CAN SHELL, AND ASSOCIATED TOOLING AND METHOD

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is non-provisional utility application of and claims priority to U.S. Provisional Patent Application Ser. No. 63/651,063, May 23, 2024, entitled, “Can Shell, And Associated Tooling And Method.”

FIELD OF THE INVENTION

The disclosed and claimed concept relates to can shells. The disclosed concept also relates to tooling and associated methods for providing such can shells.

BACKGROUND OF THE INVENTION

Metallic containers (e.g., cans) are structured to hold products such as, but not limited to, food and beverages. Generally, a metallic container includes a can body and a can end. The can body, in an exemplary embodiment, includes a base and a depending sidewall. The can body defines a generally enclosed space that is open at one end. The can body is filled with product and the can end is then coupled to the can body at the open end.

A “can end,” as used herein, is the element coupled to a can body to form a container. The “can end” includes a tab or similar device structured to open the container. As discussed below, “can end” is, typically, formed from a “shell.” That is, a shell is formed from a generally planar blank cut from sheet material. The blank is formed to include an annular countersink, a chuck wall, and other constructs.

A container is exposed to pressures during processing. For example, some food items are cooked and/or sterilized while in the container. Such a container is exposed to both internal pressure, also identified herein as “buckle” or “buckle pressure,” as well as external pressure, also identified herein as “reverse buckle” or “reverse buckle pressure.” A container, that is the can body and the can end, must have the strength to resist deformation due to buckle pressure and/or reverse buckle pressure.

Generally, the strength of the container is related to the thickness of the metal from which the can body and the can end is formed, as well as the shape of these elements. This application primarily addresses the can ends rather than the can bodies. The can ends are either a “sanitary” can end or an “easy open” end. As used herein, a “sanitary” end is a can end that does not have a tab or score profile to open and would have to be opened by use of a can opener or other device. As used herein, an “easy open” can end includes a tear panel and a tab. The tear panel is defined by a score profile, or scoreline, on the exterior surface (identified herein as the “public side”) of the can end. The tab is attached (e.g., without limitation, riveted) adjacent the tear panel. The pull tab is structured to be lifted and/or pulled to sever the scoreline and deflect and/or remove the severable panel, thereby creating an opening for dispensing the contents of the container. The following addresses an “easy open” can end but is also applicable to a “sanitary” can end. That is, a “sanitary” can end is produced in a similar manner, and coupled to a can body in a similar manner. Thus, as used herein, a can end is further defined as including constructs that are used for both “sanitary” can ends and “easy open” ends.

When the can end is made, it originates as a blank, which is cut from a sheet metal product (e.g., without limitation, sheet aluminum; sheet steel). In an exemplary embodiment, the blank is then formed into a “shell” in a shell press. As used herein, a “shell” is a construct that started as a generally planar blank and which has been subjected to forming operations other than rivet forming and tab staking. The shell press includes a number of tool stations where each station performs a forming operation (or which may include a null station that does not perform a forming operation). The blank moves through successive stations and is formed into the “shell.” A shell is, in an exemplary embodiment, a “sanitary” can end that is structured to be coupled to a can body.

For an “easy open” end, a shell is further conveyed to a conversion press, which also has a number of successive tool stations. As the shell advances from one tool station to the next, conversion operations such as, for example and without limitation, rivet forming, paneling, scoring, embossing, and tab staking, are performed until the shell is fully converted into the desired can end and is discharged from the press. Thus, as used herein, a “can end” includes a “shell” as well as a construct including a tab and a score line.

In the can making industry, large volumes of metal are required in order to manufacture a considerable number of cans. An ongoing objective in the industry is to reduce the amount of metal that is consumed. Efforts are constantly being made, therefore, to reduce the thickness or gauge (sometimes referred to as “down-gauging”) of the stock material from which can ends, tabs, and can bodies are made. However, as less material (e.g., thinner gauge) is used, problems arise that require the development of unique solutions. When the base gauge of the metal is too thin, the can end can have insufficient buckle resistance and can deform.

There is, therefore, a need for improvement in can ends and shells.

SUMMARY OF THE INVENTION

In accordance with an aspect of the disclosed concept, a can shell comprises: a center panel; an inclined panel wall extending at a downward angle from the center panel; an annular countersink formed around the inclined panel wall, the annular countersink including an inner countersink wall and an outer countersink wall; a chuck wall extending from the outer countersink wall, the chuck wall including a kick portion having a curved shape beginning at a point lower than a lowest point of the inclined panel wall; and a curl extending radially outwardly from the chuck wall.

In accordance with another aspect of the disclosed concept, tooling for forming a can shell comprises: an upper tool assembly; and a lower tool assembly, said upper tool assembly and said lower tool assembly are structured to cooperate and to form a can shell, said can shell including a center panel, an inclined panel wall extending at a downward angle from the center panel, an annular countersink formed around the inclined panel wall, the annular countersink including an inner countersink wall and an outer countersink wall, a chuck wall extending from the outer countersink wall, the chuck wall including a kick portion having a curved shape beginning at a point lower than a lowest point of the inclined panel wall, and a curl extending radially outwardly from the chuck wall.

In accordance with another aspect of the disclosed concept, a method of forming a can shell comprises: providing a blank; providing a tooling with an upper tool assembly and a lower tool assembly; introducing the blank between the upper tool assembly and the lower tool assembly; forming the blank to include a center panel, an inclined panel wall extending at a downward angle from the center panel, an annular countersink formed around the inclined panel wall, the annular countersink including an inner countersink wall and an outer countersink wall, a chuck wall extending from the outer countersink wall, the chuck wall including a kick portion having a curved shape beginning at a point lower than a lowest point of the inclined panel wall, and a curl extending radially outwardly from the chuck wall.

BRIEF DESCRIPTION OF THE DRAWINGS

A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:

FIG. 1 is a top isometric view of a can shell in accordance with an example embodiment of the disclosed concept;

FIG. 2 is a bottom isometric view of the can shell of FIG. 1;

FIG. 3 is a side view of the can shell of FIG. 1;

FIG. 4 is a cross-sectional side view of the can shell of FIG. 1;

FIG. 5 is an enlarged detail view of the can shell of FIG. 1 taken from callout 5 in FIG. 4 and from line 4 in FIG. 6;

FIG. 6 is a top plan view of the can shell of FIG. 1;

FIG. 7 is a bottom plan view of the can shell of FIG. 1;

FIG. 8 is a cross-sectional comparison of a can shell in accordance with an example embodiment of the disclosed concept with an existing can shell;

FIG. 9 is a cross-sectional comparison of a can shell attached to a can body in accordance with an example embodiment of the disclosed concept with an existing can shell;

FIG. 10 is an overlay comparison of a can shell in accordance with an example embodiment of the disclosed concept with an existing can shell;

FIG. 11 is a cross-sectional view of a can shell in accordance with an example embodiment of the disclosed concept;

FIG. 12 is a cross-sectional view of tooling, including an enlarged detail view, to form a can shell in accordance with an example embodiment of the disclosed concept;

FIG. 13 is a cross-sectional view of tooling, including an enlarged detail view, to form an existing can shell; and

FIG. 14 is a cross-sectional view of tooling to form an existing can shell.

DETAILED DESCRIPTION OF THE INVENTION

It will be appreciated that the specific elements illustrated in the figures herein and described in the following specification are simply exemplary embodiments of the disclosed concept, which are provided as non-limiting examples solely for the purpose of illustration. Therefore, specific dimensions, orientations, assembly, number of components used, embodiment configurations and other physical characteristics related to the embodiments disclosed herein are not to be considered limiting on the scope of the disclosed concept.

Directional phrases used herein, such as, for example, clockwise, counterclockwise, left, right, top, bottom, upwards, downwards and derivatives thereof, relate to the orientation of the elements shown in the drawings and are not limiting upon the claims unless expressly recited therein.

As used herein, the singular form of “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

As used herein, “structured to [verb]” means that the identified element or assembly has a structure that is shaped, sized, disposed, coupled and/or configured to perform the identified verb. For example, a member that is “structured to move” is movably coupled to another element and includes elements that cause the member to move or the member is otherwise configured to move in response to other elements or assemblies. As such, as used herein, “structured to [verb]” recites structure and not function. Further, as used herein, “structured to [verb]” means that the identified element or assembly is intended to, and is designed to, perform the identified verb. Thus, an element that is merely capable of performing the identified verb but which is not intended to, and is not designed to, perform the identified verb is not “structured to [verb].”

As used herein, “associated” means that the elements are part of the same assembly and/or operate together, or, act upon/with each other in some manner. For example, an automobile has four tires and four hub caps. While all the elements are coupled as part of the automobile, it is understood that each hubcap is “associated” with a specific tire.

As used herein, the term “number” shall mean one or an integer greater than one (i.e., a plurality).

FIGS. 1-7 are various views of a can shell 10 in accordance with an example embodiment of the disclosed concept. FIG. 1 is a top isometric view of the can shell 10 in accordance with an example embodiment of the disclosed concept. FIG. 2 is a bottom isometric view of the can shell 10. FIG. 3 is a side view of the can shell 10. FIG. 4 is a cross-sectional side view of the can shell 10. FIG. 5 is an enlarged detail view of the can shell 10 taken from callout 5 in FIG. 4 and line 4 in FIG. 6. FIG. 6 is a top plan view of the can shell 10. FIG. 7 is a bottom plan view of the can shell 10.

FIGS. 8-10 are various comparison views of the can shell 10 in accordance with an example embodiment of the disclosed concept with respect to an existing can shell 100. FIG. 8 is a cross-sectional comparison of the can shell 10 with the existing can shell 100. FIG. 9 is a cross-sectional comparison of the can shell 10 attached to a can body with the existing can shell 100. FIG. 10 is an overlay comparison of the can shell 10 with the existing can shell 100.

The can shell 10 includes a center panel 12, an inclined panel wall 13, an annular countersink 14, a chuck wall 16, and a curl 18. The center panel 12 extends radially outward from the center of the can shell 10. The inclined panel wall 13 extends from the outer end of the center panel 12 at a downward angle to the annular countersink 14. The annular countersink 14 includes an inner countersink wall 15 and an outer countersink wall 17. The chuck wall 16 extends upward from the outer countersink wall 17 to the curl 18. The can shell 10 may be formed from a substantially planar blank. The can shell 10 may be converted into a can end in a subsequent conversion process, which may include forming a rivet in the can shell 10, scoring a tab opening in the can shell 10, and staking a tab to the can shell 10.

The can shell 10 in accordance with an example embodiment of the disclosed concept includes a kick portion 20 in the chuck wall 16. The kick portion 20 has a curved shape which has a radius R1 with respect to a point on an exterior of the can shell 10. That is, the kick portion 20 has a concave shape with respect to an exterior of the can shell 10. In some example embodiments, the kick portion 20 may extend from the outer countersink wall 17 to an inner wall 24 of the curl 18. In some example embodiments, the kick portion 20 may comprise the entire chuck wall 16. In some example embodiments, the kick portion 20 may comprise a portion of the chuck wall 16. For example, the kick portion 20 may extend from the outer countersink wall 17 to an upper chuck wall portion 22. The upper chuck wall portion 22 may extend from the kick portion 20 to the inner wall 24 of the curl 18. Similarly, in some example embodiments, a lower chuck wall portion may be disposed between the outer countersink wall 17 and the kick portion 20. In some example embodiments, the kick portion 20 begins in a plane below the lowest point of the inclined panel wall 13. That is, the curved shape of the kick portion 20 of the chuck wall 16 begins at a lower point of the chuck wall 16 below the lowest point of the inclined panel wall 13.

The can shell 10 in accordance with example embodiments of the disclosed concept provides increased resistance to buckle pressure than the existing can shell 100. Further, the can shell 10 is interchangeable with the existing can shell 100. That is, the can shell 10 may be converted into a can end and attached to the same can bodies as the existing can shell 100. Further, the can shell 10 can utilize the same size blank and same amount of metal as the existing can shell 100. In some example embodiments, as the can shell 10 provides increased resistance to buckle pressure with respect to the existing can shell 100, the can shell 10 may use a lower gauge of metal, and thus reduce metal usage while still providing adequate resistance to buckle pressure.

As shown in FIGS. 8-10, the existing can shell 100 includes a center panel 112, an inclined panel wall 113, an annular countersink 114, and a curl 118 similar to the can shell 10 in accordance with an example embodiment of the disclosed concept. However, the chuck wall 116 in the existing can shell 100 does not include the kick portion 20 of the can shell 10. Rather, the chuck wall 116 extends linearly from an outer countersink wall 117 to an upper chuck wall portion 122. That is, the chuck wall 116 of the existing can shell 100 has a linear shape that extends directly in a linear path from the outer countersink wall 117 to a point above the lowest point of the inclined panel wall 113.

As noted above, the can shell 10 in accordance with example embodiments of the disclosed concept provides increased resistance to buckle pressure over the existing can shell 100 by providing the kick portion 20 in the chuck wall 16. It will be appreciated that in some example embodiments of the disclosed concept, the kick portion 20 begins at a point lower than the lowest point of the inclined panel wall 13. In addition to increased resistance to buckle pressure, the can shell 10 is interchangeable with the existing can shell 100, thus allowing the can shell 10 to be used with existing tooling for converting can shells into can ends as well as with existing tooling for attaching can ends to can bodies. Further, the can shell 10 can use the same size blanks and amount of metal used to form the existing can shell 100, thus allowing a current supply of blanks to form the can shell 10 in accordance with an example embodiment of the disclosed concept. Additionally, the can shell 10 can use a lower gauge blank than the existing can shell 100, thus reducing metal usage.

FIG. 11 is an overlay comparison of the can shell 10 and the existing can shell 100. It will be appreciated that in some example embodiments, the existing can shell 100 can be converted into the can shell 10 in accordance with an example embodiment of the disclosed concept. That is, the kick portion 20 can be formed in the chuck wall 116 of the existing can shell 100 in order to form the can shell 10 in accordance with an example embodiment of the disclosed concept. It will be appreciated that the conversion may be performed as an addition to the shell forming process or as part of the process of converting the can shell to a can end.

While FIG. 11 is described in reference to converting the existing can shell 100 to the can shell 10 in accordance with an example embodiment of the disclosed concept, it will also be appreciated that the can shell 10 may be formed from a blank where the kick portion 20 is formed directly rather than forming a linear chuck wall first and them forming the kick portion 20 in the linear chuck wall.

FIG. 12 is a cross-sectional view of tooling for forming the can shell 10 and FIGS. 13-14 are cross-sectional views of tooling for forming the existing can shell 100. The tooling for forming the can shell 10 includes upper tooling and lower tooling. The upper tooling includes an inner pressure sleeve 200 and die center 204, and the lower tooling includes a die core ring 202. A blank is disposed between the upper tooling and the lower tooling, and the upper tooling is pressed onto the lower tooling to form the can shell 10. In the process of pressing the upper tooling onto the lower tooling, the inner pressure sleeve 200 is pressed onto the die core ring 202 to form the chuck wall 16 including the kick portion 20 of the can shell. The shape of the inner pressure sleeve 200 and die core ring 202 corresponds to the shape of the chuck wall 16 including the kick portion 20 so as to form the chuck wall 16 including the kick portion 20.

FIGS. 13 and 14 show the tooling to form the existing can shell 100. The tooling included upper tooling and lower tooling. However, the tooling in FIGS. 13 and 14 includes an inner pressure sleeve 300, die core ring 302, and die center 304 having a different shape than the inner pressure sleeve 200, die core ring 202, and die center 204 for forming the can shell 10 in accordance with example embodiments of the disclosed concept. For example, the inner pressure sleeve 300 includes a deeper countersink forming portion and the die core ring 302 has a corresponding shape. Additionally, the die center 304 does not include a notched edge. In some example embodiments, the tooling for forming the existing can shell 100 can be retrofitted to form the can shell 10 by replacing the inner pressure sleeve 300, die core ring 302, and die center 304 with the inner pressure sleeve 200, die core ring 202, and die center 204 of FIG. 12.

It will be appreciated that the disclosed concept also covers methods of forming the can shell 10. The disclosed concept covers methods of forming the can shell 10 from a blank as well as methods of forming the can shell 10 from the existing can shell 100. It will also be appreciated that the disclosed concept also covers forming the can shell 10 in the shell forming process, as well as forming the can shell 10 in the conversion process, such as in a conversion press.

Market demands have increased the desire of can manufacturers to use recycled and/or recyclable materials for multiple reasons, including considerations of both cost and environmental impacts. In addition, the inclusion of recycled and/or recyclable materials is a desirable marketing concept that is attractive to both product vendors and end consumers. However, some recycled and/or recyclable materials may have less strength than common materials used in existing can shells. For example, the existing can shell 100 may be formed of one type of aluminum, but if the existing can shell 100 was formed of a recycled and/or recyclable type of aluminum with less strength or different properties, the existing can shell 100 may not be able to provide sufficient resistance to buckle pressure and may have to result to using a thicker gauge, and thus more material, to compensate. The can shell 10 in accordance with example embodiments of the disclosed concept provides an increased resistance to buckle pressure, and thus may be formed of materials having less strength, such as for example and without limitation, recycled and/or recyclable materials having less strength than standard materials, and still provide sufficient resistance to buckle pressure without using an increased gauge or more material. It will be appreciated that in some embodiments, the can shell 10 is composed of aluminum and in some embodiments the can shell is composed of a recycled and/or recyclable type of aluminum that has less strength than type of aluminum commonly used for existing can shells.

While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of disclosed concept which is to be given the full breadth of the claims appended and any and all equivalents thereof.