METHOD AND APPARATUS OF FORMING A DEBOSS IN A CLOSED END OF A METALLIC CUP

Abstract

An apparatus and method for forming a deboss in a closed end-wall of a metallic cup is provided. The deboss apparatus generally includes a rotatable turret with tooling assemblies. The tooling assemblies are configured to receive a metallic cup formed by upstream equipment. The metallic cup formed by the upstream equipment has a closed end-wall that is generally planar. As the turret rotates, the tooling assemblies are configured to form a deboss in the closed end-wall of the metallic cup. In one embodiment, the deboss projects inwardly into an interior of the metallic cup. The metallic cup with a deboss is subsequently stripped from the tooling assembly for further processing.

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. 62/436,177 filed Dec. 19, 2016, which is incorporated herein in its entirety by reference.

FIELD OF THE INVENTION

The present invention relates generally to the manufacturing of metallic containers. More specifically, the present invention relates to a method and apparatus for forming a deboss in a closed end-wall of a metallic cup to enhance performance during subsequent operations in which the metallic cup is formed into a metallic container.

BACKGROUND

Metallic containers offer distributors and consumers many benefits. The body of a metallic container provides optimal protection properties for products. For example, the metallic body prevents CO₂ migration and transmission of UV radiation which may damage the contents, such as beverages or other consumable products, negatively influencing the flavor, appearance, or color of the product. Metallic 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.

Metallic containers are also produced in a large variety of sizes. Common sizes range from approximately 6 ounces to approximately 32 ounces or larger. Exemplary diameter sizes for metallic 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 containers may also be produced in various shapes but are frequently cylindrical.

Because of these and other benefits, sales of metallic containers were valued at approximately $53 billion globally in 2014. A sizable 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. Because of the high speeds of metallic container production lines, techniques or processes that may work in other industries or with containers formed of other materials do not necessarily work at the high speeds required for metallic container production lines. Accordingly, specialized equipment is required for many of the operations performed to form the metallic containers. The production equipment must also be durable and easy to service to avoid down-time on the high-speed production lines used to form metallic containers.

An important consideration in designing and fabricating metallic containers involves providing a desirable balance between minimizing material requirements (such as providing relatively thin-gauge metal) while achieving a metallic 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 metallic containers which maintain integrity and/or form even when the contents are under pressure due to carbonated or otherwise gas-pressured contents and/or arising from high internal temperatures, including, in some cases, pasteurization temperatures.

Metallic 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 generally 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 or other product. An example of a known process of forming a container body for a metallic beverage container 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 Oct. 26, 2016) which is incorporated herein by reference in its entirety.

Typical processes of forming the body of a metallic container include subjecting a thin sheet of metal alloy to a series of operations including blanking out a substantially round disk, drawing the disk into a cup, and subsequently redrawing, ironing, and/or forming the cup. One of the first steps performed on such a metal sheet is a cupping process in which the sheet is blanked into a substantially round blank. The blank is drawn into a seamless metallic cup to establish an initial shape and inside diameter of the metallic cup. A second draw operation is frequently performed on the cup to reduce the cup diameter further and bring the diameter of the cylindrical body to the final body diameter. Subsequently, the metallic cup is pushed through a series of ironing rings to thin the wall of the cylindrical body to a selected thickness. During these ironing processes, performed with equipment commonly referred to as a bodymaker, the diameter of the cylindrical body is essentially maintained while the outer wall length is substantially increased to establish the capacity of the final metallic container. A variety of different bodymakers are known to those of skill in the art and are generally described in PCT Publication WO 2014/047115, PCT Publication WO 2014/110387, U.S. Pat. App. Pub. 2013/0239644, U.S. Pat. No. 9,079,237, and U.S. Pat. No. 9,387,530 which are each incorporated herein in their entirety. Because typical metallic container manufacturing facilities often produce hundreds of millions or billions of metallic containers per year, the wear of components of bodymakers is inherent based of the tremendous speed and output of product.

The bodymaker can also form a dome on a closed end-wall of the metallic container. The configuration of the closed end-wall of the metallic container is important for a variety of reasons. The outside dome profile is often configured for purposes of stacking metallic 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. The recessed or concave dome is configured to resist deformation due to internal fluid pressures. More specifically, the geometry of the closed end-wall and the concave dome can be configured to increase the pressure at which concave dome is deformed or reversed. The geometry of the concave dome is also important to improve the drop resistance of the metallic container and reduce the risk of damage caused when the closed end-wall of a filled metallic container is dropped onto a hard surface during shipping, storage, and use. This drop resistance can be described as the cumulative drop height at which the closed end-wall is damaged sufficiently to preclude the metallic container from standing upright on a flat surface.

One problem experienced during the formation of metallic containers is that the closed end-wall of the metallic cup is prone to thinning and wrinkling during the drawing, ironing, and dome forming operations performed by the bodymaker to transform the metallic cup into a container body. More specifically, continual efforts to decrease the weight of metallic containers, known as light-weighting of the containers, by using thinner sheets of stock metal has resulted in undesirable wrinkling of the sheet during formation of the container body. The closed end-wall is particularly susceptible to thinning of the metal and to the formation of fractures in the metal.

One prior art method of overcoming these problems is to form a deboss in a closed end-wall of the metallic cup before the redraw, ironing, and dome forming operations are performed. The deboss of the end-wall improves performance in the final container body as well as during subsequent forming operations performed on the metallic cup by breaking the forming operation of the bottom portion of the container body into two stages. The deboss makes subsequent container manufacturing operations easier to execute with reduced wrinkling, reduction in thinning of the metal, and improved container performance. This enables the manufacture of lighter containers with improved appearance and performance characteristics and reduces the thinning and wrinkling experienced during conversion of metallic cups without a deboss.

Prior art methods and apparatus used to form a deboss in a metallic cup typically include modifying a press, such as a cupping press or a bodymaker, to form the deboss in one machine at the end of a blank and draw process used to form the metallic cup. This has required a conversion of the press action to increase the stroke length of a crank of the press as well as the phase timing angle of the press. Alternatively, existing cupping presses can be converted to produce a metallic cup with a deboss. However, converting a cupping press to form a deboss in a metallic cup typically involves a large expense and may compromise the speed and reliability of the cupping press.

Presses modified to form a deboss during metallic cup formation may operate at reduced production rates compared to similar presses that do not form a deboss. The modification of existing presses also causes operational and maintenance problems because the deboss tooling is located at the bottom of the press and is difficult to access and service. For example, in a traditional cupping press, cups formed by the press drop out of the bottom of the cupping press. However, if the cupping press is modified to form a deboss, the tooling to form the deboss is positioned below the cup forming tooling of the cupping press. Accordingly, a jammed cup or scrap generated during operation of the modified cupping press are challenging to clear and correct. This results in increased down-time of the container production line associated with the press and associated losses. One example of an apparatus for forming a deboss in a metallic cup is disclosed in U.S. Pat. No. 5,394,727 which is incorporated herein in its entirety.

Other methods of forming the deboss use a vertical double acting stamping press to form the deboss at the end of the blank and draw operation. Alternatively, it is also possible to modify short-stroke body makers used for redrawing metallic cups to form a deboss. However, these options require a large capital expense for additional equipment and the use of substantial amounts of floor space in the manufacturing facility. Further, many existing metallic container production lines do not have sufficient production floor space available for additional cupping presses or body makers which typically are quite large. Because of these and other problems associated with prior art equipment and methods of forming a deboss in a metallic cup, there has been limited commercial use of these systems.

Accordingly, it would be beneficial to have an apparatus that receives a pre-formed metallic cup without a deboss and forms a deboss in a closed end-wall portion of the metallic cup as well as a method of forming a deboss in a pre-formed metallic cup.

SUMMARY OF THE INVENTION

The present invention provides systems and methods for forming a deboss in a closed end-wall of a metallic cup in a cost-effective, fast, and reliable manner. One aspect of the present invention is a method of forming a deboss in a metallic cup at low cost and high speed. Another aspect is a system and method of forming a deboss in a metallic cup that requires less production space than prior art bodymakers and cupping presses. Still another aspect of the present invention is a deboss apparatus that is cost effective to purchase and operate and which operates in a fast and reliable manner. Yet another aspect of the present invention is a method and apparatus of forming a deboss in a metallic cup that does not require modification of existing cupping presses or bodymakers. Another aspect of the present invention is an apparatus for forming a deboss which has fewer moving parts and which has tooling that is easier to service and replace compared to prior art bodymakers and cupping presses operable to form a deboss in a metallic cup. It is another aspect of the present invention to provide a deboss apparatus that is smaller, and takes up less production floor space, than conventional cupping presses and known horizontal body-makers.

One aspect of the present invention is a deboss apparatus that receives a metallic cup and forms a deboss in a closed end-wall of the metallic cup. The deboss apparatus includes a rotatable turret or table with a plurality of tooling stations. The turret is operable to rotate around a central shaft or axis of the deboss apparatus. Metallic cups without debosses are received by an infeed mechanism of the deboss apparatus and loaded into the tooling stations. In one embodiment, the metallic cups generally include a closed end-wall, a sidewall extending from the end-wall, and an open end opposite the close end-wall. Optionally, the closed end-walls are generally planar when the metallic cups are received by the infeed mechanism.

In one embodiment, the sidewall height of the metallic cups to be debossed is between approximately 0.7 inch and approximately 3.0 inches. In another embodiment, the initial sidewall height is between approximately 1.0 and approximately 2.0 inches.

In one embodiment, the turret includes between 12 and 20 tooling stations. Each of the tooling stations of the deboss apparatus includes tooling to form a deboss in the closed end-wall portion of a metallic cup. More specifically, in one embodiment, each tooling station includes a ram, an interior sleeve, a pressure pad, and a forming tool. In one embodiment, the pressure pad is moveably associated with the turret. Optionally, the pressure pad can travel between approximately 0.10 inches and approximately 0.60 inches along an axis substantially parallel to the shaft or axis of the deboss apparatus.

The interior sleeve is slightly smaller in diameter than the interior diameter of the metallic cup. The interior sleeve enters the open end of the metallic cup and applies pressure to the flat bottom (or closed end-wall) of the metallic cup. The interior sleeve and metallic cup push against the forming tool. The interior sleeve must clear the metallic cup and have enough stroke to form the deboss. Thus, in one embodiment, the interior sleeve has a stroke length at least equal to the sidewall height of the metallic cup plus the maximum travel distance of the pressure pad. In another embodiment, the stroke of the interior sleeve is between approximately 1.0 and approximately 3.0 inches. In one embodiment, the pressure pad and the forming tool do not project above a surface of the turret.

In one embodiment, the interior sleeve is interconnected to the ram. Optionally, the ram can have a stroke of between approximately 1.0 inches and approximately 3.0 inches, and in another embodiment, between approximately 1.2 inches and 2.0 inches. In still another embodiment, the ram applies a forming load of between approximately 500 pounds and approximately 3,200 pounds of force which is transmitted to the metallic cup.

The turret is configured to rotate at a predetermined rate. In one embodiment, the turret rotates at up to approximately 175 to 300 rotations per minute (rpm) such that the deboss apparatus may form a deboss in up to approximately 3,500 metallic cups per minute. In another embodiment, the turret is operable to rotate at 150 to 250 rpm to produce 3,000 deboss metallic cups per minute. In another embodiment, the turret rotates at between approximately 70 and 150 rpm to produce between approximately 1,400 and approximately 1,800 deboss metallic cups per minute. In this manner, the deboss apparatus can be configured to operate in metallic container production lines that operate at a variety of rates.

Another aspect of the present invention is a forming apparatus for shaping a closed end-wall portion of a metallic cup. The forming apparatus includes, but is not limited to: (1) a turret operable to rotate at a predetermined rate; and (2) a plurality of tooling assemblies associated with the turret, each of the tooling assemblies comprising: (i) a pressure pad to receive the metallic cup, the pressure pad operably engaged to the turret; (ii) a forming tool associated with the pressure pad; (iii) a ram with a stroke oriented substantially perpendicular to the turret; and (iv) an interior sleeve interconnected to the ram, the interior sleeve having an exterior diameter no greater than an interior diameter of the metallic cup, wherein, when the turret rotates, the ram moves in a forward stroke such that the interior sleeve applies a force to the metallic cup and the forming tool forms the deboss with the predetermined shape in the closed end-wall portion of the metallic cup.

The forming tool has a geometric profile selected to form the deboss with the predetermined shape. In one embodiment, the forming tool optionally includes a protrusion. Optionally, the forming tool is interconnected to the turret. More specifically, the forming tool may be interconnected to the turret such that the forming tool is substantially stationary during the stroke of the ram. In one embodiment, the form tool does not project above a plane defined by an exterior surface of the turret.

Optionally, the forming tool is generally concentrically aligned within a cavity of the pressure pad. In one embodiment, an interior diameter of the cavity of the pressure pad is less than an interior diameter of a chamber of the interior sleeve.

In one embodiment, the forming tool includes a body portion which is generally cylindrical. In another embodiment, the body portion includes an end with a planar portion. The optional protrusion may include a sidewall that extends from the end of the body portion. In this manner, the end of the body portion defines a shoulder between a body of the forming tool and the protrusion. In another embodiment, the body of the forming tool has an exterior diameter that is greater than the maximum exterior diameter of the protrusion. Optionally, the protrusion includes an end-wall defining a plane that is approximately parallel to a plane defined by the end of the body portion.

In one embodiment, the forming apparatus includes from 12 to 20 tooling assemblies. Optionally, the tooling assemblies can be positioned proximate to a periphery of the turret. In another embodiment, the tooling assemblies are substantially evenly spaced around the turret at a predetermined distance from a center of the turret.

In one embodiment, the forming apparatus further includes a biasing means to bias the pressure pad with respect to the turret. In one embodiment, the biasing means comprises at least one coil spring. In another embodiment, the biasing means biases the pressure pad away from the turret. Optionally, the pressure pad does not project beyond the plane defined by an upper surface of the turret. The pressure pad, in one embodiment, includes a lip which defines a recess to retain a metallic cup. Alternatively, in another embodiment, a free end of the forming apparatus can be generally planar. In one embodiment, the free end of the pressure pad is configured to support a portion of a closed end-wall of a metallic cup. Optionally, the free end has a shape that is annular. In another embodiment, when the metallic cup is positioned in the tooling assembly, the annular end of the pressure pad is positioned approximately even with the plane define by the turret upper surface.

Optionally, in another embodiment, the forming apparatus includes an infeed mechanism that positions the metallic cup in a tooling assembly of the deboss apparatus. In one embodiment, the infeed mechanism positions the metallic cup in the pressure pad of one of the tooling assemblies. Alternatively, the infeed mechanism can position the metallic cup on an interior sleeve of a tooling assembly.

The forming apparatus can also include an outfeed mechanism that receives the metallic cup after the forming apparatus forms the deboss in the metallic cup. In one embodiment, one or more of the infeed mechanism and the outfeed mechanism is a starwheel. The infeed mechanism can also include an infeed track. Similarly, the outfeed mechanism can optionally include an outfeed track.

In one embodiment, the ram is operably engaged to an upper portion of the turret of the forming apparatus, the upper turret portion being spaced from the pressure pad. In one embodiment the interior sleeve and ram are driven by a cam. More specifically, the ram can include a cam follower configured to engage a cam of the forming apparatus. Optionally, the cam is formed on a shaft of the forming apparatus. The cam is operable to translate the rotational force of the turret into a linear force substantially perpendicular to the turret for performing the deboss operation. As the turret and the associated cam complete a revolution, the cam follower forces the ram to move in at least one cycle including one forward and one backward stroke.

Another aspect of the present invention is a method of forming a deboss in a closed end-wall portion of a metallic cup. The method comprises: (1) receiving the metallic cup in an infeed mechanism associated with a forming apparatus, the closed end-wall of the metallic cup being generally planar; (2) feeding the metallic cup to a turret of the forming apparatus, the turret rotatable around a central axis and including a plurality of tooling stations, each of the tooling stations comprising: (i) a pressure pad operably associated with the turret; (ii) a ram operably engaged by an upper turret spaced from the turret, the ram having a stroke oriented substantially parallel to the central axis; (iii) an interior sleeve interconnected to the ram, the interior sleeve having an exterior diameter no greater than an interior diameter of the metallic cup; and (iv) a forming tool associated with the pressure pad, the forming tool having a geometric profile selected to form the deboss with a predetermined shape in the closed end-wall portion of the metallic cup; and (3) rotating the turret at a predetermined rate, wherein, when the ram moves in a forward stroke, the interior sleeve applies a force to the metallic cup and presses the closed end-wall against the forming tool to form the deboss with the predetermined shape in the closed end-wall portion of the metallic cup. Optionally, the method may further include inspecting the metallic cup for irregularities or damage. In one embodiment, the tooling stations are positioned a predetermined distance from a perimeter of the turret.

The turret can rotate at a predetermined rate. In one embodiment, the turret is operable to rotate at from approximately 70 rpm to approximately 300 rpm. In another embodiment, the turret is operable to rotate at between approximately 70 rpm and approximately 150 rpm.

The rate of rotation of the turret and the number of tooling stations can be selected to produce a predetermined number of cups per minute. In one embodiment, the turret includes tooling stations and rotates at a rate sufficient to produce from about 500 cups per minute to about 4,000 cups per minute. In one embodiment, the turret includes tooling stations and rotates at a rate to produce from approximately 1,400 to approximately 1,800 debossed cups per minute. In another embodiment, the turret produces up to approximately 3,500 debossed cups per minute. Optionally, the turret includes from 6 to 30 tooling stations. In one embodiment, the turret includes from 12 to 20 tooling stations.

Optionally, the ram driving the interior sleeve has a stroke of between approximately 1.5 inches and approximately 3.0 inches. In one embodiment, the deboss apparatus includes a cam which is engaged by a cam follower of the ram. In another embodiment, the cam follower and ram apply a forming load of between approximately 500 pounds and approximately 3,200 pounds of force.

In one embodiment, the pressure pad is moveably biased with respect to the turret, for example, by a spring. In another embodiment, the pressure pad includes a lip to retain a metallic cup in a predetermined alignment. Optionally, the pressure pad may have a free end to support a closed end-wall of a metallic cup, the free end being generally planar with a central cavity. In one embodiment, the free end of the pressure pad has a shape that is generally annular. In one embodiment, the annular surface of the pressure pad is biased to a position substantially level with a surface of the turret before the metallic cup is fed to the turret.

The forming tool has a generally cylindrical body and an end-wall. In one embodiment, the end-wall is generally planar. Additionally, or alternatively, the forming tool can include a protrusion. Optionally, the protrusion extends from the end-wall of the forming tool, the end-wall defining a shoulder between the body of the forming tool and the protrusion. In another embodiment, the body of the forming tool has an exterior diameter that is greater than the maximum exterior diameter of the protrusion. In yet another embodiment, the protrusion extends into a chamber of the interior sleeve during formation of the deboss. In one embodiment, the interior sleeve chamber has an interior diameter that is greater than an interior diameter of a cavity of the pressure pad. In one embodiment, the forming tool is positioned within the cavity of the pressure pad.

In one embodiment, the deboss includes a closed end with an interior surface that is not supported when the metallic cup presses against the forming tool. More specifically, when the ram moves in the forward stroke, an interior surface of a portion of the closed end-wall that is formed into the deboss does not contact the forming apparatus.

It is yet another aspect of the present invention to provide a metallic cup with a deboss formed by a deboss apparatus. The metallic cup comprises: (1) a sidewall portion; (2) a closed end-wall portion; and (3) a deboss formed in the closed end-wall portion. The deboss generally includes a neck extending from the closed end-wall and a closed end. In one embodiment, the neck has a reduced diameter at a position distal to the closed end-wall.

In one embodiment, the deboss has a depth of between approximately 11% and approximately 15% of the height of the sidewall portion. Alternatively, in another embodiment, the deboss depth is between approximately 26% and approximately 30% of the sidewall height. In still another embodiment, the deboss depth is between approximately 0.1 inches and approximately 0.60 inches. Optionally, the deboss depth is approximately 0.15 inches. Alternatively, the deboss depth is approximately 0.30 inches. In another embodiment, the deboss depth is about 0.375 inches. In one embodiment, the deboss is substantially centered in the closed end-wall portion.

In one embodiment, the deboss of the metallic cup is formed by a deboss apparatus of the present invention. The deboss apparatus includes a turret operable to rotate at a predetermined rate. A plurality of tooling assemblies are associated with the turret. The tooling assemblies generally include a pressure pad to hold the metallic cup. As the turret rotates, a ram presses an interior sleeve into an open end of the metallic cup. The interior sleeve presses the closed end-wall of the metallic cup against forming tool. The forming tool has a geometric profile configured to form the deboss in the closed end-wall portion of the metallic cup.

As will be appreciated by one of skill in the art, the method and apparatus of the current invention may be used to form a deboss in metallic cups of any material used to form metallic containers, including without limitation aluminum, tin plate steel, steel, and combinations thereof. Further, the method and apparatus of the current invention may be used to form debosses in cups that are subsequently formed into container bodies or vessels of any size and shape and for storing any type of product for any industry. Accordingly, cups formed by the method and apparatus of the present invention may be formed into containers or vessels used to store or contain liquids and gases of all types, including consumer products and beverages as well as industrial chemicals and products. Additionally, it is contemplated that various features and devices shown and/or described with respect to one embodiment may be combined with or substituted for features or devices of other embodiments regardless of whether or not such a combination or substitution is specifically shown or described herein.

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 metallic cups that are subsequently formed into 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.

Although metallic cups are described as being formed by a draw and wall ironing (DWI) process, alternatively, the metallic cups may be formed by a draw, redraw processes. Further, 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 coated steel, 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” or “approximately.” 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 or embodiment. 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. 1 is a schematic flow diagram which depicts the progression of a metallic cup formed by upstream equipment to a deboss apparatus of one embodiment of the present invention, the deboss apparatus being configured to form a deboss in a closed end-wall of the metallic cup, and the flow of the metallic cup to downstream equipment that performs subsequent operations on the metallic cup;

FIG. 2A is a top plan view of one embodiment of a deboss apparatus of the present invention with an upper turret portion removed for clarity and illustrating a rotary turret with tooling assemblies that receive metallic cups from an infeed mechanism and the tooling assemblies subsequently releasing the metallic cups to an outfeed mechanism;

FIG. 2B is a front elevation view of the deboss apparatus of FIG. 2A;

FIG. 3 is a partial cross-sectional front elevation view taken along line 3-3 of FIG. 2A illustrating a tooling assembly of the deboss apparatus before receiving a metallic cup according to one embodiment of the present invention;

FIG. 3A is a partial cross-sectional front elevation view similar to FIG. 3 and illustrating a tooling assembly of another embodiment of the present invention;

FIG. 4 is a cross-sectional front elevation view of a pressure pad of one embodiment of the present invention;

FIG. 4A is cross-sectional front elevation view of another embodiment of a pressure pad;

FIG. 5 is a cross-sectional front elevation view of a form tool according to one embodiment of the present invention;

FIG. 5A is another cross-sectional front elevation view illustrating a form tool of another embodiment of the present disclosure;

FIG. 6 is another partial cross-sectional front elevation view taken along line 6-6 of FIG. 2A and illustrating a metallic cup positioned in a tooling assembly of the deboss apparatus before a forming stroke of the tooling assembly is completed according to another embodiment of the present invention; and

FIG. 7 is still another partial cross-sectional front elevation view similar to FIG. 6 and taken along line 7-7 of FIG. 2A illustrating another tooling assembly of the deboss apparatus according to one embodiment of the present invention, the tooling assembly shown after a forming stroke has been completed to form a deboss in a metallic cup.

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      Upstream equipment
4      Metallic cup devoid of a deboss
6      Sidewall
7      Height of sidewall
8      Closed end-wall
10     Deboss apparatus
12     Turret
13     Turret upper portion
14     Shaft of turret
15     Shaft axis
16     Recess
18     Tooling assembly
19     Surface of turret
20     Longitudinal axis of tooling assembly
22     Ram
23     Cam follower
24     Interior sleeve
25     Cam or groove
26     Outer nose of the interior sleeve
28     Chamber of interior sleeve
29     Interior diameter of the sleeve chamber
30     Pressure pad
31     Lip of pressure pad
32     Recess of pressure pad
33     Cavity of pressure pad
34     Upper surface portion of pressure pad
35     Interior surface portion of the pressure pad
36     Biasing means or coil spring
37A    Diameter of pressure pad
37B    Interior diameter of pressure pad cavity
38     Height of pressure pad
39     Wear plug
40     Form tool
41     Body of form tool
42     Protrusion of the form tool
43     Sidewall
44     End-wall of form tool
45     Surface of form tool body
46     Infeed mechanism or starwheel
47     Infeed conveyor
48     Devices for positioning metallic cups
49     Exterior diameter of the form tool
50     Outfeed mechanism or starwheel
51     Height of form tool
52     Devices for positioning metallic cups
54     Outfeed conveyor
60     Metallic cup with deboss
61     Diameter
62     Sidewall
63     Height of sidewall
64     Closed end-wall
66     Deboss
67     Neck
68     Deboss depth
69     Closed end
70     Maximum diameter of deboss
72     Minimum diameter of deboss
74     Downstream equipment
R1     Radius of interior sleeve nose
R2     Radius of protrusion
R3     Radius between closed end-wall and deboss
R4     Radius of deboss
R5     Radius of pressure pad
R6     Radius of pressure pad
R7     Outer radius of form tool

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. 1, a schematic flow diagram of the progressive formation of a metallic cup 60 with a closed end-wall 64 having a deboss 66 according to one embodiment of the present invention is illustrated. Upstream equipment 2 forms a metallic cup 4. The upstream equipment 2 can be a cup drawing process or a draw and redraw process to make the metallic cup 4. Accordingly, the metallic cup 4 may be formed by either a draw machine or a draw and redraw process. In one embodiment, the upstream equipment is a cupper known to those of skill in the art.

The metallic cup 4 generally includes a sidewall 6 and a closed end-wall 8. The sidewall 6 has a shape that is generally cylindrical. In one embodiment, the closed end-wall 8 is generally planar. The sidewall 6 has a predetermined height. In one embodiment, the sidewall height is between approximately 0.750 inches and approximately 2.5 inches. In another embodiment, the sidewall height is between approximately 1.0 and 2.0 inches. In one embodiment, the metallic cup 4 has a diameter of between approximately 3.00 inches and approximately 4.00 inches. In one optional embodiment, the diameter is approximately 3⅝ inches, or approximately 3.63 inches. As one of skill in the art will appreciate, the deboss apparatus 10 of the present invention may be configured to form a deboss on metallic cups 4 of any height and diameter.

A deboss apparatus 10 of one embodiment of the present invention receives the metallic cup 4 from the upstream equipment 2. Referring now to FIGS. 2A-7, the deboss apparatus 10 generally includes a table or turret 12 with a plurality of tooling assemblies 18. Each tooling assembly 18 generally includes a ram 22, an interior sleeve 24, a pressure pad 30, and a form tool 40. The deboss apparatus 10 is similar to a container necker known to those of skill in the art. Examples of necking apparatus are described in U.S. Pat. No. 8,807,325, and U.S. Pat. No. 9,308,570 which are each incorporated herein by reference in their entirety. In one embodiment, the deboss apparatus 10 operates in a manner similar to the rotary drawing presses described in U.S. Patent Application No. 2016/0107219 (“the '210 publication”), which is incorporated herein by reference in its entirety. However, the deboss apparatus 10 includes tooling assemblies 18 with different tooling and which perform different operations compared to the tooling of known necking apparatus or of the rotary drawing presses described in the '210 publication.

In one embodiment, the deboss apparatus 10 includes from 10 to 24 tooling assemblies 18. In another embodiment, the deboss apparatus 10 has sixteen tooling assemblies 18; however, one of skill in the art will appreciate that the deboss apparatus 10 can include any number of tooling assemblies 18. Accordingly, in still another embodiment, the apparatus 10 includes 12 tooling assemblies.

In operation, the turret 12 rotates around a shaft 14 (or axis 15) at a predetermined rate. Optionally, the turret 12 can rotate at speeds of between approximately 75 and 300 rpm. In another embodiment, the turret 12 rotates at between approximately 70 and 90 rpm to produce approximately 1,800 metallic cups 60 with a deboss 66 per minute. In one embodiment, deboss apparatus 10 includes twelve tooling assemblies 18 and the turret 12 is operable to rotate at more than approximately 300 rpm. In this manner, the deboss apparatus 10 can produce 3,000 or more deboss metallic cups 60 per minute.

Referring now to FIG. 2B, the deboss apparatus 10 optionally includes an upper turret portion 13. The rams 22 are operably interconnected to, and substantially evenly spaced around, the upper turret portion 13. Each ram 22 is aligned substantially parallel to an axis 15 of the shaft 14.

The rams 22 are configured to move with respect to an associated pressure pad 30 of a tooling assembly 18. In one embodiment, the rams 22 include a cam follower 23 that engages a cam 25 of the deboss apparatus 10. The cam 25 is shaped to move the cam follower 23 and the ram 22 toward and away from the turret 12. Accordingly, with each full rotation of the turret 12, each ram 22 and the interconnected interior sleeve 24 moves through a motion path of a forward and a return stroke. In one embodiment, the cam 25 comprises a groove formed in the shaft 14. In one embodiment, the groove 25 has a generally arcuate shape formed radially around shaft 14.

Optionally, the ram 22 is mounted to the upper turret 13 in a guide bushing. In one embodiment, each ram 22 is capable of a stroke of between approximately 0.75 inches and approximately 3 inches. In another embodiment, the stroke of the ram 22 is between approximately 1.0 inches and approximately 2.0 inches. In an optional embodiment, the stroke of the ram 22 is approximately 1.5 inches.

Referring now to FIG. 2A, a metallic cup 4 without a deboss is positioned in a tooling assembly 18 by an infeed mechanism 46. In one embodiment, the infeed mechanism 46 positions the metallic cup 4 in the tooling assembly 18 such that a closed end-wall portion 8 of the metallic cup 4 is proximate to the turret 12. The infeed mechanism 46 can include a conveyor 47 interconnected to the upstream equipment 2. In one embodiment, the infeed mechanism 46 comprises a starwheel with devices 48 for positioning metallic cups 4. Suitable infeed mechanisms 46 are known to those of skill in the art and include, but are not limited to, those described in U.S. Pat. No. 8,807,325, PCT Publication WO 2011/113710, and PCT Publication WO 2014/108489 which are each incorporated herein by reference in their entirety.

Referring now to FIG. 3, a tooling assembly 18A is illustrated before the tooling assembly 18A has received a metallic cup 4. More specifically, the tooling assembly 18A is illustrated when the tooling assembly 18A has rotated to a position between the outfeed mechanism 50 and the infeed mechanism 46.

The tooling assembly 18A generally includes a ram 22, an interior sleeve 24 (also referred to as a hold-down sleeve or a draw/pressure sleeve), a pressure pad 30, biasing means 36, and a forming tool 40. Optionally, the forming tool 40 includes a protrusion 42. In one embodiment, the interior sleeve 24, pressure pad 30, and forming tool 40 are each substantially concentrically aligned with the ram 22 along a longitudinal axis 20 of the tooling assembly 18A. In one embodiment, the longitudinal axis 20 is substantially parallel to the shaft axis 15 of the deboss apparatus 10.

The biasing means 36 bias the pressure pad 30 to a predetermined position with respect to the turret 12. In one embodiment, before a metallic cup 4 is received in the tooling assembly 18A, an annual surface 34 of the pressure pad 30 projects above a surface 19 of the turret 12 and towards the ram 22. The forming tool 40 is positioned within a cavity 33 of the pressure pad 30.

As the turret 12 rotates, the ram 22 applies a force generally parallel to the tooling axis 20 to the interior sleeve 24. In one embodiment, the ram 22 applies a forming load of between approximately 500 pounds and approximately 4,000 pounds. In another embodiment, the ram 22 applies between approximately 500 pounds and approximately 3,200 pounds of force. In still another embodiment, the ram 22 applies between approximately 500 pounds and approximately 1,000 pounds of force to the interior sleeve 24.

The interior sleeve 24 is interconnected to the ram 22 and is sized to fit at least partially within an interior of a metallic cup 4, 60. Accordingly, the interior sleeve 24 has an exterior diameter approximately equal to (but slightly less than) the interior diameter of a metallic cup 4, 60. In one embodiment, an outer nose portion 26 of the interior sleeve 24 has a radius R1 of less than approximately 0.10 inches.

The interior sleeve 24 also includes a recess or chamber 28. In one embodiment, the chamber 28 has a depth at least equal to a height of the protrusion 42 of the form tool 40. In one embodiment, the chamber 28 has a depth of at least approximately 0.5 inches and up to approximately 1.1 inches. Optionally, the depth of the sleeve chamber 28 may be greater than the height of the form tool protrusion 42. In this manner, the weight of the interior sleeve 24 may be reduced. More specifically, a deep chamber 28 will lighten the interior sleeve 24 which beneficially reduces the rotating mass of the tooling of the deboss apparatus 10.

The interior sleeve 24 can move, or has a stroke, substantially parallel to the tooling axis 20. The stroke of the interior sleeve 24 has a length sufficient to clear the cup sidewall 6, 62 during loading of the metallic cup 4 into the tooling assembly 18 and to move the pressure pad 30 axially by a predetermined distance. In one embodiment, the interior sleeve stroke is between approximately 1 inch and approximately 4 inches. In another embodiment, the interior sleeve 24 can travel between approximately 1.0 inches and approximately 3.0 inches along the tooling axis 20 relative to the turret 12. In yet another embodiment, the interior sleeve 24 can travel between approximately 0.75 inches and approximately 2.0 inches with respect to the turret 12. In another embodiment, the interior sleeve stroke is between approximately 1.5 inches and approximately 2.5 inches. As one of skill in the art will appreciate, the stroke of the interior sleeve 24 is determined by the design of the cam follower 23 and the cam 25 and is selected based on the size of the metallic cup 60 and the deboss 66 to be formed.

Referring now to FIG. 3A, an optional embodiment of a tooling assembly 18A of the present invention is generally illustrated. The tooling assembly 18A includes a pressure pad 30A that is similar pressure pad 30 of FIG. 3. However, pressure pad 30A does not include a lip 31. Accordingly, a free end 34 of the pressure pad 30A oriented opposite to the biasing means 36 is generally planar. Additionally, or alternatively, the pressure pad 30A can be oriented with the turret 12A such that the free end 34 does not extend beyond an upper surface 19 of the turret 12A. Similarly, in one embodiment, the form tool 40 can be fixed to the turret 12A such that an end-wall 44 of the form tool does not project above a plane defined by the upper surface 19 of the turret 12A. In this manner, a closed end-wall 8, 64 of a metallic cup can move with respect to the turret surface 19 without obstruction from the pressure pad 30A and/or the form tool 40 during loading and unloading into a tooling assembly 18.

Referring now to FIG. 4, a pressure pad 30 of one embodiment of the present invention is illustrated. The pressure pad 30 has a generally cylindrical shape. The pressure pad 30 may have any predetermined diameter 37A and height 38. Optionally, the diameter 37A is between approximately 3.0 inches and approximately 4.5 inches. In another embodiment, the diameter 37A is between approximately 3.65 inches and approximately 3.75 inches. In one embodiment, the height 38 is between approximately 1.1 inches and approximately 2.1 inches.

A cavity 33 is formed in the pressure pad. In one embodiment, the cavity extends through the pressure pad 30. The cavity 33 has an interior surface portion 35 that establishes a clearance between an outside diameter of the form tool 40 and the interior diameter 37B of the pressure pad 30. The pressure pad 30 can thus move freely relative to the form tool 40 and generally parallel to the tool axis 20. In one embodiment, the cavity diameter 37B is between approximately 2.0 inches and approximately 2.4 inches. In another embodiment, the cavity diameter 37B is between approximately 2.2 inches and approximately 2.3 inches. Optionally, the cavity diameter 37B is less than an interior diameter 29 of the chamber 28 of the interior sleeve 24.

The upper surface portion 34 of the pressure pad 30 is adapted to hold and retain a metallic cup 4, 60 in a predetermined alignment with respect to the interior sleeve 24 and the form tool 40. In one embodiment, the upper surface portion 34 is substantially planar. In another embodiment, the upper surface portion 34 has a shape that is annular. Optionally, in another embodiment, the pressure pad 30 can include a lip 31 that extends from the upper surface portion 34. The lip 31 defines a pocket or recess 32 adapted to hold and retain the metallic cup 4, 60 in the predetermined alignment. The recess 32 has an interior diameter no less than the exterior diameter of the metallic cup 4, 60. Optionally, at least a portion of the pressure pad 30 proximate to and including the upper surface portion 34 is formed of carbide. In one embodiment, a portion of the pressure pad 30 is formed of steel.

Referring now to FIG. 4A, another embodiment of a pressure pad 30A is illustrated. Pressure pad 30A may be used with the deboss apparatus 10 interchangeably with the pressure pad 30A in all embodiments of the present invention. The pressure pad 30A is generally similar to pressure pad 30 and includes many of the same features and dimensions. However, pressure pad 30A does not include a lip 31. Additionally, a radius R5 is formed between the upper surface 34 and the cylindrical body of the pressure pad 30A. In one embodiment, the radius R5 can range from approximately 0.03 inches to approximately 0.1 inches. In one embodiment, pressure pad 30A includes a radius R6 between the upper surface 34 and the cavity interior surface 35. Optionally, radius R6 can be between approximately 0.02 inches and approximately 0.06 inches.

Additionally, FIG. 4A illustrates an optional wear plug 39 associated with the pressure pad 30A. The wear plug 39 extends at least partially beyond the circumference of the cylindrical body of the pressure pad 30A. In one embodiment, a plurality of wear plugs 39 are spaced substantially evenly around a circumference of the cylindrical body of the pressure pads 30, 30A. Optionally, the pressure pads 30, 30A can include from eight to sixteen wear plugs 39. In one embodiment, the pressure pad 30A includes at least one flange to retain the wear plug 39.

Referring again to FIGS. 3, 3A, in one embodiment, the pressure pads 30, 30A are movable with respect to the turret. Accordingly, the pressure pads 30, 30A can move generally parallel to the longitudinal axis 20 toward the turret 12 in response to receiving a force transmitted by the ram 22 and the interior sleeve 24. In one embodiment, the pressure pads 30, 30A have a stroke of between approximately 0.1 inches and 0.6 inches. In another embodiment, the stroke of the pressure pads 30, 30A is between approximately 0.1 inches and approximately 0.5 inches. Optionally, the pressure pad stroke is between approximately 0.20 inches and approximately 0.40 inches.

Optionally, the pressure pads 30, 30A are operably retained to the turret 12 by biasing means 36. The biasing means 36 is generally arranged between the pressure pad 30 and the turret 12. Biasing means 36 is selected to provide a predetermined support force to the pressure pads 30, 30A. In one embodiment, the biasing means 36 comprises one or more coil springs. The coil springs may be arranged in a spring pack. However, in another embodiment, the biasing means 36 comprises a compressible material. In one embodiment, the biasing means 36 is capable of supporting between approximately 500 pounds and at least approximately 3,000 pounds of force. In another embodiment, biasing means 36 can provide a support force of between approximately 500 pounds and approximately 4,000 pounds. In yet another embodiment, the biasing means 36 provides a support force of between approximately 500 pounds and approximately 1,500 pounds. In one embodiment, biasing means 36 is positioned at least partially within a groove or recess 16 formed in the turret 12. Optionally, the biasing means 36 is configured to bias the pressure pads 30, 30A away from the turret 12.

The pressure pads 30, 30A and biasing means 36 are releasably interconnected to the turret 12. In one embodiment, the pressure pads 30, 30A and biasing means 36 are configured to be quickly changed to deliver different forming loads to metallic cups 4, 60 formed by the deboss apparatus 10.

The forming tool 40 is operably associated with the turret 12. In one embodiment, the forming tool 40 is positioned at least partially within the cavity 33 of the pressure pads 30, 30A. In another embodiment, the form tool 40 is generally arranged below the pressure pads 30, 30A when the pressure pad 30 is biased away from the turret 12. Optionally, the form tool 40 is fixedly interconnected to the turret 12. Thus, in one embodiment, the form tool 40 does not move, or is substantially immobile, during formation of a deboss 66 in a metallic cup 60. Additionally, or alternatively, at least a portion of the form tool 40 may be recessed below a plane defined by an upper surface 19 of the turret 12.

Referring now to FIG. 5, a form tool 40 of one embodiment of the present invention is illustrated separate from the pressure pad 30. The form tool 40 generally includes a body 41. In one embodiment, the body 41 has a shape that is generally cylindrical. An exterior diameter 49 of the body 41 is selected to be about equal to, but no greater than, an interior diameter 37B of the pressure pad cavity 33. Accordingly, the pressure pads 30, 30A can move with respect to the form tool 40 in response to a force received from a ram 22 of the deboss apparatus 10. Optionally, the exterior diameter 49 is between approximately 2.0 inches and approximately 2.4 inches. In another embodiment, the exterior diameter 49 is between approximately 2.2 inches and approximately 2.3 inches. In one embodiment, the exterior diameter 49 is less than an interior diameter 29 of the chamber 28 of the interior sleeve 24.

In one embodiment, the form tool body 41 has a surface 45 that is substantially planar. When the form tool 40 is associated with the turret 12, the surface 45 is positioned distal to the turret 12. More specifically, the tool surface 45 faces an interior sleeve 24 of a tooling station 18. In one embodiment, at least a portion of the form tool 40 comprises carbide.

Optionally, a protrusion 42 projects from the surface 45 of the body 41. The body surface 45 defines a shoulder between the protrusion 42 and the body 41. In one embodiment, the protrusion 42 includes a sidewall 43 interconnected to the body 41. An end-wall 44 is interconnected to the sidewall 43. Optionally, the end-wall 44 is generally planar. Alternatively, the end-wall 44 may have a surface that is not planar.

The protrusion 42 has a shape selected to form a deboss 66 with a predetermined profile in a metallic cup 60. In one embodiment, the protrusion 42 has a frustum shape of a truncated cone. However, the protrusion 42 can have any cross-sectional profile selected to form a deboss 66 of a predetermined size and shape.

In one embodiment, the protrusion sidewall 43 has a cross-section that is generally planar. Alternatively, in another embodiment, the cross-section of the sidewall 43 is not planar. More specifically, the sidewall 43 can optionally have a cross-section that is arcuate. Other shapes of the sidewall 43 are contemplated.

In one embodiment, the protrusion sidewall 43 extends from the surface 45 of the body 41 at an oblique angle. More specifically, in one embodiment, a first diameter of the protrusion 42 proximately to the body surface 45 is greater than a second diameter of the protrusion 42 proximate to the end-wall 44. In another embodiment, the sidewall 43 of the protrusion 42 is approximately orthogonal to the body surface 45. More specifically, the sidewall 43 can optionally be approximately parallel to the exterior surface of the form tool body 41. Accordingly, in one embodiment, the protrusion is generally cylindrical with a diameter which is different than the body diameter 49.

Optionally, a second radius R2 is formed between the surface 45 and the sidewall 43. The second radius R2 is selected to form an interior radius R3 (illustrated in FIG. 1) between the closed end-wall 64 and the deboss 66 formed in the metallic cup 60.

A radius R7 may optionally be formed between the end-wall 44 and the sidewall 43. In one embodiment, radius R7 is between approximately 0.05 inches and approximately 0.15 inches.

Referring now to FIG. 5A, another embodiment of a form tool 40A is illustrated. Form tool 40A may be used with the deboss apparatus 10 interchangeably with form tool 40 in all embodiments of the present invention.

Form tool 40A includes a body 41 with a sidewall 43 and an end-wall 44. The body 41 is generally cylindrical. Optionally, a radius R7 is formed between the sidewall 43 and the end-wall 44. In one embodiment, the end-wall 44 is generally planar. The form tool 40A has a diameter 49 and a height 51. In one embodiment, the height 51 is between approximately 2.0 inches and approximately 3.2 inches.

Referring now to FIG. 6, a tooling assembly 18B is illustrated when rotated proximate to the infeed mechanism 46. More specifically, the infeed mechanism 46 has conveyed a metallic cup 4 into the tooling assembly 18B. The metallic cup 4 sits in or on the upper surface portion 34 of the pressure pad 30. In one embodiment, the metallic cup 4 is received at least partially within the pressure pad recess 32. The metallic cup 4 is positioned with a closed end-wall 8 proximate to the pressure pad 30. In this manner the closed end-wall 8 extends across the pressure pad cavity 33. An open end of the metallic cup faces the interior sleeve 24.

When the biasing means 36 is not compressed, such as when the tooling assembly 18B is proximate to the infeed mechanism 46, the pressure pad 30 supports the metallic cup 4 with the closed end-wall 8 a predetermined distance from the forming tool 40. In one embodiment, the end-wall 44 of the form tool 40 does not contact the closed end-wall 8. Subsequently, as the turret 12 rotates, the ram 22 moves the interior sleeve 24 toward the metallic cup 4 and the turret 12. The interior sleeve 24 moves into an interior of the metallic cup 4 and contacts an interior surface of the closed end-wall 8. The metallic cup 4 is pressed downwardly by the ram 22 and interior sleeve 24 and the end-wall 44 of the form tool 40 applies a force to the closed end-wall 8 of the metallic cup. In this manner, the form tool 40 is configured to create a metallic cup 60 with a deboss 66 in a closed end-wall 64.

Referring now to FIG. 7, another tooling assembly 18C and a metallic cup 60 are illustrated during a forming stroke. As the turret 12 rotates, the interior sleeve 24 is driven down by the cam 25 and the ram 22 and the interior sleeve 24 enters the interior of the metallic cup 60. As the turret rotation and corresponding forward stroke continue, the interior sleeve 24 presses on the closed end-wall 64 of the metallic cup 60, driving the metallic cup and the pressure pad 30 toward the turret 12 as the biasing means 36 compresses. The metallic cup 60 is clamped between the interior sleeve 24 and the pressure pad 30. In one embodiment, a center portion of the closed end-wall 64 of the metallic cup 60 is not supported as the deboss 66 is formed. More specifically, in one embodiment, an interior surface of the closed end-wall 64 that is formed into the deboss 66 does not contact a tool of the deboss apparatus 10 during the forming stroke of the ram 22.

The forward stroke of the ram 22 causes the closed end-wall 64 of the metallic cup 60 to contact the form tool 40, clamping the metallic cup between the interior sleeve 24 and the pressure pad 30. As the deboss 66 is formed, the metal of the metallic cup 60 is prone to wrinkling; however, the clamping force on the closed end-wall 64 between interior sleeve 24 and the pressure pad 30 provide resistance to wrinkling. The interior sleeve 24 continues the forward stroke until the deboss is fully formed, as generally illustrated in FIG. 7. The closed end-wall 64 is then formed and/or drawn between the interior sleeve 24 and the form tool 40 as the ram 22 completes the forward stroke.

The form tool 40 may extend at least partially into the chamber 28 of the interior sleeve 24 during the stroke of the ram 22. Accordingly, as described above, the interior sleeve chamber 28 has a depth at least equal to the height of the optional protrusion 42. In one embodiment, the depth of the interior sleeve chamber 28 is greater than the height of the protrusion 42. Optionally, in one embodiment, the chamber 28 has a depth of at least approximately 0.6 inches.

As material of the metallic cup 60 in drawn inwardly to form the deboss 66, the height of the sidewall 62 of the metallic cup decreases. The cup bottom, or closed end-wall 64, is clamped, but the clamp surfaces are large and the clamping forces are relatively low. Accordingly, in one embodiment, the metal of the metallic cup 64 does not thin or stretch appreciably. More specifically, in one embodiment, the material of the closed end-wall 64 can slide between the interior sleeve 24 and the pressure pad 30 during formation of the deboss 66. Forming a deboss 66 in a metallic cup 60 with the deboss apparatus 10 improves the appearance and performance of a metallic container subsequently formed from the metallic cup 60 by downstream equipment 74.

As the turret 12 continues rotating, the ram 22 completes the forward stroke and begins the return stroke. During the return stroke, the ram 22 and interior sleeve 24 move along the longitudinal axis 20 away from the turret 12 and the interior sleeve 24 retracts from the interior of the metallic cup 60 back to a position similar to that illustrated in FIG. 6. The metallic cup 60 with the deboss 66 is then conveyed out of the tooling assembly 18C by a support device 52 of an outfeed mechanism 50. The outfeed mechanism 50 may be the same as, or similar to, the infeed mechanism 46. In one embodiment, the outfeed mechanism 50 comprises a starwheel.

In one embodiment, each tooling assembly 18 includes an aperture for compressed air to strip the metallic cup 60 from the interior sleeve 24. Alternatively, stripper fingers may be included with the tooling assembly 18 to remove the metallic cup 60 from the interior sleeve 24. One example of a stripper finger is generally described in U.S. Pat. No. 6,032,505 which is incorporated herein by reference in its entirety. Optionally, a stripper can be positioned at least partially within the chamber 28 of the interior sleeve 24.

Referring again to FIG. 1, the deboss 66 formed by the tooling 18 of the deboss apparatus 10 may have a geometry with any predetermined size and profile. The deboss 66 generally includes a neck portion 67 extending from the closed end-wall 64 of the metallic cup 60. A radius R3 is formed between the closed end-wall 64 and the neck 67. Optionally, the interior radius R3 is between approximately 0.06 inches and approximately 0.2 inches. A closed end 69 is interconnected to the neck portion 67. Optionally, the neck portion 67 has a cross-section that is generally planar. Additionally, or alternatively, the closed end 69 can be generally planar. A radius R4 is formed between the neck 67 and the closed end 69. In one embodiment, the radius R4 is approximately equal to the radius R3. In another embodiment, the radius R4 is between approximately 0.06 inches and approximately 0.2 inches. Optionally, one or more of the radii R3, R4 can be altered by varying the diameter 49 of the form tool 40, 40A and an interior diameter 29 of the chamber 28 of the interior sleeve 24.

In one embodiment, in which the metallic cup 60 has a diameter 61 of between approximately 3.53 inches and approximately 3.73 inches, the deboss 66 has a maximum diameter 70 of between approximately 2.44 inches and approximately 2.64 inches. In another embodiment, the maximum diameter 70 of the deboss 66 is between approximately 68% and approximately 72% of the diameter 61 of the metallic cup 60.

The deboss 66 has a minimum diameter 72 which, in one embodiment, is between approximately 1.9 inches and approximately 2.1 inches. In another embodiment, the minimum diameter 72 is between approximately 2.01 inches and approximately 2.03 inches. In another embodiment, the deboss minimum diameter 72 is between approximately 54% and approximately 58% of the cup diameter 61. Optionally, in another embodiment, the minimum diameter 72 is between approximately 78% and approximately 81% of the maximum deboss diameter 70.

The deboss 66 may be of any predetermined depth 68. In one embodiment, the deboss 66 has a depth 68 of between approximately 0.05 inches and approximately 0.50 inch or, in another embodiment, between approximately 0.10 inches and approximately 0.40 inches. In another embodiment, the deboss depth 68 is between approximately 0.25 inches and approximately 0.35 inches.

As previously described, forming the deboss 66 does not significantly thin the material of the closed end-wall 64 of the metallic cup 60. Accordingly, in one embodiment, when a metallic cup 4 formed of 0.0100 gauge metal is fed into the deboss apparatus 10, the deboss closed end 69 has a thickness that is not less than 0.01 inches. In another embodiment, the closed end-wall 64 has a thickness which is not less than 0.01 inches. In another embodiment, when the metallic cup 4 is formed of 0.0100 gauge metal, the neck 67 of the deboss 66 has a thickness of not less than approximately 0.008 inches. In still another embodiment, when the metallic cup 4 is formed of 0.0100 gauge metal, no portion of the closed end-wall 64 or deboss 66 have a thickness of less than approximately 0.008 inches.

In one embodiment, the deboss 66A of the metallic cup 60A has a depth 68A of between approximately 0.14 inches and approximately 0.16 inches. In one embodiment, the sidewall 62A has a height 63A of between approximately 0.90 inches and approximately 1.3 inches after the deboss 66A is formed. In contrast, in one embodiment the sidewall 6 of the metallic cup 4 has an initial height 7 of between approximately 1.0 inches and approximately 1.5 inches before the deboss 66 is formed. In another embodiment, forming the deboss 66A reduces the sidewall height 7 by between approximately 0.010 inches and approximately 0.15 inches. In another embodiment, the deboss depth 68A is between approximately 11% and approximately 15% of the sidewall height 63A of the metallic cup 60A.

In another embodiment, the deboss 66B has a depth 68B of between approximately 0.2 inches and approximately 0.4 inches. For this embodiment, when the initial sidewall height 7 is between approximately 1.0 inches and approximately 2.0 inches, the sidewall 62B has a height 63B which decreases to between approximately 0.98 inches and approximately 1.18 inches when the deboss 66B is formed. In another embodiment, the deboss depth 68B is between approximately 26% and approximately 30% of the height 63B of the sidewall 62B.

In one embodiment, a single form tool 40, 40A can be used to form metallic cups 60A, 60B having debosses 66A, 66B of different depths 68. More specifically, the depth 68 of a deboss 66 formed by the deboss apparatus 10 can be adjusted by one or more of altering the stroke length of the rams 22, adjusting the biasing force of the biasing means 36, and altering the stroke length of the pressure pad 30. Accordingly, the form tool 40, 40A does not need to be replaced to adjust the depth 68 of a deboss 66 and can be used to form debosses 66 with a variety of different depths 68.

After the metallic cup 60 is removed from the deboss apparatus 10 by the outfeed mechanism 50, the metallic cup 60 can be transported to downstream equipment 74. The downstream equipment 74 can include a conveyor 54 to transport the metallic cups 60 to downstream equipment 74. In one embodiment, the downstream equipment 74 includes a bodymaker.

Optionally, the metallic cups 60 may be inspected for irregularities and damage, such as dents or protrusions. In one embodiment, a sensor is configured to visually inspect the metallic cup. The sensor may be the same as, or similar, sensors described in U.S. Pat. No. 7,905,174 which is incorporated herein in its entirety by reference. Alternatively, the metallic cups 60 can be inspected using an electrode that identifies voltage changes associated with surface irregularities. One example of a device including an electrode for detecting surface irregularities in metallic objects is described in U.S. Patent Application Publication No. 2012/0119725 which is incorporated herein by reference in its entirety.

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 forming apparatus for shaping a closed end-wall portion of a metallic cup, comprising:

a turret operable to rotate at a predetermined rate; and

a plurality of tooling assemblies associated with the turret, each of the tooling assemblies comprising: a pressure pad to receive the metallic cup, the pressure pad operably engaged to the turret; a forming tool associated with the pressure pad and having a geometric profile selected to form a deboss with a predetermined shape in the closed end-wall portion of the metallic cup; a ram with a stroke oriented substantially perpendicular to the turret; and an interior sleeve interconnected to the ram, the interior sleeve having an exterior diameter no greater than an interior diameter of the metallic cup, wherein, when the turret rotates, the ram moves in a forward stroke such that the interior sleeve applies a force to the metallic cup and the forming tool forms the deboss with the predetermined shape in the closed end-wall portion of the metallic cup.

2. The apparatus of claim 1, further comprising a biasing means to bias the pressure pad in relation to the turret.

3. The apparatus of claim 2, wherein the biasing means biases the pressure pad away from the turret.

4. The apparatus of claim 2, wherein the biasing means comprises at least one spring.

5. The apparatus of claim 1, wherein the ram is operably engaged to an upper portion of the turret of the forming apparatus, the upper turret portion spaced from the pressure pad.

6. The apparatus of claim 1, wherein the ram includes a cam follower which engages a cam of the forming apparatus.

7. The apparatus of claim 6, wherein the cam is formed on a shaft of the forming apparatus.

8. The apparatus of claim 1, wherein the forming tool includes an end that is generally planar, and wherein the end of the forming tool does not extend beyond a plane defined by an upper surface of the turret.

9. The apparatus of claim 1, wherein the pressure pad includes an annular end to support a portion of the closed end-wall of the metallic cup, the annular end being generally planar.

10. The apparatus of claim 9, wherein the annular end of the pressure pad does not extend beyond a plane defined by an upper surface of the turret.

11. The apparatus of claim 10, wherein, when the metallic cup is positioned in the tooling assembly, the annular end of the pressure pad is positioned approximately even with the plane define by the turret upper surface.

12. The apparatus of claim 1, wherein the forming tool is interconnected to the turret such that the forming tool is substantially stationary during the stroke of the ram.

13. The apparatus of claim 1, wherein the interior sleeve includes a chamber with an interior diameter that is greater than an interior diameter of a cavity of the pressure pad.

14. The apparatus of claim 1, further comprising:

an infeed mechanism that positions the metallic cup in the pressure pad of one of the tooling assemblies; and

an outfeed mechanism that receives the metallic cup from the pressure pad after the forming apparatus forms the deboss in the metallic cup.

15. A method of forming a deboss in a closed end-wall portion of a metallic cup, comprising:

receiving the metallic cup in an infeed mechanism associated with a forming apparatus;

feeding the metallic cup to a turret of the forming apparatus, the turret rotatable around a central axis and including a plurality of tooling stations, each of the tooling stations comprising: a pressure pad operably associated with the turret and including an annular surface to support the metallic cup; a ram operably engaged by an upper turret spaced from the turret, the ram having a stroke oriented substantially parallel to the central axis an interior sleeve interconnected to the ram, the interior sleeve having an exterior diameter no greater than an interior diameter of the metallic cup; and a forming tool associated with the pressure pad, the forming tool having a geometric profile selected to form the deboss with a predetermined shape in the closed end-wall portion of the metallic cup; and

rotating the turret at a predetermined rate, wherein, when the ram moves in a forward stroke, the interior sleeve applies a force to the metallic cup and presses the closed end-wall against the forming tool to form the deboss with the predetermined shape in the closed end-wall portion of the metallic cup.

16. The method of claim 15, wherein the pressure pad is biased to the turret by a spring.

17. The method of claim 15, wherein the forming apparatus includes a cam which is engaged by a cam follower of the ram.

18. The method of claim 15, further comprising biasing the annular surface of the pressure pad to a position substantially level with a surface of the turret before the metallic cup is fed to the turret.

19. The method of claim 15, wherein the forming tool extends into a chamber of the interior sleeve, the chamber having an interior diameter that is greater than an interior diameter of a cavity of the pressure pad.

20. The method of claim 15, wherein the deboss includes a closed end with an interior surface that is not supported when the metallic cup presses against the protrusion of the forming tool.