the beverage container 2 described above in conjunction with FIG. 1.

The track rollers 42 are interconnected to pivot arms 46. In one embodiment, the track rollers 42 include a stud portion that threadably engages a bore formed in the pivot arms 46.

The pivot arms 46 have radially inward edge portions. Optionally, the radially inward edge portions of the pivot arms 46 may be shaped to engage a portion of a wedge member 52 of the reform apparatus 20. In one embodiment, the radially inward edges of the pivot arms 46 form a ramp 47. The ramp 47 has a maximum thickness proximate to the reform rollers 40. Said another way, the radially inward edges of the pivot arms 46 slope inwardly proximate to the dome receptacle 36.

The pivot arms 46 are pivotally interconnected to a carrier element 48. The pivot arms 46 are biased inwardly toward the longitudinal axis 21. Optionally, the pivot arms 46 include by spring bushings 50 that bias the pivot arms inwardly. In one embodiment, a medial portion of each spring bushing 50 is positioned at least partially within a bore of one of the pivot arms 46. End portions of each spring bushing 50 are interconnected to the carrier element 48. The medial portion of each spring bushing 50 can rotate with respect to the end portions. Each of the spring bushings 40 has a longitudinal axis. In one embodiment, the longitudinal axes of the spring bushings 40 are substantially parallel. In another embodiment, the spring bushing longitudinal axes define a plane that is substantially perpendicular to the reform apparatus axis 21.

In one embodiment, the spring bushings 50 are pre-loaded. In another embodiment, the spring bushings 50 are not preloaded when installed in the reform apparatus 20. In this manner, angular actuation of the spring bushings 50 is increased compared to spring bushings that are pre-loaded. Additionally, spring bushings 50 which are not preloaded generally have a longer service life compared to spring bushings that are pre-loaded. In one embodiment, the spring bushings 50 apply between about 3 lbf and about 7 lbf to the pivot arms 46 to bias distal ends of the pivot arms inwardly.

Optionally, the reform apparatus 20 may also include compression springs 82. By including both compression springs 82 and spring bushings 50 in the reform apparatus 20, the load on the spring bushings 50 may be reduced. In this manner, the service life of the spring bushings 50 is increased. In one embodiment, the service life of the spring bushings 50 is at least equal to the design life of the reform apparatus 20 such that spring bushings 50 are not scheduled to be service or replaced during the service life of the reform apparatus 20.

In one embodiment, the compression springs 82 are positioned between pivot arms 46 and the carrier element 48. In one embodiment, the compression springs 82 are aligned generally perpendicular to the longitudinal axis 21 of the reform apparatus 20; however, it will be appreciated by one of skill in the art that the compression springs 82 may be arranged in a different position with respect to the pivot arms 46 and the carrier element 48. Optionally, the compression springs apply between about 3 lbf and about 7 lbf to the pivot arms 46 to bias the distal ends of the pivot arms inwardly.

The spring bushings 50 and the compression springs 82 are adapted to bias the pivot arms 46 radially inwardly toward the longitudinal axis 21 as illustrated in FIG. 3. A set screw 84 may be associated with each compression spring 82. By rotating the optional set screw 84, the bias force applied to the pivot arms 46 by the compression springs 82 may be adjusted. In one embodiment, the reform apparatus 20 includes the spring bushings 50. In another embodiment, the reform apparatus includes the compression springs 82. Optionally, the reform apparatus may include both the spring bushings 50 and the compression springs 82.

In one embodiment, when the track rollers 42 are biased inwardly, an angle 45 between the apparatus axis 21 and the track roller axis 43 is no greater than approximately 0.450. In another embodiment, the angle 45 is less than approximately 0.350. In a more preferred embodiment, the angle 45 is approximately 0.3290. In one embodiment, an exterior distance 68 between the roller annular edges 41 is less than approximately 1.9 inches when the reform rollers 40 are in the unactuated state. In a more preferred embodiment, the distance 68 is approximately 1.78 inches. In another embodiment, the distance 68 is between about 1.6 inches and 1.9 inches when the reform rollers 40 are in the unactuated state.

A distance 69 (illustrated in FIG. 5) separating the roller annular edges 41 in the unactuated state is less than approximately 0.01 inches. In a more preferred embodiment, the distance 69 is approximately 0.002 inches. Further, as shown in FIG. 5, a distance 67 between an exterior surface portion of the dome receptacle 36 and an exterior surface portion of the reform rollers 40 is less than approximately 0.095 inches. In a more preferred embodiment, the distance 67 is approximately 0.092 inches.

Threaded fasteners 51 (illustrated in FIG. 3) may be used to retain the spring bushings 50 in the pivot arms 46. Similarly, additional threaded fasteners 51A (illustrated in FIG. 5) may retain the spring bushings 50 to the carrier element 48. In one embodiment, threaded fasteners 51A have a different dimension than threaded fasteners 51.

The carrier element 48 is substantially concentrically aligned with, and rotationally interconnected to, the tooling element 24 and the dome receptacle 36 by bearings 39. The bearings 39 are held in predetermined positions by retaining rings 44B. In this manner, the carrier element 48 may rotate axially around the longitudinal axis 21 of the reform apparatus 20. Although any type of bearing may be used with the reform apparatus 20, in one embodiment the bearings 39 have a bore diameter of approximately 2.0 inches and an outer diameter of approximately 2.5 inches.

A wedge member 52 is positioned between the pivot arms 46. The wedge member 52 is interconnected to a driver element 54 by threaded fasteners 56 (illustrated in FIG. 8). The cap 58 of a threaded fastener interconnects the driver element 54 to the shaft 30. As illustrated in FIGS. 4 and 8, the driver element 54 may optionally include an aperture sized to at least partially receive the screw cap 58. Additionally, the driver element 54 may include a recess adapted to receive the distal portion 62 of the wedge member 52. More specifically, the recess may have a shape and size substantially the same as the shape and size of the wedge distal portion 62.

The wedge member 52 is adapted to move axially substantially parallel to the longitudinal axis 21 between the pivot arms 46. The wedge member 52 is configured to engage the pivot arms 46 when the wedge member 52 is advanced toward the dome receptacle 36. In this manner, the wedge member 52 can impart axial and rotational movement to the pivot arms 46. More specifically, exterior edges of the wedge member 52 are shaped to engage an inwardly facing edge of each of the pivot arms 46. In one embodiment, the wedge member 52 includes recesses or grooves 60 (best seen in FIG. 6) that engage the ramp 47 of each pivot arm 46. The grooves 60 are tapered and increase in depth from a portion 62 of the wedge member 52 distal to the reform roller 40 to a portion 64 of the wedge member 52 proximate to the reform rollers 40. Said another way, the proximal portion 64 between the grooves 60 has a width that is less than the width of the distal portion 62 of the wedge member 52. The spring bushings 50 and/or the compression springs 82 bias the pivot arms 46 inwardly against the centrifugal force when the wedge member 52 rotates the pivot arms 46 around the longitudinal axis 21.

The wedge member 52 may be made of any durable and long lasting material. In one embodiment, the wedge member 52 is made of engineered plastic. In another embodiment, the wedge member 52 is made of an organic thermoplastic polymer. Optionally, the wedge member 52 may be made of Polyether ether ketone (or “PEEK”). However, it is contemplated that other materials may be used to form the wedge member 52, such as a metallic material. In one embodiment, the wedge member 52 is formed of a single piece of material. However, in another embodiment, illustrated in FIG. 19A, 19B, a wedge member 52A of another embodiment of the present invention is formed of two or more pieces that are interconnected together.

The reform apparatus 20 may also include a number of shims 65, 66. For example, shims 65 may be positioned between the track rollers 42 and the pivot arms 46. In one embodiment, the shims 65 have an inner diameter of approximately 0.25 inches, and outer diameter of approximately 0.375 inches, and a thickness of between about 0.01 inches to about 0.06 inches. Shims 66 may also be positioned between the housing 22 and the tooling element 24. In one embodiment, shims 66 have an inner diameter of approximately 70 mm, an outer diameter of approximately 76 mm, and a thickness of between about 0.1 mm to about 0.5 mm.

Referring now to FIG. 9A, in operation a beverage container 2 is mounted to a mandrel 70. The mandrel 70 moves the beverage container 2 axially and generally along the longitudinal axis 21 toward the dome receptacle 36 of the reform apparatus 20. Referring now to FIGS. 9B-9C, the mandrel 70 continues moving axially until the annular support member 10 of the closed end of the beverage container 2 is positioned on the annular bead 38 of the dome receptacle 36 of the reform apparatus 20. In one embodiment, the mandrel does not rotate axially around the longitudinal axis 21.

Referring now to FIGS. 10-15, when the beverage container 2 is in a predetermined position on the dome receptacle 36, the ram 28 and shaft 30 of the reform apparatus 20 advance axially within the housing 22 toward the dome receptacle 36 substantially parallel to the longitudinal axis 21. As shown in FIG. 11, the axial movement of the ram 28 and shaft 30 cause the driver element 54 to push the wedge member 52 axially between the pivot arms 46 toward the reform rollers 40. This causes the wedge member 52 to engage the pivot arms 46. In one embodiment, the grooves 60 of the wedge member 52 engage the ramp 47 of each pivot arm 46. The axial rotation of the wedge member 52 around the longitudinal axis 21 is thus transferred to the pivot arms 46. Accordingly, the pivot arms 46 begin to rotate axially around the longitudinal axis 21. In some embodiment, the wedge member 52 is rotating continuously.

As the ram 28 and shaft 30 continue pushing the wedge member 52 toward the dome receptacle 36, the ramps 47 of the pivot arms 46 follow the grooves 60 of the wedge member 52. In this manner, the radially inward bias of the spring bushings 50 and compression springs 82 is overcome and the pivot arms 46 are pushed radially outwardly away from the longitudinal axis 21. Accordingly, in one embodiment, the reform rollers 40 move to the actuated state and apply a predetermined force to the inner wall portion 12 of the container body dome 14 in response to movement of the wedge member 52. Said differently, the movement of the reform rollers 40 to the actuated state is not in response to a force applied to the reform apparatus 20 from the beverage container 2. Thus, the reform apparatus 20 of the present invention applies less force to the beverage container 2 during reforming of the domed portion 14 compared to known reforming apparatus. In one embodiment, the reform apparatus 20 may be used to form a groove 16 on a beverage container 2 with a thinner container body 4 than prior art reforming apparatus. Thus, beverage containers 2 formed of thinner gaged material may be reformed with the reform apparatus 20 of the present invention, reducing the amount of material and associated costs used to form the beverage container 2.

In one embodiment, the angle 45 between the track roller axis 43 and reform apparatus axis 21 increases to greater than approximately 1.0° when distal ends of the pivot arms 46 move outwardly. In a more preferred embodiment, the angle 45 increases to more than about 1.2°. In a still more preferred embodiment, when the reform apparatus 20 is in the actuated state, the angle 45 increases to approximately 1.24°. In another embodiment, the angle 45 increases by at least about approximately 0.90 when the reform apparatus 20 moves to the actuated state.

In the actuated state of the reform apparatus 20, the annular edge 41 of each reform roller 40 projects at least partially beyond an interior diameter of the annular bead 38 of the dome receptacle 36. In one embodiment, the exterior distance 68 between the roller annular edges 41 increases to greater than approximately 1.8 inches. In a more preferred embodiment, the distance 68 is more than approximately 1.85 inches. In a still more preferred embodiment, the distance 68 is approximately 1.87 inches. In another embodiment, in the actuated state, the distance 68 is between about 1.8 inches and about 2.0 inches. In another embodiment, the distance 68 increases by between approximately 0.08 inches and 0.09 inches when the reform apparatus 20 moves to the actuated state.

The distance 31 between the end portion 23 of the housing 22 and the end portion 29 of the ram 28 decreases in the actuated state of the reform apparatus 20. In one embodiment, in the actuated state, the distance 31 is less than approximately 0.25 inches. In another embodiment, the distance 31 is between approximately 0.18 inches and approximately 0.25 inches. In a more preferred embodiment, the distance is between about 0.187 inches and about 0.247 inches. In another embodiment, the distance 31 is approximately 0.217 inches when the reform apparatus 20 is in the actuated state.

The distance 67 between the exterior surface portion of the dome receptacle 36 and the exterior surface portion of the reform rollers 40 also decreases in the actuated state of the reform apparatus 20. In one embodiment, the distance 67 is less than approximately 0.09 inches. In a more preferred embodiment, the distance 67 is approximately 0.087 inches.

Accordingly, as shown in FIG. 15, when the annular support member 10 of a beverage container 2 is in the predetermined position in the annular bead 38 of the dome receptacle 36, the annular edge 41 of the reform rollers 40 apply a predetermined force to the inner wall portion 12 of the container body 4. As the pivot arms 46 rotate axially around the apparatus axis 21, the roller annular edges 41 form the groove 16 circumferentially around the inner wall portion 12.

After at least one of a predetermined number of rotations and a predetermined period of time, the ram 28 and shaft 30 begin to move axially away from the dome receptacle 36 in a direction substantially parallel to apparatus axis 21. The wedge member 52 moves at least partially out of the space between the pivot arms 46 and the wedge member 52 loses engagement of the pivot arms 46. In one embodiment, the ramps 47 of the pivot arms 46 move out of the wedge grooves 60. Accordingly, the spring bushings 50 and compression springs 82 bias inwardly toward longitudinal axis 21, returning the reform rollers 40 to the disengaged state, as illustrated in FIGS. 9B-9C. The beverage container 2 may then be removed from the reform apparatus 20 by the mandrel 70.

Referring now to FIGS. 16-17, a carrier element 48 of an embodiment of the present invention is generally illustrated. The carrier element 48 is shown separated from the housing 22 of the reform apparatus 20 with the tooling element 24, second retaining ring 34, and the dome receptacle 36 removed for clarity. Apertures 72 are formed in the carrier element 48 to receive the spring bushings 50. In FIG. 16, the wedge member 52 is partially withdrawn from between the pivot arms 46 showing a grove 60 of one embodiment of the present invention.

Referring now to FIG. 17, the wedge member 52 is shown completely withdrawn from the carrier element 48. The proximal portion 64 is shown illustrating that, in one embodiment of the present invention, the wedge groove 60 is deeper at the proximal portion 64 than at the distal portion 62 of the wedge member 52. The proximal portion 64 of the groove 60 may also optionally include a groove portion 61 with a slope that is different than the slope of groove 60. The exterior cross-sectional shape of the wedge member 52 is substantially uniform from the distal portion 62 to the proximal portion 64 except within the groove 60. Said another way, the exterior shape and dimensions of the wedge member 52 are substantially uniform.

Referring now to FIGS. 18A-18B, partial cross-sectional views of spring bushings 50 of the present invention are illustrated. The spring bushing 50 generally comprises two fixed sleeves 86 with a common core 90. A load bearing sleeve 88 is rotationally interconnected to core 90. The load bearing sleeve 88 can rotate axially with respect to the fixed sleeves 86. In one embodiment, the load bearing sleeve 88 is limited to a predetermined amount of axial rotation with respect to the fixed sleeves 86. In one embodiment, the fixed sleeves 86 are interconnected to the aperture 72 of the carrier element 48. Similarly, the load bearing sleeve 88 is received within an aperture formed through the pivot arm 46. In this manner, the pivot arm 46 is interconnected to the carrier element 48.

First springs 92 and second springs 94 are arranged generally radially within the core 90. More specifically, a first end of each spring 92, 94 is interconnected to a first portion 96 of the core 90 and a second end of each spring 92, 94 is interconnect to a second portion 98 of the core 90. Two axial gaps 100 separate the first and second core portions 96, 98. Although only one of the axial gaps 100 is illustrated in FIGS. 18A, 18B, both axial gaps 100A, 100B are illustrated in FIGS. 3-4. In one embodiment, the springs 92, 94 comprise a plate of flexible material. In another embodiment, the first springs 92 are transverse to the second springs 94. As will be appreciated by one of skill in the art, since the spring bushing 50 does not include sliding parts, no lubrication is generally required and limited or no friction is created.

Spring bushings 50 of any suitable type may be used with the reform apparatus 20 of the present invention. In one embodiment, suitable spring bushings 50 may be obtained from C-Flex Bearing Co, Inc., although other suppliers are contemplated.

Referring now to FIGS. 19A-19B, a wedge member 52A of another embodiment of the present invention is illustrated. The wedge member 52A has the same or similar dimensions as wedge member 52 and may be made of the same or similar materials. Similar to wedge member 52, wedge member 52A is shaped to engage an interior portion of a pivot arm. In one embodiment, the wedge member 52A includes grooves 60 that have a first depth at a distal portion 62 of the wedge member 52A and a second greater depth at a proximal portion 64. Optionally, the groove 60 includes a second portion 61 which has a different slope. The wedge member 52A further comprises a first portion 102 interconnected to a second portion 104. Additionally, in one embodiment, wedge member 52A includes rollers 106 received in apertures 108 of the first portion 102 and the second portion 104.

Referring now to FIG. 19C, as the wedge member 52A is driven axially forward toward the dome receptacle 36, the rollers 106 contact the angled surface, or ramps 47 of the pivot arms 46. Inner radial surfaces of the rollers 106 contact each other and resist movement inward. Since the rollers 106 are captured in the apertures 108, the rollers 106 roll against each other and roll up the inclined surface of the pivot arms 46 forcing the pivot arms to open as the pivot arms 46 rotate about pivot points held by the spring bushings 50. The rollers 106 then act as roller bearings, rolling instead of sliding. In this manner, the rollers 106 reduce friction and wear.

The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limiting of the invention to the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments described and shown in the figures were chosen and described in order to best explain the principles of the invention, the practical application, and to enable those of ordinary skill in the art to understand the invention.

While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. Moreover, references made herein to “the present invention” or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to a particular description. It is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims.

Claims

1. A reforming apparatus for shaping an inner wall portion of a closed end of a metallic container, comprising:

a tooling support element;

a dome receptacle interconnected to a distal end of the tooling support element and including a surface portion adapted to support the closed end of the metallic container;

pivot arms positioned within the tooling support element;

spring bushings positioned at least partially within the pivot arms to provide an inward biasing force to the pivot arms;

a track roller interconnected to a distal end of each of the pivot arms;

a reform roller interconnected to a distal end of each track roller, each reform roller including an annular edge with a predetermined shape;

a wedge member positioned between the pivot arms and in operable contact to travel between the pivot arms; and

a shaft interconnected to a proximal end of the wedge member to selectively supply axial movement to the wedge member, wherein when the wedge member is advanced toward the dome receptacle between the pivot arms by the shaft, the pivot arms extend outwardly and the annular edges of the reform rollers engage the inner wall portion of the metallic container.

2. The apparatus of claim 1, wherein an exterior distance between the annular edges of the reform rollers increases by at least about 0.08 inches when the pivot arms extend outwardly.

3. The apparatus of claim 2, wherein an angle between the reform rollers and a longitudinal axis of the reforming apparatus increases by at least about 0.9° when the pivot arms extend outwardly.

4. The apparatus of claim 1, wherein each of the pivot arms includes an interior side which slopes inwardly proximate to the distal end of each pivot arm.

5. The apparatus of claim 1, wherein the wedge member includes grooves to engage an interior side of each of the pivot arms when the wedge member is advanced axially between the pivot arms by the shaft.

6. The apparatus of claim 5, wherein the grooves of the wedge member include a first portion with a first slope and a second portion with a second slope.

7. The apparatus of claim 5, wherein the grooves of the wedge member have a first depth proximate to the shaft which is less than a second depth of the grooves proximate to the reform rollers.

8. The apparatus of claim 1, wherein the wedge member comprises at least one of an engineered plastic and an organic thermoplastic polymer.

9. The apparatus of claim 1, wherein the spring bushings comprise:

an outer portion with a central bore; and

an inner portion positioned within the central bore of the outer portion, the inner portion including at least one peripheral gap along a length of the inner portion.

10. The apparatus of claim 1, wherein the spring bushings are aligned with a plane that is substantially perpendicular to an axis of rotation of the shaft.

11. The apparatus of claim 1, further including a compression spring interconnected to an exterior side of each of the pivot arms to apply an inward biasing force to each of the pivot arms.

12. The apparatus of claim 1, wherein the wedge member supplies an outwardly oriented force and rotational movement to the pivot arms.

13. A tool adapted to shape an inner wall of a metallic container dome, comprising:

a tool assembly with an upper end and a lower end, the upper end having a substantially flat upper surface adapted to engage the dome of the metallic container;

two pivot arms positioned within the tool assembly;

a reform roller associated with an upper end of each pivot arm;

a wedge member positioned between the two pivot arms and having a tapered geometric profile between an upper end and a lower end to engage an inward portion of each of the two pivot arms; and

a rotatable shaft operably engaged to the lower end of the wedge member, wherein when force is applied to the lower end of the wedge member, the pivot arms extend outwardly and annular edges of the reform rollers engage the inner wall of the metallic container dome.

14. The tool of claim 13, further comprising biasing elements interconnected to the tool assembly to bias each of the two pivot arms inwardly.

15. The tool of claim 14, wherein the biasing elements comprise at least one of a spring bushing positioned at least partially within each of the two pivot arms and a compression spring interconnected to an exterior side of each of the two pivot arms.

16. The tool of claim 13, wherein the wedge member includes two outwardly facing grooves to capture the two pivot arms.

17. A method of reforming an inner wall portion of a metallic container, comprising:

positioning a lower dome portion of the metallic container on a reforming apparatus, comprising: a tooling housing element with a first end and a second end; a dome receptacle interconnected to the first end of the tooling housing element and including a support surface configured to support the lower dome portion of the metallic container; pivot arms located within the tooling housing element; a reform roller associated with each pivot arm, each reform roller including an annular edge; and a wedge member arranged between the pivot arms and operable to travel between the pivot arms toward the dome receptacle, the wedge member adapted to extend the pivot arms outwardly when the wedge member travels toward the dome receptacle;

moving the wedge member toward the dome receptacle;

engaging the inner wall portion of the metallic container with the annular edges of the reform rollers to form a predetermined geometry in the inner wall portion of the metallic container; and

moving the wedge member away from the dome receptacle to disengage the reform rollers from the inner wall portion of the metallic container.

18. The method of claim 17, wherein the reforming apparatus further comprises a shaft interconnected to an end of the wedge member that is distal to the dome receptacle.

19. The method of claim 17, wherein the reforming apparatus further comprises springs to bias the pivot arms inwardly.

20. The method of claim 19, wherein the springs comprise spring bushings positioned at least partially within the pivot arms.