TOOL PACK ARRANGEMENT FOR BODYMAKER AND BODYMAKER INCLUDING SAME

Description

FIELD OF THE INVENTION

The disclosed concept relates generally to bodymakers for forming metal containers such as those used in the food and beverage industries and, more particularly, to tool pack arrangements used in such bodymakers.

BACKGROUND OF THE INVENTION

Metal sheets can be stamped or drawn to form the metal sheets into desirable shapes suitable for various applications. A lubricant or forming fluid may be used to reduce friction and control the flow of material during the forming process. The lubricant or forming fluid may be used as a coolant, since the metal may heat during the forming process. A variety of lubricants or forming fluids are available, and different formulations may be suitable for different forming processes or for the resultant formed product. For example, some water-based lubricants may be easy to remove or leave little residue after cleaning but may not provide sufficient lubrication for some forming processes. Conversely, some oil-based lubricants may provide suitable levels of lubrication and good cooling capabilities but may leave a residue or be difficult to remove from the formed metal surface, limiting their use for some formed products. In high-rate manufacturing processes, improper forming can sometimes result in damaged metal products which can jam the forming equipment, resulting in costly down time.

Beverage containers are commonly made using such high-rate manufacturing processes. As an example, the process of making conventional beverage containers generally includes making a blank out of metal material, such as aluminum. The blank may be drawn into a shallow cup and redrawn to reduce the diameter and deepen the cup. The cup may be ironed to reduce the wall thickness of the cup by driving the metal material through one or more ironing dies using a punch or ram. Existing ironing dies can create excessive friction between the cup sidewalls and the die, causing the cup walls to tear or otherwise weaken. Additionally, the excessive friction may dislodge metal particulate from the cup, which can build up on the die, leading to frequent die cleaning or replacement. Accordingly, there exists a need for improved ironing arrangements for forming beverage containers, such as can bodies.

SUMMARY OF THE INVENTION

Embodiments of the disclosed concept minimize the potential of particles (e.g., fines/filings/debris) from certain materials (e.g., nickel) of cups/cans from building up onto tool components (e.g., tool pack dies, ram bodies) that are formed during cold working can forming operations of a bodymaker machine, such as employed, for example, in the beverage can industry.

As one aspect of the disclosed concept, a toolpack arrangement for a can bodymaker is provided. The toolpack arrangement comprises: a plurality of coolant supply rings, each coolant supply ring comprising: a body having a central opening defined therethrough; a circumferential coolant reservoir defined in the body about the central opening; a coolant passage defined in the body, the coolant passage extending from an inlet port disposed at an outer surface of the body to the circumferential coolant reservoir, the inlet structured to receive a pressurized flow of coolant from a source of pressurized flow of coolant; and a circumferential array of outlet ports extending from the circumferential coolant reservoir and circumferentially spaced about the central opening; and a plurality of dies, each die defining a die opening having a diameter different than the other dies of the plurality; wherein the plurality of coolant supply rings and the plurality of dies are coupled together in an alternating pattern to form a toolpack with the central openings and the die openings aligned about a common axis to define a forming passage through the toolpack that is structured to have a portion of a ram body reciprocatingly pass therethrough during can forming operations of the bodymaker, wherein each outlet port of each coolant supply ring is sized and configured to direct a stream of the coolant from the circumferential coolant reservoir into the forming passage in a forward direction toward an adjacent die of the toolpack.

The stream of coolant from each outlet port may be directed at an angle of 15 degrees or less with respect to a reference line disposed parallel to the common axis of the forming passage.

The toolpack arrangement may further comprise the source of the pressurized flow of coolant in communication with the inlet port of each of coolant supply ring via a respective supply line coupled to the inlet port. The source of the pressurized flow of coolant may be structured to provide the pressurized flow of coolant at a pressure of or about 1000 psi. The source of the pressurized flow of coolant may be structured to provide the pressurized flow of coolant at a flow rate at or about 20 gallons per minute. The source of the pressurized flow of coolant may be structured to provide the pressurized flow of coolant at a pressure of or about 1000 psi and at a flow rate at or about 20 gallons per minute.

As another aspect of the disclosed concept, a can bodymaker is provided. The can bodymaker comprises: a frame; a ram having a substantially cylindrical ram body; an operating mechanism coupled to the frame and operatively coupled to the ram body so as to be structured to move the ram body in a reciprocating manner; and a toolpack arrangement comprising: a plurality of coolant supply rings, each coolant supply ring comprising: a body having a central opening defined therethrough; a circumferential coolant reservoir defined in the body about the central opening; a coolant passage defined in the body, the coolant passage extending from an inlet port disposed at an outer surface of the body to the circumferential coolant reservoir, the inlet structured to receive a pressurized flow of coolant from a source of pressurized flow of coolant; and a circumferential array of outlet ports extending from the circumferential coolant reservoir and circumferentially spaced about the central opening; and a plurality of dies, each die defining a die opening having a diameter different than the other dies of the plurality; wherein the plurality of coolant supply rings and the plurality of dies are coupled together in an alternating pattern to form a toolpack coupled to the frame with the central openings and the die openings aligned about a common axis to define a forming passage through the toolpack that is structured to have a portion of a ram body reciprocatingly pass therethrough during can forming operations of the bodymaker, wherein each outlet port of each coolant supply ring is sized and configured to direct a stream of the coolant from the circumferential coolant reservoir into the forming passage in a forward direction toward an adjacent die of the toolpack during forming operations.

The stream of coolant from each outlet port may be directed at an angle of 15 degrees or less with respect to a reference line disposed parallel to the common axis of the forming passage.

The can bodymaker may further comprise the source of the pressurized flow of coolant in communication with the inlet port of each of coolant supply ring via a respective supply line coupled to the inlet port. The source of the pressurized flow of coolant may be structured to provide the pressurized flow of coolant at a pressure of or about 1000 psi. The source of the pressurized flow of coolant may be structured to provide the pressurized flow of coolant at a flow rate at or about 20 gallons per minute. The source of the pressurized flow of coolant may be structured to provide the pressurized flow of coolant at a pressure of or about 1000 psi and at a flow rate at or about 20 gallons per minute.

These and other objects, features, and characteristics of the disclosed concept, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the disclosed concept.

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 partially schematic view of a can bodymaker including a toolpack arrangement in accordance with an example embodiment of the disclosed concept;

FIG. 2 is a sectional view of the toolpack of the bodymaker of FIG. 1 sectioned along a central axis of the toolpack showing a schematic depiction of the transformation of a cup to a can body through the toolpack;

FIG. 3 is a perspective view of a coolant supply ring in accordance with an example embodiment of the disclosed concept such as employed in the toolpack of FIG. 2 shown with coolant dispersed via a circumferential array of outlet ports thereof; and

FIG. 4 is a sectional view of the coolant supply ring of FIG. 3 as indicated in FIG. 3 shown with coolant dispersed via a circumferential array of outlet ports thereof.

DETAILED DESCRIPTION OF THE INVENTION

The specific elements illustrated in the drawings and described herein are simply exemplary embodiments of the disclosed concept. Accordingly, specific dimensions, orientations and other physical characteristics related to the embodiments disclosed herein are not to be considered limiting on the scope of the disclosed concept.

As employed herein, the term “can” refers to any known or suitable container, which is structured to contain a substance (e.g., without limitation, liquid; food; any other suitable substance), and expressly includes, but is not limited to, beverage cans, such as beer and soda cans, as well as cans used for food.

As used herein, “coupled” means a link between two or more elements, whether direct or indirect, so long as a link occurs. An object resting on another object held in place only by gravity is not “coupled” to the lower object unless the upper object is otherwise maintained substantially in place. That is, for example, a book on a table is not coupled thereto, but a book glued to a table is coupled thereto.

As used herein, “directly coupled” means that two elements are coupled in direct contact with each other.

As used herein, “fixedly coupled” or “fixed” means that two components are coupled so as to move as one while maintaining a constant orientation relative to each other. The fixed components may, or may not, be directly coupled.

As used herein, the word “unitary” means a component is created as a single piece or unit. That is, a component that includes pieces that are created separately and then coupled together as a unit is not a “unitary” component or body.

As used herein, “engage,” when used in reference to gears or other components having teeth, means that the teeth of the gears interface with each other and the rotation of one gear causes the other gear to rotate as well.

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

Referring now to FIG. 1, a representative portion of can forming machine, or can bodymaker 10, in accordance with an example embodiment of the disclosed concept is shown partially schematically. The can bodymaker 10 includes an operating mechanism 12 (shown schematically) that is structured to provide a cyclical and/or reciprocating motion (such as shown by the double-headed arrow 14), a ram 16, a load station 18, a die assembly or toolpack 20 provided as a portion of a toolpack arrangement 22 in accordance with an example embodiment of the disclosed concept, and a can stripper 24. In the example embodiment shown in FIG. 1, each of the aforementioned components are coupled, directly or indirectly, to a frame, or housing (shown generally as 26) of the bodymaker 10, for maintaining such components, and/or selected portions thereof, in a known relationship with respect to one or more of the other of such components.

Continuing to refer to FIG. 1, the ram 16 has an elongated, substantially cylindrical ram body 28 positioned about a longitudinal axis 30 such that ram 16 moves back and forth generally along the longitudinal axis 30. The ram body 28 includes a proximal end 32 positioned nearest, and coupled to, the operating mechanism 12, and a distal end 34 positioned opposite the proximal end 32. A punch 36 is disposed at, over, or on the distal end 34 of the ram body 28. The punch 36 is a generally cylindrical body with a concave distal end which may be shaped to correspond to a cavity of a domer die of a domer assembly (not shown). The operating mechanism 12 provides a reciprocal motion to the ram body 28 causing the ram body 28, and therefore the punch 36 positioned at the distal end 34 of the ram body 28, to move back and forth along the longitudinal axis 30. That is, the punch 36 is structured to reciprocate between a retracted position, wherein the punch 36 is positioned between the load station 18 and the operating mechanism 12, and an extended position, wherein the ram body extends generally horizontally through the tool pack 20 and the distal end 34 and punch 36 extends from the toolpack 20 (such as shown in FIG. 1).

Referring now to FIG. 2, the tool pack 20 includes a plurality (four as shown) of die(s) 40 each having a die opening 42 therein having a different diameter than the other dies 40. In such example, the die opening 42A in the first die 40A is slightly larger than the opening 42B in the second die 40B; the opening 42B in the second die 40B is slightly larger than the opening 42C in the third die 40C; and the opening 42C in the third die 40C is slightly larger than the opening 42D in the fourth die 40D.

Continuing to refer to FIG. 2, and additionally to FIGS. 3 and 4, the tool pack 20 further includes a plurality of coolant supply rings 50 (labeled 50A, 50B, 50C, 50D in FIG. 2). Each coolant supply ring 50 includes a body 52 having a central opening 54 defined therethrough. In the example embodiment shown in FIGS. 3 and 4, the body 52 is generally disc-shaped, however, it is to be appreciated that the general shape of the body 52 may vary without varying from the scope of the disclosed concept. Each coolant supply ring 50 further includes: a circumferential coolant reservoir 56 defined in the body 52 about the central opening 54, a coolant passage 58 defined in the body 52 and extending from an inlet port 60 disposed at an outer surface 62 of the body 52 to the circumferential coolant reservoir 56, and a circumferential array 64 of outlet ports 66 extending from the circumferential coolant reservoir 56 and circumferentially spaced about the central opening 54. The inlet 60 is structured to receive a pressurized flow of coolant 68 (e.g., via a supply line 70) from a source 72 (FIG. 1, e.g., a high pressure pump 74 in communication with a coolant reservoir 76 (shown schematically)) of coolant provided as a part of toolpack arrangement 22 and communicate the coolant 68 via the coolant passage 58 to the circumferential coolant reservoir 56 where the coolant 68 then exits the coolant supply ring 50 via the outlet ports 66 of the circumferential array 64 as discussed further below. In example embodiments of the disclosed concept coolant pressures of about 1,000 psi with a flow rate about 20 GPM have been employed.

As shown in FIG. 2, the plurality of coolant supply rings 50 and the plurality of dies 40 are coupled together in an alternating pattern (i.e., supply ring 50A-die 40A-supply ring 50B-die 40B-supply ring 50C-die 40C-supply ring 50D-die 40D) to form the toolpack 20 with the central openings 54 and the die openings 42 aligned about a common axis 80 to define a forming passage 82 through the toolpack 20 that is structured to have the a portion of the ram body 28 (e.g., punch 36) reciprocatingly pass therethrough during can forming operations of the bodymaker 10. As with a conventional toolpack, in order to best form a can body, ideally the common axis 80 of the forming passage 82 is generally aligned with the longitudinal axis 30 of the ram body 28 (and vice versa) such that the ram body 28 and the punch 36 on the end thereof pass concentrically through the central opening 52 of each of the supply rings 50 as well as the die openings 42 of each of the dies 40 during a can forming operation.

The sectional view of FIG. 2 depicts the transformation of a cup 2 to a can body 4 while omitting showing the punch 36 on/over which the cup 2 would be disposed and formed. As the cup 2 passes forward through the toolpack 20 (i.e., from left to right in FIG. 2), streams 84 (only some are numbered) of high pressure coolant are provided from the circumferential coolant reservoir 56 into the forming passage 82 in a generally forward (i.e., from left to right in FIG. 2) direction toward the adjacent die 42 of the toolpack 20 by the circumferential array 64 of outlet ports 66 such that the coolant sprays onto both inner and outer surfaces of the cup/can that is being formed through cold working by the dies 40. The coolant spray forms a film barrier at two key locations: i) between the ram/punch and the cup/can, and ii) between the die tooling and the cup/can. Such barrier films minimize, if not prevent, the increased & unwanted frictional affects of Nickel alloy particles (of the cup/can body) inadvertently adhering to the bodymaker tooling (ram & dies). In example embodiments of the disclosed concept, the outlet ports 66 are each positioned at an angle θ with respect to a reference line RL parallel to the common axis 80 of the forming passage 82 of 15 degrees or less.

From the foregoing it is thus to be appreciated that embodiments of the disclosed concept minimize the potential of particles (e.g., fines/filings/debris) from certain materials (e.g., nickel) of cups/cans from building up onto tool components (e.g., tool pack dies, ram bodies) that are formed during cold working can forming operations of a bodymaker machine, such as employed, for example, in the beverage can industry.

While specific embodiments of the disclosed concept 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.

In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word “comprising” or “including” does not exclude the presence of elements or steps other than those listed in a claim. In a device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. In any device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain elements are recited in mutually different dependent claims does not indicate that these elements cannot be used in combination.