TAPERED CUP AND METHOD OF FORMING THE SAME
A metal cup and method of forming the same is provided. Metal cups of the present disclosure comprise a plurality of thin, straight-walled sections and a tapered profile. A domed portion is provided in the bottom of the cup. The cup may comprise a disposable cup, a reusable cup, or a recyclable cup.
Latest Ball Corporation Patents:
This U.S. Non-Provisional patent application claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 63/323,331 filed on Mar. 24, 2022, and is related to U.S. patent application Ser. No. 16/214,477, which is a Continuation-in-Part of and claims the benefit of priority from U.S. patent application Ser. No. 15/811,032, filed Nov. 13, 2017, and claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 62/455,697, filed Feb. 7, 2017, the entire disclosures of which are hereby incorporated by reference.
FIELDThe present disclosure relates generally to metal cups and methods of forming the same. More specifically, the present disclosure relates to beverage cups formed from a metal. Various embodiments of the present disclosure provide for a thin-walled beverage cup that is stackable with cups of similar construction.
BACKGROUNDExisting disposable beverage cups and drinking containers typically comprise a plastic material. Plastic cups are manufactured from injection molding or thermoforming operations, whereby many lightweight and disposable cups may be formed. Existing metallic beverage containers generally comprise drinking cans including an end closure secured to the upper end of a filled can.
U.S. Pat. No. 4,366,696 to Durgin et al., which is hereby incorporated by reference in its entirety, discloses a nestable can and method of forming the same from a blank. Durgin et al., however, fail to disclose various features of the present disclosure including, for example, a tapered or stepped geometry as shown and described herein and methods of forming the same.
U.S. Pat. No. 4,914,937 to Bulso et al., which is hereby incorporated by reference in its entirety, discloses a method of forming a tapered container. Bulso et al. provide a straight-walled cup and a method of forming the same, but is devoid of various teachings of the present disclosure.
U.S. Pat. No. 6,463,776 to Enoki et al., which is hereby incorporated by reference in its entirety, discloses a manufacturing method for bottle-shaped cans with a neck and shoulder portion. Enoki et al. fail to disclose various features and methods of the present disclosure. For example, Enoki et al. fail to provide a cup-shaped container with tapered, straight sidewalls.
SUMMARYAccordingly, there has been a long-felt and unmet need to provide a metal cup that is reusable and recyclable. There has also been a need to provide a tapered metal cup that is stackable to enhance shipping and storing of a plurality of cups.
In various embodiments, a tapered metal cup is provided that comprises shallow wall angles. Shallow wall angles, at least as used herein, comprise wall angles that are less than 30 and preferably less than approximately 10 degrees as measured from a vertical center line or vertical axis of the cup. The angular sides and shallow wall angles of cups as shown and described herein allow for stackability of at least two cups, which provides advantages for shipping and storage. In some embodiments, wall angles are provided that are larger than 10 degrees. In some embodiments, wall angles are provided that are between approximately 1 and 20 degrees.
In various embodiments, metal cups are provided comprising thin-walled aluminum. Preferably, metal cups are provided comprising a recycled aluminum alloy. Various embodiments, including those comprising thin-walled aluminum provide cups that are lightweight, are formed of a recycled and/or recyclable material, and are more rigid, useful, and durable than conventional plastic cups, for example.
Embodiments of the present disclosure contemplate recyclable and/or reusable containers. In various embodiments, reusable cups are provided. As used herein, the term “reusable” generally refers to a container that can be reused one or more times and/or washed without significant degradation to the container(s). In some embodiments, reusability is achieved and provided by stable and robust coatings that are operable to withstand soap, detergent, and high heat commonly associated with dish washers and residential hot water heaters (e.g. 110-140 degrees Fahrenheit). In some embodiments, containers are provided that are intended to be recyclable and not necessarily reusable. For example, containers are contemplated with coatings that are not intended or sufficiently stable to withstand washing operations. Additionally, reusable cups are contemplated as being provided with enhanced structural rigidity to withstand multiple uses and/or washes. Rigidity is contemplated as being enhanced by mechanical strengthening (e.g. ribs and/or increased wall thickness). In some embodiments, wall thickness is selectively increased in specific regions.
In some embodiments, a metal cup is provided with a constant wall thickness along at least a portion of the cup. An incoming gauge of the cup is reduced to a thinner wall thickness in the sidewalls of the cup. Horizontally-extending steps or ribs preferably extend around an entire circumference of the cup, and are provided to add strength to the finished cup while maintaining a lightweight character of the cup. The steps or ribs are provided as transition points between sections of the finished cup having different diameters. Alternatively, a tapered cup is provided without ribs, where the cup comprises a relatively smooth and linear sidewall which extends from the upper end of the tapered cup to the closed lower end.
In some embodiments, one or more roll forming operations are performed to increase the strength of a cup. In various embodiments, one or more rolling operations are provided during the formation of a container and wherein two rollers are provided and one of the rollers comprises a mandrel. The rolling operation(s) increase stiffness in the metal by adding stress or pre-stressing the material. Rolling operation(s) of the present disclosure are also contemplate for the forming of ribs, reinforcing the container in specific locations, embossing the cup, proving rings or ribs in a sidewall or dome, and other features. Rings and ribs of the present disclosure may be provided as horizontal elements or may be provided at an angle relative to an axis of a container. Angled ribs or rings are contemplated as comprising helical, thread-like elements that provide strength and increase hoop strength and/or facilitate stacking or nesting of containers.
In various embodiments, a method of forming a metal cup is provided. In one embodiment, a method of forming a metal cup comprises feeding an aluminum coil into a cupping press and producing a straight-walled cup from a substantially circular blank cut from the aluminum coil. In some embodiments, the cup preferably has a constant wall thickness that is approximately equal to the incoming gauge of the aluminum. In other embodiments, cup side walls thicken during a cupper draw process. The cup is then fed into a bodymaker where the metal is redrawn and ironed. The cup is further formed by washing the cup, and decorating and/or coating an outside and an inside of the cup. In certain embodiments, at least a portion of the exterior of the cup is decorated with a color, a logo, or other visual information. Subsequent to washing and coating operations, a top edge of the cup is curled, partially curled, or throttled to eliminate the sharp edge that is formed by the press. The cup is then drawn down in diameter and multiple straight wall sections are formed. Each of the straight wall sections is expanded to a larger diameter using a die with a tapered profile. Finally, a bottom dome is provided in the bottom wall of the cup wherein the dome provides enhanced structural stability to the cup. In various embodiments, a dome is provided in the bottom of a metal cup to provide enhanced strength and stackability features. It should be recognized, however, that the term “dome” is not limited to any particular geometric shape and is contemplated as including, without limitation, conical and frustoconical “dome” members. The present disclosure contemplates that a central bottom portion of the cup is positioned vertically above a standing surface of the cup.
In various embodiments, cups are provided that comprise a non-constant wall thickness. It is contemplated, for example, that the wall thickness may vary throughout the cup and the thickness in a base of the cup may be different than a thickness at other regions of the cup (for example).
In another embodiment, a method is provided wherein a bodymaker step is eliminated in favor of multiple redraw steps after the cupper. In some embodiments, the cup maintains a constant wall thickness through the entirety of the container. In further embodiments, including “draw-redraw” embodiments, a wall thickness of the cup increases from the base of the cup to the open end of the cup (i.e. the wall thickness at the top of the cup is greater than at the bottom of the cup). During the drawing process, the metal is circumferentially compressed. The blankholder suppresses or reduces wrinkling and the metal deforms as the circumference decreases. However, as the volume of metal remains constant, the thickness must increase. In some embodiments, a cup formed of 0.0096 inch gauge incoming metal is redrawn twice and comprises a thickness at the top of the cup of about 0.0109 inches. This thickness may be increased by performing additional redraws.
In one embodiment, a method of forming a tapered metallic cup is provided, the method comprising the steps of providing a stock metal material; forming at least one cup using a blank and draw operation; performing a redrawing operation on the cup to provide the cup with a predetermined height and a wall thickness; subsequent to the redrawing operation, trimming the cup to a second height; curling the top edge of the trimmed cup to form a lip; forming one or more straight wall sections in the cup by drawing the cup; expanding each of the one or more straight wall sections using one or more dies with a tapered profile; and forming a dome in the bottom of the cup. In various embodiments, each cup section is expanded by not more than 15%, wherein percentage expansion is expressed as [(final diameter−initial diameter)/initial diameter]×100. In some embodiments, a cup is redrawn to form a final shape and without further forming. In such embodiments, it is contemplated that a wall angle of the cup is relatively low (e.g. less than degrees).
In another embodiment, a method of forming a tapered metallic cup is provided, the method comprising the steps of providing a stock metal material; forming at least one cylindrical preform from the stock material; trimming the cylindrical preform to a second height; curling a top edge of the trimmed cylindrical preform to form a lip; forming a cup by providing one or more straight wall sections in the cylindrical preform by drawing the preform; expanding each of the one or more straight wall sections to a larger diameter using one or more dies with a tapered profile; and forming a dome in the bottom of the cup.
Various embodiments of the present disclosure contemplate providing a curl at an upper portion or a lip of a cup. In some embodiments, the curl extends around an entire circumference of an upper lip of a cup. In alternative embodiments, an upper lip of a cup is not rotationally symmetrical. For example, a certain curl or edge treatment may extend along only a portion of a circumference of a lip of cup. Curls of the present disclosure are contemplated as being produced using a variety of methods. Curl geometry is contemplated as comprising variations in dimensions and/or profiles. Various curls are contemplated as being provided for creating various desirable effects including, for example, protecting a user from an otherwise sharp edge; providing a preferred seat or mating surface for a lid, top, or closure; shaping or controlling materials (e.g. liquids) as they are poured or otherwise exit a cup; aesthetic purposes; stackability; nesting; and product quality or performance (e.g. added strength at the lip). In preferred embodiments, curls are provided that extend away from a centerline of a cup to provide an outboard curl with an edge of the material provided external to the cup and preferably within or partially within a curl such that the edge is not exposed. In some embodiments, cups are made without a curl. For example, cups are contemplated as being provided that are devoid of a curl and which have edge that is exposed, dulled, or “uncurled.”
Curling operations, steps and processes are referred to herein as trim, curl, and/or curl and trim operations. Curling operations are contemplated as including, but are not limited to, single curl, double curl, reprofiled curl, shaped curl, throttled curl, tucked curl, rolled curl, smoothed curl, gorged curl, lugged curl and/or lipped curl. It will also be noted that these terms and various curl methods and steps provided herein are not mutually exclusive and a plurality of curl operations and steps are contemplated as being provided on a cup.
In various embodiments of the present disclosure, one or more trimming operations are provided in the formation of a cup. In some embodiments, a cutting or trimming is provided at an upper, open end of a cup. The cut or trim is contemplated as being perpendicular to a vertical axis of a cup in some embodiments. Alternatively, the trim or cut is contemplated as being provided between approximately 35 and 145 degrees. A pilot member is contemplated for use inside a cup and/or a guide is provided on the outside of the cup. A pilot and/or guide are generally used to control concentricity or rotational symmetry during a trimming process.
In some embodiments, a trim or trimming is performed by a single point shear method wherein a single blade or double blade is provided to cut and shear trim scrap from a top of a container. Initially, a single point is pinched or cut and the blade(s) rotates around the container to complete a trim. Finally, the trim is separated and removed as a hollow cylinder. Various trim knives or bits are contemplated for use to remove metal. One or more knives could be provided to generate a controlled edge without generating metal slivers or hairs. Pinch trim operations are also contemplated wherein a tooling gap between two tools is sufficiently small that the metal shears. In such cases, a hollow cylinder is removed at a controlled height on the container.
In one embodiment, a tapered metallic cup is provided. The tapered metallic cup comprises an upper end and a lower end, and a height extending between the upper end and the lower end. The upper end comprises a curled, partially curled, or throttled lip and an opening. A plurality of tapered sections are provided between the upper end and the lower end, with a step provided between each of the tapered sections. Each of the tapered sections comprises a wall thickness and a tapered profile. Wall thickness may vary within a given panel and/or across different portions of a cup. Adjacent tapered sections of the plurality of tapered sections comprise successively smaller diameters from the upper end to the lower end, and the step provided between each of the tapered sections comprises a transition in diameter.
In some embodiments, containers and cups of the present disclosure comprise a shape, geometry, or profile which enables stacking the cups and increases the ease with which stacked cups can be separated. Specifically, in certain embodiments, at least a lower portion of a cup comprises a profile as shown and described herein that reduces or prevents a vacuum, suction force or taper-lock/friction force (result of two tapered panels, or a tapered panel and vertical-walled panel pushing into one another) that otherwise tends to prevent or impede the separation of stacked cups.
Embodiments of the present disclosure provide for methods and systems for forming metallic cups. In some embodiments, methods and associated tooling are provided for forming cups with a feature or shape that reduce at least one of a vacuum force, a suction force, and a friction force that is provided between stacked cups at least when the stacked cups are pulled apart.
In some embodiments, anti-sticking features of the present disclosure provide for a cup geometry and an outer profile of a cup that enables a gap or separation to be provided between the curls of adjacent cups even when the adjacent cups are nested or stacked. This substantially prevents adjacent cups from sticking to one another and reduces the force required to separate adjacent cups. In certain embodiments, adjacent curls of stacked cups are provided with a gap of at least approximately 0.01 inches and 0.9 inches, and more preferably of about 0.35 inches, even when the adjacent cups are fully nested (i.e. one cup is completely inserted into the adjacent cup).
In one embodiment, a tapered metallic cup is provided that comprises an upper end, a lower end, and a height extending between the upper end and the lower end. The upper end comprises a curl, one or more tapered sections are provided between the upper end and the lower end, with a step provided between each of the tapered sections in embodiments comprising a plurality of tapered sections. Each of the tapered sections comprises a wall thickness and a tapered profile. Wall thicknesses of cups of the present disclosure are contemplated as comprising thicknesses between approximately 0.002 inches and 0.010 inches. Adjacent tapered sections of the plurality of tapered sections comprise successively smaller diameters, and the step provided between each of the tapered sections comprises a transition in diameter. The lower end of the cup comprises a domed portion, a first radius, an inwardly tapered sidewall, a second radius and a third radius. The first and third radii comprise convex features, and the second radius is provided between the first and third radii.
In one embodiment, a tapered metallic cup is provided that comprises an upper end and a lower end, and a height extending between the upper end and the lower end. At least one tapered section is provided between the upper end and the lower end. Each of the tapered sections preferably comprises a tapered profile. Adjacent tapered sections of the plurality of tapered sections comprise successively smaller diameters. The lower end of the cup comprises a stacking feature with a plurality of inflection points, the stacking feature comprising a first radius, an inwardly tapered sidewall, a second radius and a third radius. The first and third radii comprise convex features, and the second radius is provided between the first and third radii.
In one embodiment, a method of forming a tapered metallic cup is provided. The method comprises providing a stock material; forming at least one cup using a blank and draw operation; performing a redrawing operation on the cup to form a predetermined height and a wall thickness; subsequent to the redrawing operation, trimming the cup to a second height; curling the top edge of the trimmed cup to form a lip; forming one or more straight wall sections in the cup by drawing the cup; expanding each of the one or more straight wall sections using one or more dies with a tapered profile; forming a dome in a bottom of the cup; and forming an anti-sticking feature in the bottom of the cup by providing a compression force on the bottom of cup radially exterior to the dome such that a lower section of the cup comprises an inward taper or slope.
In one embodiment, a method of forming a tapered metal cup is provided comprising an initial step of feeding a coil into a cupping press and blanking and drawing a portion of material into a cup. Subsequently, the cup is at least one of drawn, ironed, trimmed, washed, dried, decorated, over-varnished, internally coated and bottom sprayed. A curl is then formed at an upper end or lip of the cup. At least one and preferably a plurality of draw stages are then performed wherein the cup is drawn to a larger height, and wherein the container is narrowed in at least one of the draw stages. Subsequent to at least one of the draw stages, at least one expansion step is performed by an expansion die (for example) to expand the width and diameter of the cup to a desired amount. A final step is contemplated as comprising a reverse taper step in which a reverse taper is formed in a bottom of the cup to form an anti-sticking feature that prevents or reduces cups from nesting or sticking when provided in a stacked arrangement. This final step, which is contemplated as being an optional step, renders adjacent stacked cups to be easier to extract or separate.
In various embodiments, methods, systems and devices for cup stacking features are provided to reduce a force required to separate cups from a stacked arrangement. In some embodiment, cups are provided with geometry and features to prevent an extent or amount to which cups “nest” or extend into one another. Such features reduce a force required to separate the cups. In some embodiments, an outward projection is provided that is greater in diameter than a panel or section of a cup upon which the projection is provided. The outward projection provides a resting surface or contact point which prevents a bottom of a cup from contacting or extending down to the bottom panel of an adjacent cup. Outward projections of the present disclosure are contemplated as being provided on any one or more cup panels or segments. In some embodiments, it is contemplated that an outward projection is provided on an uppermost panel or segment. Preferably, the outward projection(s) comprise an annular element that extends completely around a circumference of a cup and comprises a rotationally symmetric feature. In alternative embodiments, however, it is contemplated that the projection(s) extend around less than an entirety of a cup circumference.
It is an object of the present disclosure to provide a stacking or nesting feature that reduces separation force between cups without significantly increasing “stack height” or the total amount of height provided by two stacked cups. The present disclosure contemplates providing a stacking feature or projection on at least one cup panel, and wherein the height of the cup panel that comprises such a feature can be altered to control or determine stack height.
In one embodiment, a tapered metallic cup is provided that comprises an upper end and a lower end, and a height extending therebetween. The upper end comprises a peripheral curl, and a plurality of panels is provided between the upper end and the lower end, with a transition provided between each of the panels. Adjacent panels of the plurality of panels comprise successively smaller diameters, and the transition provided between each of the panels comprises a transition in diameter of the cup wherein cup sections are preferably smaller in diameter toward the bottom of the cup. A semiannular projection is provided that extends along at least a portion of a circumference of the cup.
Stacking and anti-sticking features are provided herein. In some embodiments, a reverse-taper feature is provided at a lower end or bottom of a cup. In further embodiments, at least one of an outwardly and inwardly projection is provided that is/are operable to provide a diameter or bulge that is operable to contact an adjacent cup. It is specifically contemplated that one or more of these feature is provided within a single cup. Accordingly, stacking and anti-sticking features are not mutually exclusive. While is contemplated that cups are provided with a single anti-sticking or stacking feature as shown and described herein, it is further contemplated that cups are provided with multiple features that are shown and described herein, even if a specific combination is not shown in the Figures.
While various embodiments of the present disclosure comprise a cup with an upper end having a curl, the present disclosure is not limited to such embodiments. It is contemplated, for example, that cups according to various embodiments of the present disclosure do not comprise a curl at an upper or drinking end. For example, in some embodiments, an upper end of a cup comprises an edge that is not curled. The edge may be shaped with a lip roller and/or may be provided with a covering or cap. In some embodiments, an upper edge or lip of the cup is not treated, curled, or rolled. It is further contemplated that lugs or protrusions are provided on a lip. For example, lugs or protrusions for interfacing with a lid are contemplated as being provided at an upper end of the cup.
In some embodiments, a lip roller is provided to roll form a curl on an upper end of a cup. It is also contemplated that multiple rollers are provided to tuck and roll an upper edge of the cup. The cup(s) and/or tool may be heated to facilitate such operations. In some embodiments, upper ends of cups are rolled or formed while the cups are in a stacked arrangement. Additional curl forming methods and features are also contemplated in embodiments of the present disclosure. For example, methods of forming a curled and strengthened top of a cup as shown and described in Japanese Patent Application JP2004291566 to Sakuma, which is hereby incorporated by reference in its entirety, are contemplated as being provided with cups of the present disclosure.
In some embodiments, a safety seam or safety fold is provided at the upper end of the cup. The safety seam may comprise various different configuration including one or more folds, curls, or seams to convert or shape a thin or sharp metal edge to a surface or edge that is not abrasive and does not pose laceration risks to a user.
In various embodiments, it is contemplated that containers of the present disclosure are provided with a double curl wherein the lip is curled or rolled down more than once. The double curl is operable to receive an additional component (e.g. a lid) and to protect a user during drinking. Curls, including double curls are contemplated as being oriented inwardly or outwardly.
In some embodiments, cups of the present disclosure are contemplated as comprising various decorations and graphics. Various known inking and decorating steps are contemplated as being provided to stock material and containers of the present disclosure. U.S. Patent Application Publication No. 2019/0283489 to Dominico et al., which is hereby incorporated by reference in its entirety, discloses methods and systems for decorating cups. In some embodiments, graphics are provided on various portions of a cup including the dome, interior of the cup, and on one or more outer panels of the cup. Ink and decoration are contemplated as being provided on cups of the present disclosure at various stages of the cup formation process. Ink may be provided to raw material (aluminum sheet(s), a finished or formed cup, and at various stages therebetween.
Cups and containers of the present disclosure are contemplated as comprising various decorations, indicia, and added features. For example, in some embodiments, cups of the present disclosure comprise decorative inks known in the art including those discussed in U.S. Patent Application Publication No. 2019/0283489 to Dominico et al. Cups and containers of the present disclosure are also contemplated as comprising tactile inks, thermochromic inks, radio-luminescent inks, and other inks. Additionally, stickers, badges and emblems are contemplated as being provided on a cup. In some embodiments, a “badge” is provided that is formed of metal or is 3D printed to form a component that is welded or adhered to cup(s) after the cup(s) are formed. In further embodiments, shapes, logos, writing or indicia are etched or laser scribed into a formed cup or cups. It is also contemplated that stickers and peal-away stickers are provided on cups. Bar codes and QR codes are examples of indicia or information that are contemplated as being provided on cups of the present disclosure through any one or more of the aforementioned methods of printing or adding information.
Various methods of forming cups are contemplated. While certain embodiments of the present disclosure contemplate drawing operations for forming cups, additional and alternative embodiments contemplate forming a cup by one or more of: impact extrusion, spin forming, blow molding, multi-piece construction and assembly, draw and redraw, deep draw, and other methods.
In some embodiments, cups are forming using metal spinning techniques. A blank or disc of metal is contemplated as being spun or rotated at a high speed and formed into an axially symmetrical part. Such processes may be performed on a lathe or similar tool. In some embodiments, a plurality of cups is formed simultaneously on a single lathe or other rotational tool.
Cups of the present disclosure are contemplated as being made from various metals including but not limited to steel, tin plated steel, tin free steel and aluminum. The metal is contemplated as being uncoated or lightly lubricated. The incoming metal may be precoated with a polymer film. This film may be applied to the coil as liquid coating that is subsequently cured. These coatings are generally polymeric resin coatings within the epoxy, acrylic or polyester families. Alternatively, the pre-applied film may also applied by laminating with solid resin film. The film may be polyester or polyolefin. These films are often of multilayers to optimize adhesion and product protection. Such coatings are provided to optimize adhesion on the surface contacting the metal. A product protection optimized layer is provided in various embodiments.
In various embodiments, methods of forming a container are provided that comprise feeding a coil of metal into a press. In certain embodiments, a punch and blank and draw die cuts a circular blank. The blank may alternately be non-round to accommodate material anisotropy. In the same stroke, a die center cooperates with a drawing die to draw the cup. This cup is contemplated as being ejected thought the bottom of the die. Multiple tool sets are contemplated as being installed in the press to allow simultaneous forming of multiple cups.
The initial cup form is conveyed to and loaded into a redraw press. A blankholder/cupholder enters the cup and places it in contact with a redraw die. Pneumatic pressure is used to control the force between the cupholder and the redraw die. Alternatively, spring and cam driven hold down means are contemplated as well as other suitable methods. A punch moves through the hollow cupholder, contacting the cup and redraws the initial cup through the redraw die, creating a second stage cup. The second stage cup is smaller in diameter and taller than the initial cup form. When the material is drawn into the redraw die, compressive strains cause the material to thicken. The radial gap between the punch and the redraw die is preferably greater than the thickness of the redrawn metal. Use of small draw radii and high blankholder force is contemplated as resulting in some stretching of the cup sidewall.
The process to progress from an initial cup to a second stage cup may be repeated to create increasingly smaller diameter and taller containers. A high number of redraws may necessitate a trimming operation to remove earing resulting from planar anisotropy of the redrawn material. In some embodiments, a final redraw step is contemplated as comprising a tapered punch, smaller at the nose, resulting in a tapered finished cup.
A final redraw may be complete, that is the entire flange is drawn into the die, or incomplete, leaving a portion of the flange in the plane perpendicular to the cup axis. In either case, the flange is shaped in additional operations as described herein.
A profile is contemplated as being formed in a bottom of a cup in various processes and methods of the present disclosure. The bottom profile is preferably formed at the end of the forming stroke in a final stage.
Diametric reductions become more limited with additional drawing and redrawing steps. For manufacturing efficiency, the highest possible diametric reductions should be taken to achieve the desired height and diameter. Therefore, the low end of the allowable reduction range is of minimal importance. The maximum diametric reductions for aluminum are contemplated in various embodiments as: blank to initial cup form: 40-50%; initial cup form to second stage cup: 30-40%; and second stage cup to third stage cup: 20-35%. The radius over which the material draws in is in the range of 0.040″ to 0.150″ and preferably of about 0.060″ to 0.120″.
In some embodiments, cups are formed using impact extrusion methods. In such embodiments, a slug is provided and is contemplated as being pressed at high velocity and force to form a cup. The slug may be driven by a punch into a die or mold to form the cup. In such methods and embodiments, cups are formed with a single panel or section or may be formed with a plurality of panels or sections and wherein a plurality of impact extrusion steps are provided. Cups of the present disclosure (regardless of formation method) are not limited in the number of panels or sections they may comprise. Cups and containers are contemplated with as few as a single section and as many as 1,000 sections. Single panel cups formed by impact extrusion are contemplated as comprising a cylindrical cup with a vertical, non-tapered sidewall. Single panel cups are also contemplated as being formed as tapered in an initial mold step and/or with additional steps. It is further contemplated that any desired tapered is subsequently provided or formed using various methods and tooling shown and described herein.
In various embodiments, a seamed sidewall is provided in a cup. For example, in some embodiments, a cup is formed by wrapping or shaping a sheet of metal and seaming the ends together to form a vertical seam that seals the container. Such seams are contemplated as comprising a mechanically folded seam, a weld, a laser weld, a flash butt weld, or other weld, a double seam, or adhered in various ways.
Various embodiments of the present disclosure contemplate working material and forming containers by coining. As will be recognized by one of ordinary skill in the art, coining comprises subjecting metal (e.g. aluminum) to sufficiently high stress to induce plastic flow and in some embodiments reduce grain size.
In some embodiments, a cup is formed by performing a necking operation. It is contemplated, for example, that a cup is formed through one or more methods described herein and the bottom (closed end) of the cup is cut off. The open bottom is then necked and a seamed end (e.g. double-seamed end closure) is provided to reclose the bottom.
It is further contemplated that cups are formed by providing a plurality of different cup walls or sections. The multiple pieces can be arranged and secured together (e.g. by welding) to provide a formed, finished cup.
In some embodiments, cups of the present disclosure are formed using blow mold formation techniques. Blow molding or blow forming is contemplated to form metal cups as shown and described herein. Extrusion blow molding, for example, is contemplated as being provided to form a metal cup by forcing metal or other material into a mold comprising a desired shape of the cup.
In various embodiments, cups of the present disclosure are forming using a draw and redraw process (“DRD”). DRD processes are contemplated as providing a metal container or cup. Such processes are contemplated as comprising steps of cutting a blank from a sheet, drawing the blank through a die to form a first stage of a cup, and then redrawing the cup to form a can of a desired height and diameter.
In certain embodiments, metal cups of the present disclosure are formed using a deep draw method. For example, it is contemplated that one or more deep drawing processes are provided to work a sheet of metal (e.g. aluminum) into a cup using a punch. The depth of the drawn part during this process exceeds the diameter of the cup. For example, during the formation of a metal cup with a height of six inches, the draw length comprises more than six inches. Additional processes are contemplated as being combined with deep drawing methods. For example, one or more deep drawing steps are contemplated as being performed, and expansion steps are provided after deep drawing.
In some embodiments, various single panel cups are provided. In some embodiments, small (e.g. 10 ounce or smaller) cups are provided comprising a single panel. These cups may be formed using a redraw cupper. In some embodiments, single-panel cups comprise a thicker wall thickness for rigidity.
Various embodiments of the present disclosure contemplate the provision of welding to form or finish cups of the present disclosure. For example, cups are contemplated as being formed and sealed or finished by providing at least one weld vertically along a side of a cup and/or by welding a bottom (e.g. closure) to an open end of a container.
In various embodiments, cups are provided with a profile and feature in the lower portion of the cup. In some embodiments, the cup profile comprises a “reverse-taper” wherein a wall section is angled (i.e., the lower portion of the section is of greater diameter than an upper portion of the same section). Such embodiments provide for stacking features as shown and described herein. Additionally, such features provide for a stabilization or fixing of a domed portion of the cup.
In various embodiments, the formatting of an anti-sticking feature or reverse taper imparts a biaxial strain across a bottom of the container. This strain pulls excess or loose material into a taught section of metal. This taught section is less susceptible to “oil-canning,” a condition wherein a domed, convex or concave feature has a tendency to invert itself (i.e. concave to convex and vice-versa). By putting the bottom or dome in biaxial tension, this area exhibits less springbuck or oil-canning tendency.
It is an object of the present disclosure to provide a tapered metal cup with enhanced rigidity. In some embodiments, cups are provided with various features to enhance the rigidity or stiffness of the cup and various panels or sections thereof. In some embodiments, cups are provided with ribs to enhance structural integrity. Such ribs may be shaped, formed, or provided as horizontally extending ribs along a circumference (or portion thereof) of a panel. These ribs are contemplated as being provided in addition to steps or transitions between tapered sections (where present). Additionally, the present disclosure contemplates embodiments with vertically extending ribs to enhance stiffness. Such ribs may be provided along a length of a cup and across transitions or steps or may extend along specific sections of a tapered cup. It is also contemplated that features may be embossed or debossed to enhance the rigidity of one or more panels.
Certain embodiments of the present disclosure contemplate providing embossing for decorative purposes. For example, in some embodiments, metal cups of the present disclosure are provided with embossed features (e.g. logos, emblems, text, etc.) on a cup. In some embodiments, embossing is provided as a final or near final step in a cup manufacturing process. Embossing prior to drawing or expanding, for example, may result in deformation of the embossed feature. However, in some embodiments, embossing is performed prior to drawing, redrawing and/or expanding the cup to achieve a desired result.
Cups of the present disclosure are contemplated as comprising various wall thicknesses. It should be recognized that cups of the present disclosure are not limited to a certain wall thickness. Additionally, the present disclosure is not limited to cups having a single or consistent wall thickness. It is contemplated, for example, that cups of the present disclosure comprise varying wall thickness along a height of the cup and/or along the height a cup section or segment. In some embodiments, wall thickness is contemplated as being greater at the bottom of the cup than the top and increasing in thickness as one travels from the top to the bottom to provide a lower center of gravity of the cup and reduce tipping of the cup.
It is an object of the present disclosure to optimize metal usage and provide for different metal thicknesses for different locations and features of a container. Processes and methods of the present disclosure provide for a change in wall thickness during a draw-redraw operation wherein a wall thickness of a drawn container (or at least a portion thereof) will be different from the incoming container. Additionally, methods and systems of the present disclosure contemplate the provision of a “rework taper” wherein incoming metal with an initial gauge (e.g. 0.003-0.030 inches and preferably of between about 0.096 inches) in a base portion and a transition to a wall thickness portion on the ironed container (e.g. 0.002-0.030 inches and preferably of between about 0.0070 and 0.0030 inches). For example, in embodiments wherein a metal thickness in the base portion is approximately 0.096 inches and the thickness in a wall portion is approximately 0.0060 inches, a gradual transition or taper is provided between these two thicknesses. This taper or “rework taper” is contemplated as being a linear gradual transition, but alternatives are contemplated. Variations in wall thickness are contemplated to: decrease metal thickness and save material and cost; strengthen specific features and portions of a cup (e.g., the curl or top panel); weaken specific portions or features (e.g. lids or tear-away portions); and provide for various ergonomic features and benefits.
In one embodiment, a container is provided with a dome in the bottom of the cup comprising a first thickness (Td). Adjacent panels extending from the dome comprise varying wall thickness.
In some embodiments, lower panels comprise varying wall thicknesses along their length and upper panel(s) comprise a substantially consistent thickness that is less than the lower wall thicknesses. An uppermost panel is contemplated as comprising a curl and comprise a thicker wall thickness (at least relative to the lowermost panel thickness(es)) for providing curl stability. In certain embodiments a transition from thin to thick wall thickness is provided in a second uppermost panel to transition from a thinwalled middle portion of the cup to a thick uppermost portion to support the curl and drinking operations, and to prevent denting on the top most panel. Additionally, thick sections are contemplated as being provided in various areas or sections of a cup. For example, it is contemplated that a transition from a thin wall section to a thick wall section is provided and the thick wall section transitions back to a thin wall section. This is contemplated, for example, at a step or transition wherein the thickness of the wall is variable and increases to provide additional support to a specific portion of the cup.
In some embodiments, methods of forming metal cups are provided that comprise a step of preforming a base of the container. In certain embodiments, a base of a container or cup is preformed and surplus metal material is provided in the base. The surplus material is then available for use as the container is further formed or worked (e.g. drawn).
In some embodiments, cups of the present disclosure are provided with relief features, shaping or “restricking.” Features and methods of forming such features are shown and described, for example, in U.S. Pat. No. 9,358,604 to Jentzsch et al., which is hereby incorporated by reference in its entirety. The methods and tooling disclosed in U.S. Pat. No. 9,358,604 are contemplated as being applied or used with cups of the present disclosure.
Although various embodiments of the present disclosure contemplate and provide round cups that are rotationally symmetrical, the present disclosure is not limited to such embodiments. For example, various non-round cup shapes and container shapes are contemplated. Square and/or rectangular cups are contemplated and are formed from bending and/or dies and tooling that are not round. In some embodiments, a non-round container is formed by bending a sheet of material into a desired shape (comprising four sides, for example) and securing a bottom by at least one of seaming and welding the bottom to the container. Non-round containers can also be formed by draw and redraw processes from blanks. These containers are contemplated as being formed from tooling (e.g. dies) with one or more stiffening beads, drawbeads, or other methods known in the art and to help control or retard the flow of metal during forming.
In various embodiments, containers of the present disclosure are provided with a bottom having an upstanding dome portion. The dome portion is surrounded by an annular standing surface. In some embodiments, a plurality of feet or lugs are provided in at least one of the dome portion and the annular standing surface. For example, in certain embodiments, three or more protruding feet are formed in the device and extend from the annular standing surface.
Domes of the present disclosure are contemplated as comprising convex features that extend upwardly into an interior volume of the cup. In some embodiments, it is contemplated that sidewalls and domes of the cups of the disclosure comprise features, indicia, and/or ornamentation. For example, it is contemplated that a dome can be embossed or reformed to provide certain shapes and features on the dome (e.g. logos at the bottom of a cup). Domes of the present disclosure (and other portions of a cup) are contemplated as being coined, embossed, or debossed to provide shapes and features in the dome.
While preferred embodiments of the present disclosure contemplate the use of aluminum and pre-coated aluminum, it should be recognized that the present disclosure and containers described herein are not limited to any particular metal, coating, or coated metal. In some embodiments, a base coat is applied to a cup or container prior to decorating. In some embodiments, a base coat is provided that comprises a full color (e.g. white) coating that is applied before decorating and is cured in an oven. The base coat is contemplated as being applied by an applicator roll as a consistent coat at a consistent thickness around the outside of the container. Coating and painting may also be applied by spraying, electrostatic application, etc.
Although various embodiments of the present disclosure contemplate cups and containers with domes, the present disclosure is not limited to containers with such a feature. It is also contemplated that cups of the present disclosure are provided with a flat bottom that is devoid of an upstanding dome.
In various embodiments, insulated containers are provided. In some embodiments, it is contemplated that two or more cups in accordance with any one or more of the embodiments of the present disclosure are provided. Preferably, one cup is of smaller dimension(s) than another cup. The plurality of cups are nested and connected (e.g. double seamed together at the upper end of the cups) to form a finished cup. It is contemplated that an insulating material is provided between the two cups. Insulating materials of the present disclosure include but are not limited to ambient air, argon, Styrofoam, and various combinations thereof.
Cups and containers of the present disclosure are contemplated as being made from various metals including steel, tin plated steel, tin free steel and more preferably aluminum. The metal may be uncoated or lightly lubricated. The incoming metal may be precoated with a polymer film. This film may be applied to the coil as liquid coating that is subsequently cured. These coatings are generally polymeric resin coatings within the epoxy, acrylic or polyester families. Alternatively, the pre-applied film may also applied by laminating with solid resin film. The film may be polyester or polyolefin. These films are often of multilayers to optimize adhesion and product protection. A layer with optimize adhesion is provided on the surface contacting the metal. A product protection optimized layer is away from the metal.
In one embodiment, a method of forming a cup is provided that comprises: providing a coil or quantity of raw metal into a press. A punch and blank and draw die is provided to cut a circular blank from the coil. The blank is contemplated as being non-round in alternative embodiments to accommodate material anisotropy. In the same stroke, a die center cooperated with a drawing die to draw an initial cup form. This initial form is contemplated as being ejected through the bottom of the die. Multiple tool sets are contemplated as being installed in the press to allow simultaneous forming of multiple initial cup forms. The initial cup is conveyed to and loaded into a redraw press. A blankholder or cupholder is used to control a force between the cupholder ad a redraw die. A punch moved through the hollow cupholder and contacts the initial cup form and redraws the initial cup form through the redraw die, creating a second stage cup. The second stage cup is smaller in diameter and taller than the initial cup form. The material is drawn into the redraw die and compressive strains cause the material to thicken. A radial gap between the punch and the redraw die is greater than the thickness of the redrawn metal in some embodiments. Use of small draw radii and high blankholder force may result in some stretching of the cup sidewall. The process of forming an initial cup to a second stage cup can be repeated to create increasingly smaller diameter and taller containers. A high number of redraws is contemplated and may necessitate a trimming operation to remove earing. A final redraw step comprises a tapered punch to form a tapered, final cup. The final redraw may comprise a combined or single step, or may comprise a plurality of redraw steps. A final redraw may be complete (i.e. the entire flange is drawn into the die) or a portion of the flange may be left perpendicular to the top of the cup. The flange is shaped in additional operations as shown and described herein. Diametric reductions become more limited with additional drawing and redrawing steps. For manufacturing efficiency, the maximum diametric reductions for aluminum are contemplated in some embodiments as: blank to initial cup: 40-50%; initial cup to secondary stage cup: 20-30%; second stage to third stage cup: 15-30%. The radius over which the material draws in in the range of 0.040″ to 0.150″, more preferably 0.060″ to 0.120″.
While various embodiments of the present disclosure contemplate containers and cups with a plurality of sections or panels, further embodiments contemplate containers or cups that are devoid of steps or transitions and generally comprise a single panel or a single angled straight-walled section. The straight-walled section may be tapered. Single panel cups of the present disclosure are contemplated as being formed by various methods and techniques including, for example, blank-and-draw (or “deep draw”) impact extrusion and spin forming methods.
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 disclosure. The present disclosure is set forth in various levels of detail in the Summary as well as in the attached drawings and the Detailed Description and no limitation as to the scope of the present disclosure is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary. Additional aspects of the present disclosure will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.
Those of skill in the art will recognize that the following description is merely illustrative of the principles of the disclosure, which may be applied in various ways to provide many different alternative embodiments. This description is made for illustrating the general principles of the teachings of this disclosure and is not meant to limit the inventive concepts disclosed herein.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosure and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosure.
It should be understood that the drawings are not necessarily to scale. 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 disclosure is not necessarily limited to the particular embodiments illustrated herein.
The straight-walled preform 2 comprises a height H1 of between approximately 3.0 and 10.0 inches. In preferred embodiments, the preform 2 comprises a height H1 of between approximately 3.5 and 5.5 inches, and more preferably of between approximately 3.7 and 4.2 inches. A bottom portion of the preform comprises a radius of curvature resulting from the shape and contact of the punch used to form the cup. In various embodiments, this radius R is between approximately 0.025 inches and 0.250 inches, and preferably of between approximately 0.080 inches and 0.100 inches.
Prior to or subsequent to the forming of the curl 6, the preform 4 may be washed, coated, and/or decorated. It is contemplated that at least one of the inside and the outside of the preform is coated with epoxy resin and/or other materials that will be recognized by one of ordinary skill in the art. The cup is coated to protect the aluminum from oxidization and to prevent corrosion of the aluminum from the cup contents and avoid the aluminum imparting undesirable flavors to the beverage. It is further contemplated that an inside and/or outside of the cup is provided with paint or other ornamental treatment. Coating is contemplated as being provided to facilitate metal forming by reducing friction during forming steps.
The straight drawn cup 8 further comprises a plurality of sections 10a, 10b, 10c, 10d, 10e wherein the sections each comprise straight-wall sections of successively smaller diameter and varying height, as shown in
As shown in
As further shown in
Various internal diameters of a plurality of sections 10 are provided. In some embodiments, a finished tapered cup 20 comprises a plurality of sections 10 comprising relative diameters characterized as: 10a>10b>10c>10d>10e. Specific diameters are provided and illustrated as being measured from an upper portion of each respective section 10. The plurality of sections 10 comprise varying heights, wherein the relative heights can be characterized as: 10c>10d>10b>10e>10a. An internal diameter of a curled section 6, which also comprises a drinking interface, comprises a diameter of between approximately 2.0 and 5.0 inches. Details Y and Z are indicated on
The straight wall sections of
As shown in
The cup provided from the redraw step 54 is further subjected to forming and finishing steps as shown and described herein. In the depicted embodiment of
Subsequent to the sequence illustrated as 56 in
Subsequent to the method steps of the depicted sequence 86, the cup is then subjected to a rinsing or washing operation 100 and a decorating step 102. In
An upper portion of the cup is then trimmed at step 112. The trimmed cup is then preferably subjected to a washing operation 114. A decorating and/or coating sequence 116 is provided subsequent to washing, the decorating sequence comprising the steps of decorating the cup at step 118, providing a bottom coat 120, and/or providing an internal coating to the cup at step 122. One or more of the steps of the coating sequence 116 may be reordered, eliminated, and/or moved after a rinsing step 132.
Preferably subsequent to the coating sequence 116, final forming steps 124 are provided. The final forming steps preferably comprise at least one of providing a curl to the trimmed portion of the cup at step 126, performing at least one stepped draw operation 128 to form one or more straight walled section in the cup, and performing an expansion step 130 to expand the diameter of the straight walled section(s). The final forming steps 124 are contemplated as being reordered or eliminated depending on user requirements. A rinsing step 132 is provided as a finishing step. However, as previously noted, one or more steps of the coating sequence 116 may be re-ordered such that they occur subsequent to the rinsing step 132. The embodiment of
The cup is then advanced to finishing sequence 156, wherein the finishing sequence comprises providing a curl to the trimmed portion of the cup at step 158, providing a stepped redraw operation 160, providing an expansion operation 162 and providing a dome in a bottom portion of the cup at step 164. although the doming step 164 is contemplated as occurring a final step in the embodiment of
After the coating and decorating sequence 180, the method of
In various embodiments, the first radius 224 comprises a radius of between approximately 0.050 inches and 0.20 inches, and preferably of about 0.100 inches. In various embodiments, the second radius 220 comprises a radius of between approximately 0.050 inches and 0.20 inches, and preferably of about 0.100 inches. In various embodiments, the third radius 222 comprises a radius of between approximately 0.030 inches and 0.20 inches.
In various embodiments, including but not limited to the embodiment shown in
Referring again to
The projection comprises a radius R1 that is preferably between approximately 0.0010 inches and 3.0 inches and preferably about 0.005 inches. In preferred embodiments, the projection comprises a single, constant radius. In alternative embodiments, one or more projections are provided that comprise multiple radii of curvature and/or linear portions, such as protrusions of triangular cross-sections and various other shapes of projections.
As discussed, the projection 406a can be continuous around the entire circumference of the cup or can be broken into any number of smaller discontinuous features around the circumference. For the purposes of
In various embodiments, the first internal diameter D3 comprises a constriction at or near the top of the cup 400 that is between approximately 0.8 times the second internal diameter D4 and approximately 0.999 times the second internal diameter D4. Accordingly, the first internal diameter D3 is contemplated as being a function of the second internal diameter D4. For certain cups (e.g. 16, 20 and 24 ounce volume cups), the second internal diameter D4 comprises a diameter of approximately 3.625 inches, and the first internal diameter D3 formed by the projection is between approximately 2.90 and 3.621 inches. For smaller cups comprising a second internal diameter D4 of 2.0 inches, the first internal diameter D3 formed by the projection is between approximately 1.6 and 1.999 inches. In various embodiments, it is contemplated that the first internal diameter D3 is between approximately 1.0 and 5.0 inches. However, as discussed herein, the first internal diameter D3 is preferably a function of related cup feature geometries. Various dimensions provided with respect to
While projections of the present disclosure have been illustrated as being provided in certain locations including, for example, a lower, outer region of an uppermost panel (306a in
Projections as shown and described herein are also contemplated as being provided on various different panels. For example, a projection may be provided on an upper portion of panel 412 of
In various embodiments, methods of forming cups are provided. In some embodiments, at least one projection is formed in a cup to provide a contact or resting point and wherein the projection is formed during a first expansion operation of the cup. The projection is formed by pushing on a rib or transition between cup sections (e.g. the transition between the uppermost panel and an adjacent panel. In further embodiments, it is contemplated that projections of the present disclosure are formed with an independent press that pushes on a rib or transition while retaining the rest of the cup. It is further contemplated that a rotary action is provided to pushes rollers into the rib or transition in a manner similar to the action of a spinner or dome reformer tool. For example, circumferential grooves or features are contemplated as being created by spinning rollers around an outer diameter of a cup with force pushing inwardly to create a bump or feature. It is also contemplated a tool is inserted into a cup and material is spun outwardly to form features. It is further contemplated that a reverse taper operation is provided wherein the curl of a cup is held and a punch is used to push on the rib or transition on or proximal to which a projection is to be formed, and the rib is pushed against a die with springs thus forcing the rib outwards. Additionally, an expansion tool is contemplated as being provided that squeezes past the curl and expands an uppermost panel to form a projection. It is also contemplated that a cam activated tool is provided that pushes multiple discontinuous bumps into a rib.
Inwardly extension projections provided adjacent to curl, such as those shown in
In various embodiments of the present disclosure, cups sections 10a, 10b, 10c, 10d, 10e comprise various gauges or wall thicknesses. Thickness may vary and be selected to save material costs, increase or decrease strength in certain regions of the cup, and provide for preferred user-interfaces and ergonomic feel. In some embodiments, for example, each section comprises its own thickness. The thicknesses do not necessarily decrease from the bottom of the cup to the upper portions. Any number of combinations of thicknesses or gauges are contemplated. For example, section 10d may be thicker than section 10c and section 10b may also be thicker than section 10c. Additionally, containers of the present disclosure are contemplated as comprising multi-section cups and single panel cups. Regardless of the number of steps or sections, it is contemplated that the containers comprise either linear or non-linear changes in gauge or thickness.
Single panel cups of the present disclosure are contemplated as being formed by various processes and techniques. For example, in some embodiments, single panel cups are formed by impact extrusion, spin forming, and/or other processes. In one embodiment, a straight-walled, single panel cup is formed in a blank and draw cupper also known as a “deep draw” process. The container is then expanded. The expansion step can expand the entire length of the cup or can leave a partial straight-wall section (
As shown in
A first process 900 contemplates the formation of a single panel cup by providing a coil and performing a blank and draw operation 904 on a portion of material from the coil to form an initial cup shape. One or more redraw operations 906 are provided on the initial cup shape. An expansion step 908 occurs after redraw(s) and prior to a curl or edge treatment 910. A doming operation 912 may occur at various stages including after the blank and draw step(s) 904, after the redraw step 906, after the expansion step 908, or after the edge treatment step 910. A wash, decoration, and/or coating step 916 is contemplated as being provided after the redraw step 906 and/or after the expansion step 908.
A second process 902 is contemplated and shown. The second process contemplates and provides that a curl or edge treatment step 910 is provided after a redraw step 906 and prior to the expansion step 908. A doming operation 912 may occur at various stages including after the blank and draw step(s) 904, after the redraw step 906, after the expansion step 908, or after the edge treatment step. A wash, decoration, and/or coating step 916 is contemplated as being provided after redraw step 906 and/or after curl step 910
A third process 903 is contemplated and shown in
Various embodiments of the present disclosure contemplate the provision of a dome forming step 1022 and/or washing and decorating steps 1024. Embodiments of the present disclosure including but not limited to those of
In some embodiments, tooling is provided that comprises with a number of rollers that come into contact with the edge of the metal and/or metal surfaces in order to bend and control movement into a particular form or shape. The roller geometries can be the same or different within one operation. Rollers can vary from 3 up to and including 32 rollers per operation. This is based on diameter, metal thickness, hoop strength, coatings, roller geometry/geometries, speed of the spindle (RPM), product height change, speed of stroke, and acceleration/deceleration of operation. In cases where multiple curl operations, rollers may have the same, different, or a combination of geometries. Subsequent to the 1st curl operation, a controlled tuck can achieve a particular profile. This may be referred to shaping, reprofiling, throttling, curling, tucking, rolling, and smoothing.
A 360 degree tool contacts the container in one motion to achieve a particular profile. This could create the curl, lug, profile. If multiple hits are used, such an operation could be achieved within a transfer press or similar machine.
Once a rounded, outward facing curl is established this operation forms a established profile. The edge can be pushed up tight to conjoining or with slight spacing within the curl space. The outer diameter, curl height, and radii are typically controlled to allow for a particular geometry. Once the curl is formed, but not allowing the cut edge to touch the surface of the container, a controlled expansion of the container pushes the metal of the container to meet the curl. A “curl & trim” is contemplated as occurring within one stroke or draw within a machine. The metal is moved to a particular “flanged” form prior to removing a ring of metal. In a curl & trim, the curl forming process comprises two or more operations. During one cycle of a machine, the curl will be initiated from 0 degrees to 90 degrees (+/−45 degrees). Once the metal pushes outboard a blade, knife, or shear will cut the edge to a controlled position. The finishing operations will complete the tuck of the trimmed edge to be away from a consumer. The final tuck form can vary and multiple iterations are discussed within this summary.
In some embodiments, a cup is provided with an inside diameter of between approximately 35 mm and 110 mm. A curl height 1302 is provided that is between approximately 0.020 inches and 0.200 inches. A neck angle 1304 is provided that comprises an angle of between 0 and 60 degrees. A curl diameter 1305 is between approximately 35 and 113 mm, and a curl width 1306 is contemplated as being between 0.020 inches and 0.200 inches. A lower outer curl radius 1308 comprise a radius of between approximately 0.01 inches and 0.100 inches. An upper outer curl radius 1310 comprises a radius of between approximately 0.010 inches and 0.100 inches. A lower inner curl radius 1312 comprises a radius of between approximately 0.010 and 0.100 inches. It will be recognized, however, that these dimensions and ranges of dimensions are provided to illustrate contemplated embodiments. Cups and methods of forming cups of the present disclosure are not limited to any particular dimension or proportion.
Various features and embodiments of a metal cup have been provided herein. It will be recognized, however, that various features are not necessarily specific to certain embodiments and may be provided on any one or more embodiments. The present disclosure and embodiments provided herein are not mutually exclusive and may be combined, substituted, and omitted. The scope of the invention(s) provided herein is thus not limited to any particular embodiment, drawing, or particular arrangement of features.
While various embodiments of the present disclosure have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present disclosure. Further, the invention(s) described herein are capable of other embodiments and of being practiced or of being carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purposes of description and should not be regarded as limiting. The use of “including,” “comprising,” or “adding” and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof, as well as, additional items.
Claims
1. A method of forming a metal container, the method comprising:
- providing a coil of material from which a cup is to be formed;
- cutting a blank from the coil of material;
- forming a cup from the blank of material;
- performing a redraw operation on the cup;
- providing the cup to a bodymaker;
- performing at least one of a doming operation and a finishing step subsequent to providing the cup to the bodymaker;
- expanding at least a portion of the diameter of the cup; and
- performing at least one of a doming operation and a decorating step subsequent to expanding the cup to form the container.
2. The method of claim 1, wherein the cup is formed by a blank and draw operation.
3. The method of claim 1, wherein the cup is expanding by one or more dies.
4. The method of claim 1, further comprising performing at least one of a curl and an edge treatment at an open end of the cup.
5. The method of claim 4, wherein the at least one of a curl and an edge treatment comprises a forming a curl subsequent to the expanding step.
6. The method of claim 1, wherein the finishing step comprises at least one of washing, decorating, coating, rinsing, and inspecting the cup.
7. The method of claim 6, and wherein the method comprises at least two finishing operations.
8. A method of forming a metal container, the method comprising:
- providing a coil of material from which a cup is to be formed;
- cutting a blank from the coil of material;
- forming a cup from the blank of material;
- performing a redraw operation on the cup;
- providing the cup to a bodymaker;
- performing at least one of a doming operation and a finishing step subsequent to providing the cup to the bodymaker;
- expanding at least a portion of the diameter of the cup; and
- forming a curl at an open end of the cup, wherein the curl comprises an inward curl wherein a distal end of the curl is provided proximal an interior portion of the container.
9. The method of claim 8, wherein the inward curl comprises a tuck portion comprising a substantially linear portion at a distal end of the curl.
10. The method of claim 8, wherein the inward curl comprises a curl height and the curl height is between approximately 0.050 inches and 0.200 inches.
11. The method of claim 8, wherein the inward curl comprises a curl width and the width is between approximately 0.050 inches and 0.20 inches.
12. The method of claim 8, wherein the inward curl is formed using a screw-type roller.
13. The method of claim 8, wherein the cup is expanded using one or more dies.
14. The method of claim 8, wherein a finishing step is performed prior to forming the inward curl and wherein the finishing step comprises at least one of washing, decorating, coating, rinsing, and inspecting the cup.
15. The method of claim 8, wherein the material comprises aluminum.
16. A method of forming a metal container, the method comprising:
- providing a coil of material from which a cup is to be formed;
- cutting a blank from the coil of material;
- forming a cup from the blank of material;
- performing a redraw operation on the cup;
- providing the cup to a bodymaker;
- performing at least one of a doming operation and a finishing step subsequent to providing the cup to the bodymaker;
- expanding at least a portion of the diameter of the cup; and
- forming a curl at an open end of the cup and wherein the curl comprises an inward curl.
17. The method of claim 16, wherein the cup is formed by a blank and draw operation.
18. The method of claim 16, wherein the cup is expanded by one or more dies.
19. The method of claim 16, further comprising performing an edge treatment at an open end of the cup.
20. The method of claim 19, wherein the edge treatment comprises forming the curl subsequent to the expanding step.
Type: Application
Filed: Mar 24, 2023
Publication Date: Sep 28, 2023
Applicant: Ball Corporation (Westminster, CO)
Inventors: Sean K. Fitzsimons (Firestone, CO), Matthias Van De Liefvoort (Louisville, CO), Jonathan A. Whitmore (Denver, CO), John L. Siles (Westminster, CO)
Application Number: 18/189,690
