Metal Products And Methods For Forming Components Thereof

Abstract

Generally, the instant disclosure is directed towards various methods of EMF-forming workpieces and the resulting workpieces. More specifically, the instant disclosure is directed towards various embodiments of imparting EMF-features onto workpieces, where workpieces with resulting EMF-features are configured as metal containers.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional of and claims priority to U.S. Application Ser. No. 62/265,180, entitled “Metal Products and Methods for Forming Components Thereof” filed on Dec. 9, 2015, which is incorporated by reference in its entirety.

FIELD OF THE INVENTION

Generally, the instant disclosure is directed towards EMF-forming workpieces. More specifically, the instant disclosure is directed towards different embodiments of imparting EMF-features onto workpieces, where workpieces are configured as metal containers.

BACKGROUND

Commercially available shaped metal containers made via forming operations have limited features and components.

SUMMARY OF THE DISCLOSURE

Broadly, the present disclosure relates to electromagnetic forming (EMF) processes for shaping metal containers (e.g. bottles and cans) and imparting certain components (e.g. EMF-features) onto metal containers (e.g. segmented aluminum bottle threads on metal containers).

In one embodiment, a metal container (e.g. aluminum or aluminum alloy) comprises an EMF feature.

In some embodiments, the EMF feature includes an asymmetrical configuration.

In some embodiments, the asymmetrical configuration of the EMF feature includes: a thread (e.g. configured along the upper portion of the metal container); a stamped feature (e.g. logo) on the body (e.g. configured/positioned below the neck, if the metal container is necked); a stamped feature (e.g. logo) positioned on the bottom (e.g. dome, if domed) of the metal container.

Some non-limiting examples of asymmetrical configurations of the EMF feature include: a crown-style threaded upper portion; a PET-style threaded upper portion; and combinations thereof.

In some embodiments, the EMF feature includes a symmetrical configuration.

In some embodiments, the symmetrical configuration of the EMF feature includes: a PET-style threaded upper portion; a stamped feature (e.g. logo) on the body (e.g. configured/positioned below the neck, if the metal container is necked); a stamped feature (e.g. logo) positioned on the bottom (e.g. dome, if domed) of the metal container; a carrier ring, and combinations thereof.

In some embodiments, a formed metal container (e.g. drawn, drawn and ironed, impact extruded, pressure ram forming, three-piece welded, two-piece welded, electrohydrodynamic forming, hydraulic blow forming (hydroforming) having an EMF-feature thereon configured to promote threaded engagement with a closure device (e.g. lid, cap, cover, etc) having corresponding thread to enable a secure fit or seal.

In some embodiments, a formed metal container (e.g. drawn, drawn and ironed, impact extruded) is configured with an EMF-feature comprising a PET-style threaded finish.

As used herein, PET-style thread is similar to the thread finish on a PET bottle. In some embodiments, the PET-style thread is integrally formed on a metal container (e.g. EMF-feature). In some embodiments, the PET-style thread comprises a continuous thread path (e.g. configured in a helical direction) interrupted with at least one vent slot (e.g. configured in a generally axial direction), wherein the vent slots are configured to provide a path for the release of internal gases upon opening of the container (See, e.g. FIG. 4).

In some embodiments, the formed metal container is configured with a twist-off crown thread (integrally formed on aluminum container). In some embodiments, a metal container (e.g. formed metal container) comprises at least one integrally formed (via EMF), thread configured with more than one beginning and end around the perimeter of the opening to accommodate a twist-off crown-style closure (e.g. twist-off crown-lid).

In some embodiments, the roll on pilfer proof (ROPP) thread includes one continuous thread configured to receive a closure having a tamper evident band configured/positioned beneath the thread.

In some embodiments, the twist-off crown thread is a continuous thread with a pitch less than the ROPP thread. In some embodiments, the twist-off crown thread is configured such that the beginning of one thread is directly axially in line and/or overlapping with another thread.

In some embodiments, the twist-off crown thread is configured with lugs, such that the beginning of one thread is not directly axially in line and/or overlapping with another thread.

In some embodiments, a twist-off crown is configured with an angle of attenuation of the summation of the thread lengths at less than 360°.

In some embodiments, a lug is configured such that the angle of attenuation of the summation of the thread lengths is not greater than 360°.

In some embodiments, a metal container (e.g. formed metal container) is provided, the metal container configured with an integrally formed asymmetrical thread (e.g. twist-off crown-lid or PET-Style thread).

In some embodiments, a formed metal container is configured with a PET-style threaded finish and a PET closure attached thereto. In some embodiments, the PET-style threads include PET bottle finishes configured for use on bottles retaining carbonated soft drinks. Some non-limiting examples of PET bottle finishes for carbonated soft drinks include: bottle finishes PCO 1810 or PCO 38 (e.g. having intermittent threads) and bottle finish Alcoa 1690 or Alcoa 1716 (e.g. each having vent slots).

In some embodiments, a metal container is configured with/comprises a segmented thread configured to improve venting during opening.

In some embodiments, a formed metal container having an EMF-feature comprises a twist-off crown finish. In some embodiments, the twist-off crown finish is configured for a metal crown, plastic cap, a roll-on pilfer-proof closure/cap, or combinations thereof.

Some non-limiting twist-off crown finishes include: screw threads, screw-top, screw-cap, helix, coil, duplex, external screw thread, and combinations thereof.

In some embodiments, a metal container is configured with an EMF-feature. In some embodiments, the EMF-feature selected from the group consisting of: a thread configured proximate to the open, upper end of the closed metal container, an upper rim configured from an EMF-operation (e.g. trimming); a curl configured from an EMF-operation (e.g. curling); an imprinted portion configured along the sidewall of the body (e.g. cylindrical portion of the metal container); a carrier ring configured on an upper open portion of the metal container, positioned beneath the threaded portion; a carrier ring comprising: a carrier ring insert (e.g. plastic or metal ring) and a carrier ring lip (e.g. formed via EMF and configured to secure the carrier ring insert into position along the metal container, wherein the carrier ring is configured on an upper open portion of the metal container, and positioned beneath the threaded portion; an imprinted portion configured along the bottom of the body (e.g. dome or base of the metal container); and combinations thereof.

It is noted that thread configurations and/or lug patterns are referred to herein. It is noted that lugs and threads are used interchangeably, though a lug (e.g. a projection on an object by which it may be carried or fixed in place) and a thread (a helical ridge on the outside of an object configured to allow two parts to be mechanically attached/screwed together) may differ slightly in how they are interpreted.

In some embodiments, the thread configuration comprises a continuous threaded finish configured to be used with ROPP cap/closure.

In some embodiments, the thread configuration comprises a discontinuous/segmented thread finish. In some embodiments, the segmented thread finish is configured to be usable with a ROPP cap or a PET-style plastic cap or lug cap.

In some aspects of the instant disclosure, one or more of the various embodiments, is configured to make asymmetric forming of a shaped can (e.g. aluminum can or bottle) for differentiated products branding. In some embodiments, EMF-features are configured on the sidewall, bottom, dome, upper end of the workpiece (metal container), and combinations thereof.

In some embodiments, resistance (e.g. electrical resistance) is added into the inductor (e.g. via the electrical connections, volume of material in the coil, or insulators) in order to modify the current, and thus, the resulting electromagnetic field that is imparted/pulsed onto the substrate/workpiece.

In some embodiments, the EMF-formed threads are configured with thread depths having a sufficient depth to enable secure mechanical attachment with a corresponding closure (e.g. cap, lid, cover). In some embodiments, the EMF-formed threads are configured with thread depths having radii/angles to enable secure mechanical attachment with a corresponding closure (e.g. cap, lid, cover). In some embodiments, the EMF-formed threads are configured to enable secure mechanical attachment of the closure (e.g. lid, cover, cap) and retain contents of the metal container which are pressurized and/or vacuum packed (e.g. food and/or beverages).

In some embodiments, a formed aluminum bottle is configured with thread, wherein the thread is configured to accept a plastic cap. In some embodiments, a formed aluminum bottle is configured with thread, wherein the thread is configured to accept a lug cap. In some embodiments, a formed aluminum bottle is configured with thread, wherein the thread is configured to accept a ROPP cap.

In some embodiments, a formed aluminum bottle with at least one EMF-feature is provided, wherein the EMF-features are selected from the group consisting of: threads, lugs, imprinted portions of the body, imprinted portions of the bottom/dome, carrier rings, carrier ring inserts, and combinations thereof.

In some embodiments, the segmented thread is configured to provide easier openability. In some embodiments, the segmented thread is configured to provide improved venting of carbonation gases (e.g. directed out from the upper end of the container via the recesses/grooves in the threaded pattern). In some embodiments, the thread is configured to provide improved axial column loading (e.g. measured/quantified and/or simulated).

Without being bound by a particular mechanism or theory, the skin layer, or thickness into which the EMF field penetrates into the metal substrate depends upon the frequency of the electromagnetic pulse.

In one embodiment, a method is provided, comprising: positioning the workpiece adjacent to an inductor of an EMF device, wherein at least a portion of the workpiece (the substrate) is positioned between an inductor coil and a die; discharging a power source of the EMF device to generate an electromagnetic frequency via the inductor; and generating an electromagnetic force via the inductor, wherein the inductor is positioned such that the electromagnetic force acts upon (imparts force onto) the workpiece.

In some embodiments, the workpiece and inductor are placed adjacent to (but not in contact with each other, in order to prevent arching or transferring electrical current from the inductor into the workpiece. In some embodiments, the higher the frequency of the electromagnetic pulse, the thinner the sheet that can be EM formed.

In some embodiments, the thinner the substrate of the workpiece, the lower the selected energy needed to impart an EMF feature on the workpiece.

In one embodiment, a method is provided, comprising: disposing/positioning an inductor in electrical communication with a pulsed magnetic device, such that the inductor is configured to impart a magnetic force to at least a portion of a workpiece (e.g. sidewall or bottom of a workpiece); energizing the inductor via power source to a voltage potential via transducer, capacitor, and induction coil configuration; imparting a pulsed electromagnetic frequency into the portion of the workpiece sufficient to impart a deformation in the workpiece adjacent to the inductor; directing the workpiece onto a support surface die (e.g. with thread configuration, imprinted logo), imparting via the support surface (e.g. die or imprinting/stamp) and EMF frequency, an EMF feature configured onto the workpiece.

In some embodiments, the directing step includes: imprinting the workpiece with the pattern on the die. In some embodiments, the directing step includes: molding the workpiece with the pattern on the die. In some embodiments, the directing step comprises impacting the die with the workpiece. In some embodiments, the directing step further comprises deforming the metal into the workpiece.

In some embodiments, the directing step further comprises engraving.

In some embodiments, the directing step further comprises incising.

In other embodiments, the electromagnetic force actuates the metal normally (perpendicular to a plane) away from the inductor (e.g. to create a curling operation, a trimming operation).

In some embodiments, the imparting step comprises imparting (forming via electromagnetic force acting upon the workpiece and the workpiece being directed onto the support surface (e.g. threading die)) a thread on an upper portion of the neck of a metal container (e.g. aluminum bottle).

In some embodiments, the imparting step comprises: curling the upper portion of the top portion (forming via EMF acting upon a base portion configured as an actuator to press the workpiece onto a curling tie/tooling to impart a curl on the upper end).

In some embodiments, the method comprises imparting an EMF-feature (e.g. emboss/stamp) on the bottom (e.g. dome) or sidewall (e.g. non-necked portion of the workpiece/metal container) prior to necking. In some embodiments, once the EMF-feature (e.g. stamp/emboss logo) is imparted onto the workpiece (metal container), then the container undergoes a necking step (e.g. configured via a forming operation).

In some embodiments, the method comprises imparting an EMF-feature (e.g. thread configuration and/or lug pattern) on the upper portion (e.g. adjacent to/proximate the open end of the metal container). In some embodiments, imparting an EMF-feature comprising a thread is completed after necking (e.g. such that the upper end is configured/necked to the approximate thread diameter of the sidewall (e.g. non-necked portion of the workpiece/metal container). In some embodiments, once the EMF-feature (e.g. stamp/emboss logo) is imparted onto the workpiece (metal container), then the container undergoes a neck step (e.g. configured via a forming operation).

In some embodiments, a method includes: trimming an upper end/portion positioned/proximate to the open end of a closed metal container (workpiece) to provide a trimmed upper end.

In some embodiments, the method includes: positioning a first die (threading die) and/or a second die (curling die) around the upper end of the closed metal container such that the die surfaces are positioned adjacent to the outer sidewall of the metal container, and configured proximate to the trimmed upper end; positioning a first inductor inside the open upper end of the container such that the first inductor is secured inside the container adjacent to the inner sidewall; positioning a second inductor beneath a bottom of the closed metal container, with a metallic base portion positioned between the second inductor and the bottom of the container and configured as an actuator when under an EMF-feature forming force; and directing a first electromagnetic force towards the workpiece/substrate via the first inductor to impart a first EMF-feature (e.g. thread) on the upper end of the closed metal container (workpiece) via the first die; and directing a second electromagnetic force towards the metallic base portion via the second inductor to impart a second EMF-feature (e.g. curl) onto the open, upper end of the closed metal container by directing the metal container towards the second die (e.g. tooling/die). In some embodiments, the threading and curling steps are performed simultaneously.

In some embodiments, the threading and curling steps are performed sequentially.

In some embodiments, more than one die can be employed to impart two EMF-features on a workpiece (e.g. closed-bottom, metal container) via an inductor directed electromagnetic pulse. As a non-limiting example, two dies are positioned along the outer sidewall of the workpiece, including a first die (threading die) and a second die (trimming die) are employed where the trimming die is positioned with a taller height (e.g. closer to the upper, open end of the closed bottom metal container (workpiece)). In this embodiment, the inductor is positioned inside the upper, open end of the metal container such that, as the pulse-magnetic device discharges and creates an electromagnetic pulse, through cooperation with the inductor (generating the electromagnetic pulse) and the dies, the metal workpiece is directed away from the inductor, in a generally outward direction, imparting a thread configuration/lug pattern on the upper end of the closed metal container (via the first die/threading die) and also imparting a trim along a portion of the metal container above the threaded configuration/lug pattern (via the second die/trimming die).

In some embodiments, a method is provided, including: threading an upper end of the workpiece (e.g. closed bottom metal container, aluminum bottle) via the cooperation of a threading die attached to an upper end of the workpiece and a pulsed electromagnetic force generated via an inductor of a pulsed-magnetic device; trimming the upper portion of the open end to define an upper rim positioned above the thread; and curling the upper rim to form a thread configured to receive a corresponding closure (e.g. lid, cover, cap having a corresponding thread and/or lugs).

In some embodiments, the trimming step is completed, via at least one of: a lathe-type trim or rolling-cutting edge (e.g. configured perpendicularly to the edge) such that the rolling cutting edge is configured to cut/shear the metal off to form the upper rim. In some embodiments, the trimming step is completed as an EMF-operation (e.g. with a second die positioned in staggered height from the first, threading die during forming of the EMF-feature (thread) on the upper, open end of the workpiece).

In some embodiments, the curling step is completed via forming operations with dies. In some embodiments, the curling step is completed via a pulsed electromagnetic force generated from an inductor (as set out herein).

In some embodiments, the threading die is configured to simultaneously form in the portion of the workpiece adjacent to the inductor a thread configuration via EMF with longitudinal grooves/channels for gas outlet and circular threads/lugs grooves to secure the closure (e.g. lid, cover, or a cap).

As used herein, “electromagnetic forming” (EMF) means: a type of high velocity, cold forming process, generally utilized in conjunction with electrically conductive metals. In some embodiments, electromagnetic forming refers to an impulse or high-speed forming technology using a pulsed magnetic field to apply Lorentz' forces to workpieces (e.g. metal containers, aluminum, aluminum alloys, steel, steel alloys).

In some embodiments, EMF imparts deformation of the workpiece (via at least one corresponding die) without the inductor coming into contact with the workpiece.

In some embodiments, EMF imparts deformation of the workpieces without a working medium.

In some embodiments, the inductor and die are configured to expand at least a portion of the workpiece (i.e. inductor positioned inside the metal container/workpiece adjacent to the inner sidewall and die positioned outside the workpiece adjacent to outer sidewall).

In some embodiments, the inductor and die are configured to compress (e.g. neck) at least a portion of the workpiece (i.e. inductor positioned outside the metal container/workpiece adjacent to the outer sidewall and the die positioned inside the workpiece adjacent to the inner sidewall).

In some embodiments, pulsed EMF methods and/or the corresponding pulsed magnetic device is/are utilized to provide various EMF-features configured on metal containers. Some non-limiting examples of EMF-features include: asymmetrical features, symmetrical features, finishes (e.g. thread configurations, lug patterns), other features (e.g. carrier ring, pilfer band, imprinted features, stamped features, logos, graphics, text, a curl, a hem) and/or combinations thereof.

In some embodiments, pulsed EMF methods and/or the corresponding pulsed magnetic device is/are utilized to provide EMF-operations on metal containers. Some non-limiting examples of EMF methods include: trimming, curling, threading, installing carrier ring, imprinting, and/or combinations thereof.

As used herein, “workpiece” means: an object being worked on with a tool or machine. Some non-limiting examples of a workpiece include a metal container being worked on by an electromagnetic forming device (e.g. pulsed EMF device).

In some embodiments, the metal container is configured as a bottle.

In some embodiments, the metal container is configured as a can.

In some embodiments, the metal container is configured as an aerosol can.

In some embodiments, the metal container is configured with a finish feature (e.g. mechanical configuration, threading, lugs, or the like) such that the metal container is configured to accept a closure (e.g. lid, cover, cap, crown).

In some embodiments, the metal container is configured to hold food, beverages, aerosols, wet and/or dry goods, pressurized contents, non-pressurized contents, hermetically sealed goods, and combinations thereof.

Some non-limiting examples of metals (making up the metal container) include: aluminum, aluminum alloys, steel, steel alloys, and combinations thereof. Non-limiting examples of aluminum or aluminum alloys include: 1xxx; 1060; 1070; 3xxx; 3104; 5xxx; 5182; 5052; 5042; 5352; and combinations thereof.

In some embodiments, the average thickness range of the workpiece is at least 0.003″.

In some embodiments, the thickness range of the workpiece for EMF-features and/or EMF-operations are on thin gauge cans.

In some embodiments, the thickness range for imparting EMF-features or operations on the workpiece at least 0.003″ up to 0.039″.

In some embodiments, the thickness for imparting EMF-features or EMF-operations to the workpiece is at least 0.0084″.

In some embodiments, the thickness for imparting EMF-features or EMF-operations to the workpiece is at least 0.015″.

As a non-limiting example, the workpiece comprises a container with the sidewall at least 0.003″ thick and is made from a sheet at least 0.006″ thick.

As a non-limiting example, the sheet is at least 0.009″-0.030″ thick.

It is noted that reference to upper and lower herein, with regard to the bottle, is with reference to a bottle sitting with its closed end on the table (e.g. “bottom end”) and its open end in the air (e.g. “upper end”).

Various ones of the inventive aspects noted hereinabove may be combined to yield various products and methods of making the same with a pulse-magnetic device to impart EMF-features or EMF-operations (e.g. curling, trimming, stamp/imprinting, and the like) on metal containers (e.g. having closed bottoms).

These and other aspects, advantages, and novel features of the invention are set forth in part in the description that follows and will become apparent to those skilled in the art upon examination of the following description and figures, or may be learned by practicing the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 provides an embodiment of a metal container having an EMF feature including a roll-on pilfer proof (ROPP) thread and curl, in accordance with one or more embodiments in accordance with the instant disclosure.

FIG. 2 provides an embodiment of a metal container having an EMF-feature including a PET-style integral thread formed on a metal container, in accordance with one or more embodiments of the instant disclosure.

FIG. 3 depicts an illustration of an embodiment of an EMF-feature of a twist-off crown type thread integrally formed on a metal container thereon, in accordance with the instant disclosure.

FIG. 4 depicts an illustration of an embodiment of an EMF-feature on a metal container having a PET-style thread integrally formed thereon, in accordance with the instant disclosure.

FIG. 5 depicts a computer simulation of an embodiment of an EMF-feature being formed on the workpiece, with the inductor configured inside the workpiece and generally configured in the center of the die and workpiece and the die configured outside the workpiece, in accordance with one or more embodiments of the instant disclosure. In FIG. 5, the inductor is a one-piece inductor that has a fixed height.

FIG. 6 depicts a computer simulation of an embodiment of an EMF-feature being formed on the workpiece, with the inductor configured inside the workpiece and generally configured in the center of the die and workpiece and the die configured outside the workpiece, in accordance with one or more embodiments of the instant disclosure. In FIG. 6, the inductor is a coiled-configuration that is capable of being adjusted in height (e.g. made taller, variable height, etc).

FIG. 7 depicts a computer simulation of an embodiment of an EMF-feature integrally formed in the workpiece (e.g. aluminum bottle), wherein the EMF-feature includes an asymmetrical thread finish (e.g. PET-style thread showing a vent slot), in accordance with one or more embodiments of the instant disclosure.

FIGS. 8, 9, and 10 (i.e. die halves shown separately and in closed configuration) are a die system and workpiece (depicted in position in a portion of the die of FIG. 8), in accordance with one or more embodiments of the instant disclosure. The die system of FIGS. 8-10 includes a ROPP type thread configured in a two-piece thread forming tool (with the inductor positioned inside the bottle), in accordance with various embodiments of the instant disclosure.

FIGS. 11 and 12 depicts a perspective view of two die halves, the die providing a PET-style thread for integral EMF-forming of this type feature onto the workpiece, in accordance with various embodiments of the instant disclosure (with inductor positioned inside the workpiece).

FIGS. 13-15 depict various views of a segmented tooling design for thread forming (with inductor positioned outside the bottle and die inside the bottle) in accordance with various aspects of the instant disclosure. With regard to FIG. 13, the workpiece having an integrally formed thread is depicted, in accordance with the embodiments of the instant disclosure.

FIGS. 16-19 and 22-24 depict the segmented dies of FIGS. 13-15 in conjunction with a spacer, rod, and the like, configured to retain the die in place, in accordance with one or more aspects of the instant disclosure.

FIGS. 20 and 21 depict yet another embodiment in which an EMF-feature of a PET-style thread is integrally formed on a metal container, in accordance with one or more embodiments of the instant disclosure.

FIGS. 25 and 26 depict yet another embodiment of the instant disclosure, a tooling for asymmetric sidewall imprinting utilizing pulsed EMF (with the inductor positioned inside the workpiece), in accordance with one or more embodiments of the instant disclosure.

FIG. 27 is a photograph of the incising apparatus securing a workpiece, in accordance with one or more embodiments of the instant disclosure.

FIG. 28-30 are photographs of experimental data illustrating EMF-features on the dome of a workpiece, on the sidewall of a workpiece, and on the upper end of the workpiece, in accordance with one or more embodiments of the instant disclosure.

FIG. 31 is a schematic cut away side view of an embodiment of an EMF-feature including carrier ring having an outsert (e.g. plastic or metal ring), in accordance with one or more embodiments of the instant disclosure. In some embodiments, the ring outsert is mechanically secured via the EMF-forming of the carrier ring feature adjacent to the position of the carrier ring insert, in accordance with aspects of the instant disclosure.

FIGS. 32 and 33 depict yet another embodiment for forming an EMF-feature including a carrier ring, including dies and the positioning of the inductor within the workpiece, in accordance with various embodiments of the instant disclosure.

FIG. 34 and FIG. 35 depict still another embodiment for forming an EMF-feature including a carrier ring, including dies and the positioning of the inductor within the workpiece, in accordance with various embodiments of the instant disclosure.

FIG. 36 depicts an embodiment for creating an EMF-feature on the bottom of a workpiece/metal container, including an incising step, in accordance with one or more methods of the instant disclosure.

FIG. 37 depicts an embodiment of a functional diagram the pulse-magnetic device of Example 7, in accordance with the instant disclosure.

FIG. 38 depicts a graph outlining the functional relationship between current and voltage of the pulsed magnetic installation, in accordance with one or more embodiments of the instant disclosure.

FIGS. 39A-C depict an embodiment of a configuration of the clamp, die, and inductor positioning to impart a logo on the sidewall of a workpiece, in accordance with one or more embodiments of the instant disclosure.

FIG. 40 depicts a schematic of an embodiment of the clamp and corresponding configuration of the workpiece in Example 8 for imprinting the bottom of a container, in accordance with one or more embodiments of the instant disclosure.

FIGS. 41A and 41B depict an embodiment of a trimming die and inductor configuration (41A) and the die with inductor, depicting an adjustable clamping device for securing the workpiece to the clamp to complete a trimming operation via EMF, in accordance with one or more embodiments of the instant disclosure.

DETAILED DESCRIPTION

Reference will now be made in detail to the accompanying drawings and experimental examples section, which at least assist in illustrating various pertinent embodiments of the present invention.

EXAMPLES

Example 1: EMF Feature—Threading by Expansion

Approximately 25 samples underwent EMF-forming to impart an EMF-feature (Thread) onto the sidewall (threading by expansion). Utilizing the pulse magnetic device described in Example 7, EMF-features were imparted onto the workpieces. The samples/workpieces were metal container preforms of aluminum alloy 3104 having a package diameter of 59 mm and a sheet thickness of approximately 0.0212″. The workpieces (e.g. neck completed) were configured with closed bottoms and a perimetrical sidewall extending up from the bottom of the metal container.

Utilizing the dies depicted in FIGS. 11 and 12, the samples were secured (e.g. clamped) in the auxiliary support with the inductor positioned inside the opening along the upper end of the container and the inductor configured proximate/adjacent to the inner sidewall of the workpiece/sample. A die having a thread feature or profile (e.g. PET style-thread of FIG. 4) was configured (e.g. imprinted) on the outer surface of the sample (workpiece) along the upper (open) end of the aluminum bottle, and the sample with die were configured onto (e.g. mechanically attached, secured via a clamping arrangement) the clamp/auxiliary support and positioned adjacent to the inductor on the pulse-magnetic device.

In order to evaluate forming conditions, the voltage was varied: the highest voltage was 8 kV, and the lowest was 4 kV. The EMF-forming imparted/imprinted an asymmetrical feature (e.g. PET-type thread depicted in FIGS. 4, 11 and 12) onto the workpiece (aluminum bottle).

The resulting EMF-feature (thread configurations) imparted on the upper, open end of the metal container (workpiece) were visually inspected for quality, crispness/depth of threads, wrinkling, fractures, or other observable characteristics. In evaluating these samples, it was observed that samples ran with the tooling “as-received” at 6.5 kV resulted in a large number of fractures, while samples run at 4 kV had very slight (insufficient) amount of EMF-feature/thread imparted onto it (e.g. and any runs above 4 kV resulted in fracturing).

Without being bound by a particular mechanism or theory, it was determined that a modification to the tooling would promote better imprinting of the EMF-feature (thread configuration) and reduce, prevent, and/or eliminate fractures in the EMF-feature. The sharp edges in the as-received die were modified.

Without being bound by a particular mechanism or theory, a representative listing outlining several “before” runs using the tooling as-received and comparing to two “after” runs (after the tooling was modified) confirm that the fractures observed in the thread pattern were likely attributable to the sharp edges in the die. Without being bound by a particular mechanism or theory, at no condition using the “as received tooling” was the resulting EMF-feature/thread both deep enough and fracture free. In contrast, after the tooling was modified, the EMF-feature was imparted/imprinted at the same, or higher, voltage with no resulting fracturing observed.

The working specification for this run was to provide an EMF-feature configured as a thread with a depth of: 0.0275″+/−0.005″. It is noted that for the data depicted in the table, the thread depth was quantified by measuring the distance from the thread root to the overthread location (e.g. the minor diameter of the thread subtracted from the major diameter of the thread, quantity divided by two).

	Thread Depth
Voltage	(deepest			Before/After	Thickness
Potential	measurement)	Fracture	# of	Modification	(in necked sample
(kV)	[inches]	(Yes/No)	pulses	of tooling	at thread region)
4	0.01220″	No	2	Before	0.0164″-0.01675
4.5	0.01140″	Yes	1	Before	0.0164″-0.01676
5	0.01620″	Yes	1	Before	0.0164″-0.01677
5.5	0.01965″	Yes	1	Before	0.0164″-0.01678
6	0.02170″	Yes	1	Before	0.0164″-0.01679
6.5	0.02250″	Yes	1	Before	0.0164″-0.01680
6.5	0.02265″	No	1	AFTER	0.0164″-0.01681
8	0.02410″	No	1	AFTER	0.0164″-0.01682

In order to modify the tooling a small radius (0.005″) was machined into several sharp corners on the tooling. Results of EMF-features (threads) created after machining in small radius were observed to be fracture free and when measured, the threads fell within the desired depth specification. It is noted that prior to modification, fracture occurred at energy levels of 4.5 kV and above, while after modifying the tooling, no fractures were observed or detected at an operating voltage of 8.0 kV.

Example 2: EMF Forming Threading by Reduction (Segmented Die)

With this experiment, a sample was run on a collapsible, segmented die in order to evaluate EMF-forming (creating a thread on the workpiece) via reduction of the diameter. The pulse magnetic device from Example 7 was used in this formation, with an inductor coiled around the outside of the workpiece (adjacent to the outer sidewall) and the die configured within the container (e.g. adjacent to the inner sidewall). The workpiece was aluminum alloy 3104, having a package diameter of 59 mm and a starting sheet thickness of approximately 0.0186″. The workpiece was hit with one EMF-discharge (magnetic field).

After EMF forming, the segmented die was removed from the inside of the workpiece via a puller device. Although the EMF forming worked to impart a thread configuration on the upper portion of the metal container, when visually observed, it was determined that the part would not meet commercial specifications for rigid packaging materials (e.g. aesthetics).

	Thread Depth			Thickness
	(deepest			(in necked
Voltage	measurement)	Fracture	# of	sample at
Potential (kV)	[inches]	(Yes/No)	pulses	thread region)
10.5	0.0209″	Yes	1	0.0159″-0.0164″

Example 3: EMF Feature—Imprinted Logos

Utilizing the pulse magnetic device described in Example 7, approximately 12 samples underwent EMF-forming to impart an EMF-feature onto the sidewall. The samples had a preform diameter of 59 mm and a sidewall thickness (e.g. in straightwall portion of preform) of 0.00765″ to 0.00785″ drawn and ironed from sheet of approximately 0.0176″ thick. The samples were metal container preforms (e.g. aluminum alloy 3104), configured with closed bottoms and a perimetrical sidewall extending up from the bottom of the metal container. The preform was configured as a closed-bottom cylinder.

Utilizing the set-up detailed in FIG. 39 A-C, the samples were secured (e.g. clamped) into the auxiliary support with the inductor positioned inside the container proximate/adjacent to the inner sidewall of the workpiece/sample and a sleeve containing a die having a logo insert positioned on the outer sidewall of the workpiece/sample.

Across the several runs, the voltage was varied and the die material was changed (steel vs. plastic) and the resulting logos imparted on the sidewall were visually inspected for quality, crispness/depth, wrinkling, fractures, or other observable characteristics. All samples in this experiment were hit with one-EMF pulse only.

In order to evaluate the metal containers having an EMF-feature, the samples were visually inspected and observed for definition of logos on the metal container, tightness of radii and depth of profiles on the container. Two different logos were used in this example, as depicted in FIG. 29. It was observed that for utilizing the plastic dies, a lower voltage (e.g. 3.5 kV) resulted in a good EMF-feature (logo) as compared to a steel die (e.g. ˜6-6.5 kV). Also, it is noted that the higher the voltage, the more definition was configured into the workpiece, until failure.

	Fracture
Voltage Potential (kV)	(Yes/No)	Pattern	die material	Logo Quality Comment
9 kV	No	graphic design	conducting steel	Die fully filled
(all 4 samples - same as
those later imprinted
w/Alcoa Logo)
10.8 kV	No	Alcoa logo	conducting steel	Die fully filled
(all 4 samples)
3.5	No	graphic design	non-conductive	No definition/slight metal
			die	movement
6	No	graphic design	non-conductive	good definition, die not fully
			die	filled
6.5	No	graphic design	non-conductive	Graphic Design pattern
			die	evaluated well
7	Yes	graphic design	non-conductive	Failure of logo
			die
9	Yes	graphic design	non-conductive	Failure of logo
			die
3.5	No	Alcoa logo	non-conductive	No definition/slight metal
			die	movement
6	No	Alcoa logo	non-conductive	good definition, die not fully
			die	filled
6.5	No	Alcoa logo	non-conductive	Alcoa Logo at full depth
			die
7	No	Alcoa logo	non-conductive	Alcoa Logo more defined,
			die	tighter corners
9	Yes	Alcoa logo	non-conductive	Failure of logo
			die

Example 4; EMF-Feature: Logo Forming on Dome

Utilizing the pulse magnetic device described in Example 7, a workpiece (e.g. dome, having a 59 mm package diameter, made of aluminum alloy 3104) underwent an EMF-pulse with a voltage sufficient to imprint a logo “ALCOA” onto the dome. An image of the resulting imprinted dome is depicted in FIG. 28.

Upon visual inspection of the imprinted logo, the logo was observed to have some small fractions, with good penetration into the die.

Example 5: EMF Feature—Curl/Curling the Workpiece

Utilizing the pulse magnetic device described in Example 7, approximately 30 samples underwent EMF-forming to impart an EMF-feature (e.g. curl) onto the upper end (opening) of the workpiece. The samples were taken from metal container preforms (e.g. aluminum alloy 3104, configured as open ended cylinders necked into an aluminum bottle chimney and then cut/removed from the bottom closed end of the workpiece (e.g. having no closed lower end). The removal of the lower portion of the aluminum bottle perform was only for expediency to fit the top chimney portion into existing holding fixtures.

To curl the top of the preform, a base tool (flyer) was positioned between the lower portion of the workpiece chimney and the inductor coil. In this set of examples, the base tool (flyer) was configured as an actuator to undergo displacement in the EMF field (created via the inductor) and press the workpiece chimney onto the curling die/tool (positioned on the opposite end of the workpiece chimney), imparting a curl on the upper portion of the sample. For all samples in this set, the inductor was operated at 9 kV.

Various 3xxx series alloys and 5xxx series alloy were tested to evaluate whether the equipment in this configuration could impart a curl onto different alloys. This configuration of utilizing a base tool/flyer as an actuator for completing an EMF-operation on a container was validated.

Example 6: EMF Operation—Trimming

Utilizing the pulse magnetic device described in Example 7, one open ended cylinder was iteratively trimmed via EMF (e.g. utilizing a voltage of 6.5 kV) on alternating ends with dies shown in FIG. 41A-B in order to evaluate utilizing EMF to achieve a trimming operation.

The sample was a 3104 aluminum alloy with a package diameter of 59 mm and thickness (in straightwall portion of preform) of 0.0082″ to 0.0087″. In this example, the workpiece was configured as an open ended cylinders necked into an aluminum bottle chimney then removed from the straight, lower portion of the preform (e.g. having no closed lower end). The removal of the lower portion of the aluminum bottle perform was only for expediency to fit the top chimney portion into existing holding fixtures. As trimming was completed, each trimming operation resulted in multiple shreds of metal collecting in the bottom of the apparatus/auxiliary assembly.

Example 7: Pulse-Magnetic Device (EMF Device)

A lab-scale pulse-magnetic device was configured as follows: Maximum Accumulated Energy: 10 kJ; Output Voltage Range: 1-17 kV; Short-Circuit Current: up to 800 kA; Capacity of the energy storage—68 m³ μF; Frequency: variable, up to 109 kHz; Inductance: 31 nH; Supply Voltage: 460-480 V AC, 60 Hz; and Peak Line Currents (2s): 60 A. During discharge, a pulse of electromagnetic frequency lasted for a duration of a few to several microseconds (e.g. 2 microseconds (is) to 10 microseconds long).

With reference to FIG. 37, the pulse-magnetic device consists of four modules of energy storage. Each module contains a pulse capacitor (C1 . . . C4) with the built-in vacuum discharger (SV1 . . . SV4). The modules are connected in parallel to output terminals of the pulse-magnetic device via a system of plane sheet bus bars.

In operating the pulse-magnetic device, the charging operation is sufficient to charge the energy stores to a predetermined level U₀ and synchronously discharging into the inductor L1 in automatic mode. In this configuration, the characteristic discharge into the inductive load is a single, a periodic or oscillating pulse with the discharging current frequency determined by parameters of the inductor.

The Charging unit transforms the main voltage AC of 460 . . . 480 V to high voltage DC of 20 kV. Charging is performed via the charging current controller which uses the method of pulse-phase regulation of the voltage of the high-voltage transformer. In the process of charging, the opening angle of the thyristor Q1 in the power circuit changes smoothly. Charging of capacitors C1 . . . C4 is completed in accordance with the linear law which ensures efficiency and high resource of the pulse capacitors.

The capacitors C1 . . . C4 are charged by high voltage in the range of 1 . . . 17 kV through ballast resistors R1 . . . R4. When voltage on the capacitors achieves the predetermined level—U₀, the Energy dosing unit stops charging by the command “Stop” and simultaneously starts the Trigger-pulse generator by the command “Discharge”.

The initiating pulse of 6 kV from the Trigger-pulse generator is configured to start dischargers SV1 . . . SV4 which synchronously discharge the energy storages into a common load—the working inductor L1.

In the charging process, the pulse current flows through the inductor. Amplitude of this current is 10 to 500 kA, its duration is 10 . . . 1000 μs depending on the level of the stored energy and parameters of the working inductor.

The energy which is stored by the Energy storage is smoothly dosed by varying the charge voltage: W₀=(C₀*U²₀)/2, where C₀—total capacity of the energy storage, U₀—charge voltage.

Referring to FIG. 38, the plot of the stored energy versus the charge voltage is depicted showing the functional relationship between the two, as set within the operating limits of the pulse-magnetic device.

By design, the pulse magnetic device is comprised of the basic power unit, the remote control station, the technological table, and protective box. The power unit includes: the high-voltage rectifier, the charging transformer, the power transformer for the Trigger-pulse generator and the ballast resistors of the charging unit, with the capacitors of the energy storage configured and the Trigger-pulse generator also located in the unit.

The following elements of external connections are placed on the side surface of the pedestal of the housing: the lead-in of the supply network cable, the plug-and-socket for connection of the cable of the remote-control station, terminals for grounding wires of the power unit and discharging rod. The discharging rod is set close to the pulse magnetic device and is configured to connect to the power unit.

The clamping device with output terminals for connection of the inductor is placed on the front panel of the housing. The technological table for placement of the inductor and working tooling is mounted on the front panel of the power unit.

The Energy dosing block—A5 and Voltage display—A6 are located in the remote-control station. Controls, signal indicators, the kilovoltmeter of the current value of charge voltage are placed on the panel of the remote-control station.

In some embodiments, the pulse-magnetic device utilized in one or more aspects of the instant disclosure is configured to convert electrical energy, accumulated by the capacitive energy storage, to the electromagnetic field, arising in the inductor during discharge of the energy storage. For example, the electromagnetic field of the inductor induces eddy currents in the processed material (e.g. portion of the workpiece undergoing EMF forming). Interaction of the electromagnetic field of the inductor with eddy currents in the processed material (e.g. portion of the workpiece adjacent to the inductor) leads to strain work and pulse heating of the material. The lab-scale EMF forming device described herein was utilized in the examples (experimental section) described herein.

Example 8: EMF Feature—Incising Operation on Bottom

Utilizing the pulse magnetic device described in Example 7, 1 sample: the bottom of a drawn and ironed aluminum bottle (e.g. aluminum alloy 3xxx), was incised with a setting of 8 kV in one pulse. The package diameter was 2.75″ and the sheet thickness was 0.050″.

To incise the bottom, a flyer tool was positioned between the workpiece and the inductor coil and configured as an actuator to undergo displacement in the EMF field (created via the inductor) and press the tool with lettering secured therein into the bottom of the workpiece/aluminum bottle (e.g. bottom, outer surface of the workpiece). The resulting incised logo was visually inspected for quality. It was found that all letters imprinted against the workpiece, leaving a legible message, “ALCOA ALUMINUM MADE IN THE USA” on the bottom of the sample. The logo was visually inspected and confirmed to have an acceptable definition incised upon it (e.g. all letters were fully visible, fracture free).

While various embodiments of the present invention have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention.

REFERENCE NUMERALS

• Container (e.g. closed-bottom, metal container, shaped can, bottle) 10
• Upper portion 12
• Open end (e.g. configured at top) 14
• Upper rim/edge 16
• Lower portion 18
• Bottom 20
• Base 22
• Dome 24
• Sidewall 26
• Inner sidewall 28
• Outer sidewall 30
• Body (e.g. cylindrical) 32
• Shoulder 33
• Neck 34
• Thread (e.g. thread configuration/lug pattern) 36
• Carrier ring 38
• Carrier ring outsert 40
• Carrier ring lip (e.g. formed via EMF and configured to hold/secure carrier ring insert) 90
• Imprint feature (e.g. on bottom/dome vs. on sidewall/body) 42
• Vent slots (e.g. channels, grooves configured generally axially) 44
• Individual thread/lug (e.g. individual raised ridges interspaced with/defined by valleys) 46
• Individual valleys (e.g. configured between threads, to define individual thread(s)/lug(s) and thread/lug depth) 48
• Pilfer band (configured to accommodate pilfer ring) 52
• EMF-feature 50
• Curl (e.g. or flange, or flare) 54
• closure (lid, cover, cap) 56
• Trimmed upper edge (e.g. of rim 16) 58
• Pulsed-magnetic device 60
• Inductor 62
• Die(s) 64
• Mandrel(s) 66
• Base, support for mandrel 66′
• Spacer(s) 68
• Clamp (e.g. auxiliary positioning apparatus/system) 70
• EMF/pulse/magnetic field 72
• Base/support to act as actuator 92
• Mechanical attachment area on die(s) (e.g. configured on outer sidewall of upper portion of container) 76
• Attachment components (e.g. screws) for die 78
• Die for sidewall imprinting 80
• Sleeve 82
• Insert with logo 84 (graphic 84′, text 84″)
• Die with window 86
• Window/cut-out 88
• Electrical connection (inductor to remaining electrical components of pulsed magnetic device) 94

Claims

1. A method is provided, comprising:

a. positioning a workpiece adjacent to an inductor of an EMF device, wherein at least a portion of the workpiece is positioned between an inductor coil and a die;

b. discharging a power source of the EMF device to generate an electromagnetic frequency via the inductor; and

c. generating an electromagnetic force via the inductor, wherein the inductor is positioned such that the electromagnetic force acts upon the workpiece, and

d. concomitant with the generating step, imparting an EMF-feature on the workpiece adjacent to the inductor and the die.

2. The method of claim 1, wherein the workpiece and inductor are placed adjacent to each other but not in direct contact with each other, so as to prevent arcing.

3. The method of claim 1, wherein imparting an EMF-feature comprises:

a. threading an upper portion of the workpiece, wherein the workpiece is configured as a metal container and further wherein, the upper portion is the neck of a metal container;

b. curling an upper portion of the top portion of the workpiece wherein the workpiece is configured as a metal container and further wherein the upper top portion is the open upper end of the metal container;

c. embossing a bottom portion of the workpiece, wherein the workpiece comprises a metal container and further wherein the bottom portion comprises a dome;

d. stamping a bottom portion of the workpiece, wherein the workpiece comprises a metal container and further wherein the bottom portion comprises a dome; and

e. embossing the sidewall of the workpiece, wherein the workpiece comprises a metal container and the sidewall comprises a non-necked portion of the metal container.

4. The method of claim 1, wherein the EMF-feature is selected from the group consisting of: an asymmetrical feature, a symmetrical feature, a finish, a threaded configuration, a lug pattern, a structural feature, a carrier ring, a pilfer band, an imprinted feature, a stamped feature, a logo, a graphic, a text, a curl, a hem, a trim, and/or combinations thereof.

5. A method, comprising:

a. disposing/positioning an inductor in electrical communication with a pulsed magnetic device, such that the inductor is configured to impart a magnetic force to at least a portion of: a sidewall, a bottom, or combinations thereof of a workpiece;

b. energizing the inductor via a power source to a voltage potential via a transducer, a capacitor, and an induction coil configuration;

c. imparting a pulsed electromagnetic frequency into the portion of the workpiece sufficient to impart a deformation in the workpiece adjacent to the inductor;

d. directing the workpiece onto a support surface die, and

e. imparting, via the support surface die and EMF frequency, an EMF feature configured onto the workpiece.

6. The method of claim 5, wherein the support surface die is selected from: a die, an imprinting stamp, and combinations thereof.

7. The method of claim 5, wherein the directing step is selected from the group consisting of:

a. imprinting the workpiece with the pattern on the die;

b. molding the workpiece with the pattern on the die;

c. impacting the die with the workpiece;

d. deforming the metal into the workpiece;

e. engraving the workpiece;

f. incising the workpiece; and

g. combinations thereof.

8. The method of claim 5, further comprising after the imparting step, necking an upper portion of the workpiece via a forming operation.

9. The method of claim 5, further comprising trimming an upper end portion positioned proximate to the open end of a workpiece to provide a trimmed upper end.

10. The method of claim 5, wherein the workpiece is constructed from: aluminum, aluminum alloys, steel, steel alloys, and combinations thereof.

11. The method of claim 5, wherein the workpiece comprises an AA series aluminum alloy selected from the group consisting of: a 1xxx series aluminum alloy; AA1060; AA1070; a 3xxx series alloy; AA3104; AA3004; A 5xxx series aluminum alloy; AA 5182; AA 5052; AA5042; AA5352; and combinations thereof.

12. The method of claim 5, where the workpiece is a formed aluminum bottle with at least one EMF feature selected from the group consisting of: threads, lugs, imprinted portions of the body, imprinted portions of the bottom, carrier rings, carrier ring inserts, and combinations thereof.

13. The method of claim 5, wherein the workpiece thickness range for imparting EMF-features ranges from at least 0.003″ to not greater than 0.039″.

14. The method of claim 5, wherein the workpiece comprises a container with a sidewall thickness of at least 0.003″ that is formed from a sheet having a thickness of at least 0.006″.

15. A device comprising: a metal container configured with an EMF feature selected from the group consisting of: a thread configured along the upper portion of the metal container; a stamped feature on the body of the metal container; a stamped feature positioned on the bottom of the metal container, and combinations thereof.

16. The device of claim 15, wherein the workpiece thickness ranges from at least 0.003″ to not greater than 0.039″.

17. The device of claim 15, wherein the workpiece comprises a container with a sidewall thickness of at least 0.003″ that is formed from a sheet having a thickness of at least 0.006″.

18. The device of claim 15, wherein the workpiece is constructed from: aluminum, aluminum alloys, steel, steel alloys, and combinations thereof.

19. The device of claim 15, wherein the workpiece comprises an AA series aluminum alloy selected from the group consisting of: a 1xxx series aluminum alloy; AA1060; AA1070; a 3xxx series alloy; AA3104; AA3004; A 5xxx series aluminum alloy; AA 5182; AA 5052; AA5042; AA5352; and combinations thereof.

20. The device of claim 15, wherein the EMF-feature is selected from the group consisting of: an asymmetrical feature, a symmetrical feature, a finish, a threaded configuration, a lug pattern, a structural feature, a carrier ring, a pilfer band, an imprinted feature, a stamped feature, a logo, a graphic, a text, a curl, a hem, a trim, and combinations thereof.