Dome formation profile and method of lightweight container design and manufacture

Abstract

The inventive technology includes a novel container dome profile and manufacturing process for improving container and bottle deformation failure resistance and extending material displacement modes through an initial deformation panel coordinated with complimentary geometric paneling and buttressing structures configured to initiate a controlled sequential dome profile deformation mode. Dome reversal, dome growth, and dome drop resistance characteristics are improved with a shallower profile formation depth, reducing pulldown, and lowering material consumption, resulting in lower overall container/bottle weight. Novel geometric contoured shapes enhance container resistance performance, supporting use of softer alloys or lower temper and yield strength to benefit post-processing efficiency and forming processes improvements while being configured to initiate controlled sequential dome profile deformation.

Claims

1. A deformation resistant metal container comprising: a lightweight dome profile configured to be capable of a controlled sequential dome profile deformation where said lightweight dome profile further comprises: at least one initial deformation panel positioned on an inner dome profile of said lightweight dome profile wherein said initial deformation panel comprises an inwardly raised structure having one or more tangential radial segments; a deformation panel boundary coupled with said initial deformation panel forming the boundary of said lightweight dome profile; a network of buttressing structures positioned between a plurality of geometric panels coupled with said lightweight dome profile deformation panel boundary; an inner leg configured to have an inner conical leg angle coupled with said network of buttressing structures and said plurality of geometric panels; and wherein said controlled sequential dome profile deformation is initiated in response to the application of a deformation energy to said lightweight dome profile such that movement of said initial deformation panel transfers said deformation energy outwardly through said deformation panel boundary onto said plurality of networked buttressing structures generating a leveraged deformation displacement action that supports said inner conical leg angle reinforcing the structural integrity of said lightweight dome profile.

2. The deformation resistant metal container of claim 1, wherein the initial deformation panel comprises an inwardly raised spherical domed structure defined by one or more tangential radial segments.

3. The deformation resistant metal container of claim 1, wherein said metal container comprises a metal container selected from the group consisting of: a metal can, a beverage container, a preform, a bottle, a shaped metal container, an ironed metal container, a formed metal container, and/or a metal canister.

4. The deformation resistant metal container of claim 1, wherein said deformation energy comprises a deformation energy selected from the group consisting of: a deformation energy generated by fluid or gaseous pressurization of said container, a deformation energy generated by pasteurization of said container, drop energy, dome reversal displacement energy, and container growth energy.

5. The deformation resistant metal container of claim 1, wherein said initial deformation panel, and said buttressing structures, and said geometric panels, and said deformation panel boundary, and said inner conical leg angle are integrally coupled in a network.

6. The deformation resistant metal container of claim 5, wherein said network of buttressing structures positioned between a plurality of geometric panels comprises a plurality of opposing buttressing structures positioned between a plurality of geometric panels.

7. The deformation resistant metal container of claim 5, wherein said inner conical leg angle comprises an inner conical leg angle selected from the group consisting of: an inner conical leg angle having 2-10° degrees of taper, and an inner conical leg angle having 0-15° degrees of taper.

8. The deformation resistant metal container of claim 5, wherein said lightweight dome profile comprises a lightweight dome profile positioned at a terminal end of a metal container formed from a metal having at least a gauge less than that of a comparable metal container wherein said lightweight dome profile has at least equivalent deformation resistance as said metal comparable container.

9. The deformation resistant metal container of claim 5, wherein said lightweight dome profile comprises a lightweight dome profile positioned at a terminal end of a metal container having a dome depth 20-75% less than the dome depth for a comparable container.

10. A lightweight metal dome profile comprising: at least one initial deformation panel wherein said initial deformation panel comprises an inwardly raised domed structure having a deformation panel boundary defining the outer boundary of said initial deformation panel being positioned on an inner dome profile of a metal container and wherein said initial deformation panel is coupled with at least one geometric shape at said deformation panel boundary; wherein said at least one geometric shape is configured to be capable of initiating a controlled sequential dome profile deformation in response to a deformation energy; wherein movement of said initial deformation panel transfers said deformation energy onto said at least one geometric contoured shape generating a leveraged deformation displacement action that supports an inner conical leg angle of said lightweight dome profile; and wherein said geometric shape configured to be capable of initiating a controlled sequential dome profile deformation in response to a deformation energy comprises one or more buttressing structures coupled with said initial deformation panel and configured to be capable of initiating a controlled sequential dome profile deformation in response to a deformation energy.

11. The lightweight metal dome profile of claim 10, wherein said controlled sequential dome profile deformation is initiated in response to the application of a deformation energy to said lightweight dome profile such that movement of said initial deformation panel transfers said deformation energy outwardly through said panel boundary onto one or more of said buttressing structures generating a leveraged deformation displacement action that supports said inner conical leg angle reinforcing the structural integrity of said lightweight dome profile.

12. The lightweight metal dome profile of claim 11, wherein said metal dome profile comprises a metal dome profile selected from the group consisting of: a metal can having a metal dome profile, a beverage container having a metal dome profile, a preform having a metal dome profile, a bottle having a metal dome profile, a shaped metal container having a metal dome profile, an ironed metal container having a metal dome profile, and a formed metal container having a metal dome profile.

13. The lightweight metal dome profile of claim 12, wherein said lightweight dome profile comprises a lightweight dome profile formed from a metal having at least a gauge less than that of a comparable container wherein said lightweight metal dome profile has at least equivalent deformation resistance as said comparable container.

14. The lightweight metal dome profile of claim 12, wherein said lightweight dome profile comprises a lightweight dome profile having a dome depth 20-75% less than the dome depth for a comparable metal container.

15. The lightweight metal dome profile of claim 10, wherein said inner conical leg angle comprises an inner conical leg angle selected from the group consisting of: an inner conical leg angle having 2-10° degrees of taper, and an inner conical leg angle having 0-15° degrees of taper.

16. A lightweight metal dome profile having a reduced pull down comprising: a lightweight dome profile having a reduced pull down having at least one initial deformation panel wherein said initial deformation panel comprises an inwardly raised domed structure positioned on an inner dome profile of said lightweight dome profile; at least one buttressing structure coupled with said initial deformation panel at a deformation panel boundary; an inner leg configured to have an inner conical leg angle coupled with said at least one buttressing structure and at least one geometric panel; and wherein the pulldown required to generate said lightweight dome profile is configured to be capable of a controlled sequential dome profile deformation is reduced by 20-75%.

17. The lightweight metal dome profile having a reduced pull down of claim 16, wherein said controlled sequential dome profile deformation is initiated in response to the application of a deformation energy to said lightweight dome profile such that movement of said initial deformation panel transfers said deformation energy outwardly onto said at least one buttressing structure generating a leveraged deformation displacement action that supports said inner conical leg angle reinforcing the structural integrity of said lightweight dome profile.

18. The lightweight metal dome profile having a reduced pull down of claim 17, wherein said initial deformation panel comprises an inwardly raised spherical position defined by at least one tangential radial segment.

19. The lightweight metal dome profile having a reduced pull down of claim 18, wherein said lightweight metal dome profile having a reduced pull comprises a metal container having a lightweight metal dome profile having a reduced pull down selected from the group consisting of: a metal can having a lightweight metal dome profile having a reduced pull down, a beverage container having a lightweight metal dome profile having a reduced pull down, a preform having a lightweight metal dome profile having a reduced pull down, a bottle having a lightweight metal dome profile having a reduced pull down, a shaped metal container having a lightweight metal dome profile having a reduced pull down, an ironed metal container having a lightweight metal dome profile having a reduced pull down, and a formed metal having a lightweight metal dome profile having a reduced pull down.

20. The lightweight metal dome profile having a reduced pull down of claim 18, wherein said inner conical leg angle comprises an inner conical leg angle selected from the group consisting of: an inner conical leg angle having 2-10° degrees of taper, and an inner conical leg angle having 0-15° degrees of taper.

21. The lightweight metal dome profile having a reduced pull down of claim 18, wherein said lightweight dome profile comprises a lightweight dome profile formed from a metal having at least a gauge less than that of a comparable metal container wherein said lightweight dome profile has at least equivalent deformation resistance as said comparable metal container.

22. The deformation resistant metal dome profile comprising: a lightweight dome profile configured to be capable of a controlled sequential dome profile deformation; wherein said lightweight dome profile further comprises: at least one initial deformation panel positioned at a central position on an inner dome profile of said lightweight dome profile; a deformation panel boundary defining the outer boundary of said initial deformation panel; at least one buttressing structure coupled with said initial deformation panel at said deformation panel boundary; a circumferentially positioned inner leg configured to have an inner conical leg angle coupled with said at least one buttressing structure and a plurality of geometric panels.

23. The deformation resistant metal dome profile of claim 22, wherein said controlled sequential dome profile deformation is initiated in response to the application of a deformation energy to said lightweight dome profile such that movement of said initial deformation panel transfers said deformation energy outwardly onto said at least one buttressing structures generating a staged leveraged deformation displacement action that delays deformation of said inner conical leg angle.

24. The deformation resistant metal dome profile of claim 23, wherein said staged leveraged deformation displacement action that delays deformation of said inner conical leg comprises the application of a deformation energy to said lightweight dome profile such that movement of said initial deformation panel transfers said deformation energy outwardly through said deformation panel boundary and onto at least one buttressing structure generating a leveraged deformation displacement action that supports said inner conical leg angle.

25. The deformation resistant metal dome profile of claim 23, wherein said staged leveraged deformation displacement action that delays deformation of said inner conical leg angle comprises a staged leveraged deformation displacement action that delays deformation progression of said inner conical leg angle to at least an inner conical leg angle prior to failure of said initial deformation panel resulting in deformation panel reversal.

26. The deformation resistant metal dome profile as described in of claim 25, wherein said initial deformation panel comprises an inwardly raised spherical position defined by one or more tangential radial segments.

27. The deformation resistant metal dome profile of claim 26, wherein said inner conical leg angle comprises an inner conical leg angle selected from the group consisting of: an inner conical leg angle having 2-10° degrees of taper, and an inner conical leg angle having 0-15° degrees of taper.

28. The deformation resistant metal dome profile of claim 26, wherein said lightweight dome profile comprises a lightweight dome profile formed from a metal having at least a gauge less than that of a comparable metal container wherein said deformation resistant metal dome profile has at least equivalent deformation resistance as said comparable metal container.

29. The deformation resistant metal dome profile of claim 26, wherein said lightweight dome profile positioned at a terminal end of a metal container comprises a lightweight dome profile having a dome depth 20-75% less than the dome depth for a comparable metal container.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) FIG. 1: illustrates a typical prior art container base profile of 211 can diameter with a 202 base size undergoing typical failure sequencing through complete reversal deformation. The standard progressive deterioration of the dome profile induced by excessive internal pressure is generally shown. The dome profile absorbs the internal pressure to a point of collapse resulting in a complete reversal of the convex domed contour. The reversal of the domed geometry is the defined structural failure resulting in loss of product stackability and often loss of internal pressure. These failure defects render the container quality non-usable or non-conforming to designed container performance.

(2) FIG. 2: illustrates a container dome profile according to the disclosure herein, wherein the novel geometric configurations of increased strength and reduced material consumption through strategic application of favorable geometric contoured shapes within the profile result in the sequential dome profile deformation. As detailed below, the geometric contoured shapes combine and merge in a complimentary mechanical system during material displacement, resulting in the novel sequential dome profile deformation. As also generally shown in FIG. 2, in certain embodiments, the strategic placement of geometric contoured shapes helps generate a controlled sequential dome profile deformation which may be characterized by movement of the geometric contoured shapes in a controlled displacement, resulting in a controlled and phased failure mode sequencing that is more resistant to reversal deformation. As also shown in FIG. 2, the unique geometric contoured shapes congruently compose a technical method of controlled sequential dome profile deformation to appreciatively increase the inner dome profile reversal strength through specific buttressing features. In this manner, the lightweight dome profile is able to maintain its strength and structural deformation resistance, such as might be required by industry standards or a customer's request, while utilizing lighter gauges of starting material. As further shown, the geometric contoured shapes use the deformations of material in a complimentary manner during the focused displacement of the geometric features. Moreover, the dome profile deformations are focused in a controlled geometric displacement by the design and shape of geometric features eliminating irregularities of force absorption. As shown in FIG. 2, the novel features of the invention provide benefits during a controlled sequential dome profile deformation sequence where the geometric contoured shapes may be utilized to focus the material deformation, for example, as would occur during dome failure or reversal deformation, resulting in force isolation in a complimentary manner. In this manner, the geometric contoured shapes of the inner profile mechanically utilize the material movements and deformations improving the inner dome profile strength as well as delaying the deformation phases by delaying the time of complete dome failure.

(3) FIG. 3a-b: illustrates an end-view as well as isolated cross-sectional perspective of a metallic container having a plurality of geometric contoured shapes. In this embodiment, such geometric contoured shapes include panel and intertwined buttressing structures configured to generate a controlled sequential dome profile deformation as generally described herein.

(4) FIG. 4: illustrates a perspective view of metallic container having a dome profile configured with a centrally positioned initial deformation panel coupled with a plurality of buttressing structures configured to initiate a controlled sequential dome profile deformation in one embodiment thereof. This figure further illustrates an exemplary deformation panel boundary, buttressing structures, and geometric panels, in one embodiment thereof.

(5) FIG. 5a: illustrates a front-facing view of metallic container having a dome profile configured with a centrally positioned initial deformation panel coupled with a plurality of buttressing structures configured to initiate a controlled sequential dome profile deformation, in one embodiment thereof.

(6) FIG. 5b: illustrates a side view of metallic container having an external dome profile dome profile, in one embodiment thereof.

(7) FIG. 6a: illustrates a perspective view of the internal cavity of a metallic container having a dome profile configured with a centrally positioned initial deformation panel coupled with a plurality of buttressing structures configured to initiate a controlled sequential dome profile deformation, in one embodiment thereof.

(8) FIG. 6b: illustrates a top view of the internal cavity of a metallic container having a dome profile configured with a centrally positioned initial deformation panel coupled with a plurality of buttressing structures configured to initiate a controlled sequential dome profile deformation, in one embodiment thereof.

(9) FIG. 7: illustrates a cross-sectional view of the internal cavity of a metallic container having a dome profile configured with a centrally positioned initial deformation panel coupled with a plurality of buttressing structures configured to initiate a controlled sequential dome profile deformation, in one embodiment thereof.

(10) FIG. 8: illustrates a dome profile formation device and tooling arrangement that may be used to manufacture the novel dome profile, in one embodiment thereof.

(11) FIG. 9a-b: illustrates a dome forming tool that may be used to manufacturer a metallic container having a dome profile configured with a centrally positioned initial deformation panel coupled with a plurality of buttressing structures configured to initiate a controlled sequential dome profile deformation, in one embodiment thereof.

MODE(S) FOR CARRYING OUT THE INVENTION(S)

(12) The present invention includes a variety of aspects, which may be combined in different ways. The following descriptions are provided to list elements and describe some of the embodiments of the present invention. These elements are listed with initial embodiments, however it should be understood that they may be combined in any manner and in any number to create additional embodiments. The variously described examples and preferred embodiments should not be construed to limit the present invention to only the explicitly described systems, techniques, and applications. Further, this description should be understood to support and encompass descriptions and claims of all the various embodiments, systems, techniques, methods, devices, and applications with any number of the disclosed elements, with each element alone, and also with any and all various permutations and combinations of all elements in this or any subsequent application.

(13) Generally referring to FIG. 1, a container (1) is shown having a traditional dome profile (10), in this instance for a metal can of a standardized material volume and weight is shown. This traditional dome profile (10) exhibits a inner dome profile (12) that is common within the industry. This inner or spherical dome profile (12) includes an inward protrusion of bi-radial tangent radii, or a unified blend of tangential spherical radii. The inner dome profile nose (14) radius torus has consistently been sized specifically for minimum reversal strength and sprayability between 0.050″−0.130″. Smaller inner dome profile nose (14) radii may be structurally stronger but harder to spray and more fracture prone during formation processes. Traditional inner dome profiles also typically include a circumferentially tangent dome wall angle I (16). This angle is traditionally between 2-10°, or 0-15° degrees of taper, being tangent to the inner dome profile nose (14) and the punch nose radius (15). The inner dome profile (12) initial inner dome reversal I (18) begins as inward pressure exceeds the domed shape structural resistance. During the inner dome reversal I (18) event, the inner dome profile (12) demonstrates an inner dome reversal II (20) sequencing mode of radial deflection due to internal force centralizing concentration onto the inner domed profile (12). Continuing on, the inner dome profile (12) continues to deform reaching a full spherical radius deflection and reversal sequencing identified as inner dome reversal III (22) where the dome wall angle III (25) begins to displace inwardly. The inward leaning of the dome wall angle II (24) begins to collapse from A to B degrees as the profile structure folds over collapsing the traditional domed profile (10) toward a final reversal displacement failure mode. As shown in this figure, where the dome profile structural reversal deformation exceeds the profile boundaries, identified as inner dome reversal (28). This inner dome reversal (28) results in product failure, in-stackability. Moreover, dome wall angle IV (26) C, also identified as angle C, inwardly collapses to the point that it is unrecoverable. At this point, the traditional dome profile (10) reaches a stage of full structural reversal failure (30) where the dome profile exceeds profile boundaries causing complete un-stackability and final product profile structural reversal displacement failure mode.

(14) Metal consumed by the inner or spherical dome profile (12) formation process is commonly known in the art as ‘Pulldown’ (32). Again, generally referring to FIG. 1, pulldown (32) represents the volume of metal or other material required due to dome profile depth (34). Specifically, a minimum pulldown (32) is required for traditional dome profiles (10) to meet the desired structural performance criteria. The amount of pulldown (32) is generally defined by the amount of container wall circumferential metal volume which is consumed by the inner dome profile (12) formation process. As can be seen in the figures, the deeper the inner dome profile (12) is formed, the more metal is consumed and the heavier the finished container or bottle will ultimately be. Inversely, as the dome depth (34) is reduced, the reversal resistance performance of the container is also reduced. In this manner, the effects of pulldown (32) are correlated directly to metal volume consumption of the starting material that moves downward in the circumferential walls of the body diameter or geometric shape of the inner dome profile (12). As a result, when the inner dome depth (34) is increased, the weight of the container and metal needed to manufacturer the container also increases.

(15) As noted above, the reduction of pulldown by other means or methods has produced excessive material thinning resulting in product formation defects such as fractures or other structural defects reducing container performance and axial strength. These problems define the limitations of existing art shown in FIG. 1 as the lowering dome depth (34) reaches a condition where the physical structural reversal resistance, shown sequentially in elements 18, 20, 22, 28 and 30 of FIG. 1, does not meet the minimum container performance requirements and inversely creates a heavier than optimal container weight via increased material consumption of traditional dome profile (10) geometries.

(16) The lightweight dome profile (100), in particular the decreased depth of the dome profile or dome depth (134), directly reduces pulldown (132). Due to the controlled sequential dome profile deformation attributes described herein, the depth of the dome (134) for the lightweight dome profile (100), as opposed to the dome depth (34) of a traditional dome profile (10) shown in FIG. 1, meets the acceptable dome reversal resistance, reduces the total metal volume consumed during manufacturing, allows a reduction in the outside diameter of the canister body, and provides the option of a lower starting metal gauge as well as a lower metal alloy yield strength—while increasing container performance and reducing the final container weight significantly. In a certain embodiment, the lightweight dome profile may have a dome depth 20-75% less than the dome depth of a comparable traditional container. The lightweight dome profile may also have less pulldown compared to a comparable traditional container.

(17) In one embodiment, the invention includes a novel, lightweight dome profile (100) that may be configured to include one or more geometric contoured shapes that are configured to allow the controlled sequential dome profile deformation of the dome profile (100) in response to an exerted force, such as may be generated from internal liquid pressurization, dropping the container from a height, or through pasteurization processes as generally described herein. In this preferred embodiment, a centrally positioned initial deformation panel (110) may be integrally positioned in the inner dome profile (111). In this preferred embodiment, initial deformation panel (110) may be configured to undergo a controlled sequential dome profile deformation in response to an exerted force, such as internal pressure changes in a container.

(18) Again, as generally showing in FIGS. 2-3, and 4-7, an initial deformation panel (110) may form, and/or be integrally coupled with one or more geometric contoured shapes. In the preferred embodiment shown, an initial deformation panel (110) may include a deformation panel boundary (113) having one or more spherical radii or tangential radial segments (146, 145) that may further be coupled with a plurality of buttressing structures (140), separated by alternating geometries extending radially outward from the initial deformation panel (110) to the inner leg (150) of the dome profile. As noted above, these geometric contoured shapes may act synergistically to allow a controlled sequential dome profile deformation as generally described below.

(19) In one embodiment, the lightweight dome profile (100) may be configured to under go a controlled sequential dome profile deformation. As shown in FIG. 2 generally, in a preferred embodiment reversal energy is exerted on the geometric contoured shapes of the lightweight dome profile (100) causing the displacement the coupled geometric contoured shapes or structures in a complimentary and controlled manner of primary force transference of displacement energy via work energy of the adjacent geometric structures. The displacement energy generates deformation forces during the container profile geometric structural movements that may result from excessive internal pressurization via various means such as fluid pressurization, gaseous pressurization, such as may be caused by a build up of carbon-dioxide or nitrogen, drop energy, growth energy in pasteurization or dome reversal displacement energy. Referring again to FIG. 2, in this preferred embodiment a reversal energy is exerted on the initial deformation panel (110) causing it to initiate a controlled sequential dome profile deformation. Here, the initial deformation panel (110), in response to the application of a reversal energy, begins to collapse in an initial dome reversal action. However, the preliminary movement of the initial deformation panel (110) transfers the reversal energy input outward into the adjacent buttressing structures (140). This energy transfer allows the conversion of the reversal energy into structural leverage of adjacent buttressing structures (140) via outward lateral displacement. As such, the leveraged deformation strain energy passing through the buttressing structures (140) initiates lateral dome profile displacements through outward compression supporting the vertical consistency of inner dome wall angle or inner conical leg angle (118). This change of leveraged deformation energy enables the work of the lateral deformations in the lightweight dome profile (100) to transfer vertical force concentration laterally such that the buttressing structures (140) reinforce and thereby retain the position of the inner dome wall (170). This action maintains the vertical orientation angle of the inner conical leg angle (118).

(20) As opposed to a traditional dome profile outline in FIG. 1, this prolonged retention of the inner conical leg angle (118) prevents collapse of the angle as identified as inner conical leg angle I (120), inner conical leg angle II (122), inner conical leg angle III (124). Specifically, as the reversal energy causes the reversal deformation of the initial deformation panel (110) and may transfer the reversal energy input outward into the adjacent buttressing structures (140) causing further lateral leverage in the adjacent buttressing structures (140) which, in turn, further reinforces and thereby retains the position the inner dome wall (170), maintaining the vertical orientation angle of the inner conical leg angle (118). In this manner, as the initial deformation panel (110) begins its deformation movement, the transfer of energy laterally into the buttressing structures (140) may lock-in the inner conical leg angle (118).

(21) In this embodiment, the synergistic effect of the lightweight dome profile (100) is such that as the deformation energies continue to strengthen, the buttressing structures (140) concurrently increase their mechanical leveraged action to prevent the collapse of the inner conical leg angle (118). Collapse of the inner conical leg angle (118), being an important structural failure inflection point that may result in, for example, complete dome reversal (130). The longer the inner conical leg angle (118) can be maintained, the more resistant the lightweight dome profile (100) is to the reversal energy and profile deformation movements that may result in loss of structural integrity and/or dome reversal.

(22) Again referring to FIG. 2, structural displacement of the initial deformation panel (110) allows energy transference to the initial deformation panel (110), (generally being shown as sequential failure modes, shown here as initial deformation panel reversal I (114), initial deformation panel reversal II (116), and initial deformation panel reversal III (117), to be controlled and sequential. Specifically, the configuration of the lightweight dome profile (100) allows movement of the initial deformation panel (110) which in turn causes the buttressing structures (140) to react to the deformation energy by transferring forces outward with displacement to “lock in” the inner conical leg angle (118), and retain the profile structure, for example, identified as initial deformation panel reversal III (117), over a prolonged and high force potential. The prolonged vertical orientation of the inner conical leg angle (118) over an extended time (such angles being identified at sequential failure modes by numbers 118, 120, 122, 124, 125, 126) demonstrates the primary structural improvements of the buttressing geometries displacing internal deformation energy of the inner dome profile (111) outward displacement which significantly increases dome profile total reversal performance by delaying collapse of the inner conical leg angle (identified here as number 126), resulting in significantly improved dome profile geometries resistance to deformation failure.

(23) It should be noted that the shape, placement, orientation, number, and configuration of geometric contoured shapes utilized in the a lightweight dome profile (100) may be customized to be adaptable to various container sizes, materials, conditions or specifications. Such characteristic may be modified to conform to industry or customer's requirements, or container use applications, such as a need to be pasteurized or stored in a location with high ambient temperature. For example, in some instances a initial deformation panel (110) may have a larger diameter, and/or may be coupled with one, or a plurality of buttressing structures (140), which may further take a variety of forms and shapes. Such an example is non-limiting and is merely provided to show the high-level of customization and adaptability in the invention's lightweight dome profile.

(24) The shape and size of the spherical radius of the initial deformation panel (110) in specific combination of radii (145, 146) may allow modulation of the actual and specific value of controlled structural reversal pressure of the lightweight dome profile (100). This initial deformation panel (110) of the lightweight dome profile (100) may be optimized through modulations in size, diameter, radii, placement and number, to deflect and deform initially, providing the energy transference of structural enhancement through buttressing outward leverage. The actual starting gauge of a metal, in combination of these geometric size options of initial deformation panel (110), and radii (145, 146) may produce a specified and controllable failure pressure utilized to produce the primary displacement actions, providing structural energy to the remaining geometries of the lightweight dome profile (100).

(25) This displacement action of the initial deformation panel (110) may utilize the displacement energy of the structural deformations to increase and strengthen the lightweight dome profile (100) in sequential failure modes, generally shown here as initial deformation panel reversal I (114), initial deformation panel reversal II (116), and initial deformation panel reversal III (117), through the lateral displacement leverage of the buttressed structures supporting the inner conical leg angle (in this embodiment shown at inner conical leg angle IV (125)) of the inner dome wall (170) prior to crossing a threshold of reversal failure, which in this embodiment may be shown where the inner conical leg angle is identified at 126 and/or full structural reversal failure (30). This structurally reinforcing action may compliment the profile strength of any can size and any container base dome profile by enhancing the structural reversal displacements of the adjacent geometries. In this manner, the complimentary action of this laterally deflected energy is structurally improving and strengthening geometries of the lightweight dome profile (100).

(26) Referring again to FIG. 2, continued inner dome or inner conical leg angle (118) deformation through sequential failure modes (122, 124, and 125) demonstrate the extended failure modal response of the buttressed and paneled structural geometries. Indeed, the invention provides specific structural enhancements through deformation displacement of structural geometries including a initial deformation panel (110) focusing deformation energy and distributing displacement forces outwardly improving buttressing and geometric panel (160) structures respectively, resulting in improved vertical containment of inner conical leg angle (118) for the maximum resistance to failure, maximum resistance to dome growth and maximum resistance to drop performance structural characteristics.

(27) It should be noted that a variety of configurations may be considered to be within the scope of the invention. For example, in one embodiment a single initial deformation panel (110) may be coupled with a plurality of buttressing structures (140). In the preferred embodiment shown in FIG. 3, a single initial deformation panel (110) may be approximately positioned within the center of the inner dome profile (111) and have a radius that is approximately less than that of the container, and in some instances the inner leg (150). In this preferred embodiment, six individual buttressing structures (140) may be coordinated with the centrally positioned initial deformation panel (110). Such individual buttressing structures (140) may be configured to be separated by sequentially positioned geometric panels (160), and may further be configured to maintain the inner dome wall or inner conical leg angle 118 at the formed angle over a longer period of force application and to withstand higher levels of force resistance as described above. In some embodiments, pairs of buttressing structures (140) may be positioned in opposing positions, while in other embodiments, for example as shown in FIG. 3, may be positioned sequentially and equidistantly around the centrally positioned initial deformation panel (110). Naturally, the position and number of buttressing structures (140) and geometric panels (160) may be modular in nature such that they can be configured to provide the desired level force resistance based on the size of container, amount of liquid intended to be container within the container, the type and/or gauge of a starting material, as well as the softness of the alloy utilized. For example, in some embodiments, a single pair of buttressing structures (140) may be configured in opposing positions coupled with a positioned initial deformation panel (110). Additional embodiments may include anywhere from 1, to a plurality of buttressing structures (140) depending on the variable described above.

(28) As further shown in FIGS. 2-3, as the initial deformation panel (110) sequentially passed through the failure modes previously described (generally identified as initial deformation panel reversal I (114), initial deformation panel reversal II (116), initial deformation panel reversal III (117), and initial deformation panel reversal IV (119), at a certain point it may reach failure mode (121) wherein it reaches a maximum displacement position. At this maximum displacement failure mode (identified as initial deformation panel reversal V (121), the inner dome profile (111) of the initial deformation panel (110) stretches the geometric contoured shapes, such as the buttressing structures (140) and the like, resulting in the failure of outward force containment of inner the conical leg angle (118) at a maximum reversal resistance performance for the starting gauge material.

(29) As noted above, those skilled in the art of container and bottle failure or performance often observe primary problems of traditional dome profiles in the failure mechanics and failure modes being highly correlated around the limitations of traditional geometries established around spherical radii domed shapes. As a result, traditional dome or spherical profiles demonstrate distinct limitations in which deformation resistance to internal pressure reaches a point of exceeding the elastic limit resistance of the domed spherical radius shape or inner dome profile (12) resulting in a complete dome reversal of the geometric formation.

(30) Common testing for burst pressure often demonstrates this common unrolling and/or unwrapping of the geometric configurations of traditional dome profile (10) features. Specifically, traditional dome profiles (10) undergoing inner dome profile (12) deformation and failure sequencing continue to quickly unravel the tangential profile geometries of the inner post reversal of the spherical shape due to the concentration of the internal forces being focused onto these geometries. The increased intensity of focused tensile loading from this localization of internal pressurization forces directly transmit onto the tangent radii of the inner dome conical leg angle, for example as shown in FIG. 1 at numbers 24 and 26. The concentration of this tensile loading will transfer energy into unraveling and collapse of the vertical orientation of the inner dome leg geometry by destabilizing the inward protrusion profiled geometry. The highly-leveraged forces easily collapse the tangential support leg of the inner dome profile (12) due to the instability of the dome with concentrated leverage of deformation energy in this instantaneous effect of unwrapping the geometry.

(31) For example, the direct concentration of high tensile leverage exerted, of for example as shown in FIG. 1 at numbers 24, 25, 26, focuses displacements of instability inducing reversal of the inner dome profile (12). This becomes a distinct disadvantage for traditional dome profiles (10), and in particular traditional inner dome profiles (12) such as that shown in FIG. 1. Specifically, this localization of instability through such translated tensile energies focuses concentration onto the radius at the top of the support leg or dome shoulder radius (14). This high concentration of energy results in unstable unbalanced displacement and deformation inducing inner conical leg collapse angle ‘C’ generally identified as number 26. The limitations of traditional dome profile (10) to prevent the force concentration of these tensile energies in this geometry resulting from internal pressure forces directly transfer the deformation energy into the support leg or dome shoulder radius (14), inducing reversal of the spherical inner dome profile (12), directly unravelling the remaining geometries resulting in full structural reversal failure (30). Notably, as shown in FIG. 1, once the spherical inner dome profile (12) reverses as deformation increases from internal pressure increases, there is an immediate degradation of the structural failure resistance of the profiled shape, resulting in inferior performance.

(32) As again shown in FIG. 1, the intensification of these deformation energies directly concentrates within support leg or dome shoulder radius (14) and quickens the failure mode, immediately deforming and collapsing the inner conical leg or inner conical leg angle identified in number 26 of the traditional dome profile (10). Indeed, as shown in the final failure mode of FIG. 1 identified as number 30, total failure deformation completely unwraps the inner dome profile (12) as the focused tensile force gains momentum leverage exceeding the structural resistance displacement focus of the spherical geometric formation displacement, shown generally at number 28.

(33) To illustrate this transition to a final failure mode, during typical abuse testing, skilled observers in the art audibly observe this failure event as a “pop” or a clear audible sound of final reversal blowout of the inner dome profile (12) geometry. These events typically occur below the peak reversal pressure of final testing observance. As a result, the full structural reversal failure (30) of the dome deformation happens abruptly under significantly less internal force than the peak reversal pressurization experienced and terminates with complete unwrapping of the dome wall angle I (16) in a traditional dome profile (10). Therefore, the reversal pressure resistance of traditional dome profile (10) reduces significantly once the first modal failure sequence of the dome radius reversal occurs past displacement, identified as inner dome reversal III (22). The continued time of this abrupt full structural reversal failure (30) mode is significantly shortened once the spherical radius reversal event, shown at number 22, has been reached.

(34) As described herein, the novel lightweight dome profile (100) of the present invention overcomes these early structural sequential failure accelerating sequences. Specifically, geometric contoured shapes, including a initial deformation panel (110), buttressing structures (140), geometric panel (160) and/or a deformation panel boundary (113) utilize the buttressing structures (140) and/or geometric panel (160) deformation energy in complimentary leveraged resistance, utilizing displacement of elements' structural geometries, increasing structural resistance to the unwrapping failure mode of inherent traditional dome profile (12) designs. In a preferred embodiment, one or more buttressing geometric features (140) utilize the deformation energy initial deformation panel (110), for example as shown at number 111, to lock the displacements of the center spherical panel geometries, shown at initial deformation panel reversal modes I (114), and II (116) respectively, which results in significantly higher force structural resistance and failure resistance at a lower dome depth (134) and less starting material than traditional dome profiles (10).

(35) As would be appreciated by one of ordinary skill in the art, traditional dome profiles (10) suffer from dome fracture during formation and manufacture. During the dome formation process the inner leg depth induces thinning of the starting material thicknesses which is stretched and drawn around the inner domer tooling radii during formation. The metal shape is wrapped and stretched around the inner nose radius of the tool, while it is also clamped externally from the outer domer profile of the base geometry for stackability. Therefore, the dome shoulder radius (14) radius material is in high tensile load which increases as the depth of dome (34) increases. Increasing dome depth improves failure resistance, directly increases thinning of profiles, for example the dome shoulder radius (14) and punch nose radius (15), often resulting in increased fracture problems due to exceeding elastic limits of the material. The manufacturers of containers and bottles must also complete an inspection for fracture and crack detection within the traditional dome profile (10) geometries of all containers produced. Often these fractures are difficult to detect and may not be fully visible by the light and/or camera based detection systems. These fractures may often be sub-surface and frequently do not become visibly evident until they are pressurized and/or filled with product. The failure effects of filled containers with product may occur instantly once filled and/or pressurized, or over time the failure may be delayed where failure causes greater damage of stored products and surrounding storage facilities. The fracture tendency and frequency of traditional dome profile (10) geometries greatly increases as the dome depth (34) is increased to meet minimum failure resistance pressure requirements of thinner, more weight efficient gauges. This interaction is especially prevalent as the starting material gauge thickness becomes thinner and thinner. “Lightweighting” activities applied to container and bottle manufacturing processes and material often increases the dome fracture frequency and product failure rates as the dome depth (34) is increased. Additionally, common to the art of dome formation is the limitation of the thickness of the starting metal gauge required to meet the required industry standard quality structural performance characteristics. Traditional dome profiles (10) require post-processing for starting material gauges below about 0.0106 inches or lower temper and yield strength alloys below 45 ksi. The use of thinner starting material gauges is prevented by current art due to the limited failure structural resistance performance of gauges less than about 0.0106 inches. Those skilled in the art are versed in data demonstrating that dome reversal, dome growth and drop strength performance all degrade with traditional dome profiles (10) as the starting material gauge is reduced below this threshold. This limitation of gauge thickness directly limits the container and bottle achievable material weight savings.

(36) As described herein, the lightweight dome profile (100) resolves these issues and reduces the fracture rates, with less metal thinning problems by directly reducing the required dome depth formation sensitivities with significantly lower tensile intensity concentrations of material stretching induced during improved dome profile formation and intrinsically reduced dome depth requirements of the initial deformation panel (110) structures, geometric panel (160) structures and buttressing formations (140) while meeting and exceeding the industry minimum dome failure structural resistance performance. Moreover, such geometric contoured shapes integrally formed in a lightweight dome profile (100) not only eliminate the need for post-processing or reforming. For example, embodiments of the lightweight dome profile (100) may allow for starting gauges below about 0.0106 inches, or lower temper and yield strength alloys below 45 ksi without the need for additional post-processing or reforming.

(37) In one embodiment, the invention includes a novel dome profile (1). Generally referring to FIGS. 3 through 7, in one preferred embodiment the dome profile (1) may be configured to undergo an initial structural deflection sequencing as generally shown in FIG. 2.

(38) As noted above, the invention includes methods of manufacturing the lightweight dome profile (100). As generally shown in FIGS. 9 and 9a-b, a lightweight dome profile (11) may be manufactured using formation devices as generally disclosed. In this embodiment, the tool may include a punch sleeve (230) with a corresponding punch nose (222) and a punch bolt retainer (220) mounted onto a cyclic ram of a “bodymaker.” Additionally, this tooling (200) may further include of an inner dome die (210) which may form the profile (212) which may also be referred to as the “dome post.” An outer domer die (216), also referred to as a “clamp ring” and a clamp ring retainer (214) are also demonstrated.

(39) In one embodiment, aluminum or steel coil—rolled to a desired thickness, may be initially established. Next, a cup may be cut and drawn from the aluminum or steel coil sheet which may then be fed into a bodymaker which irons, or reduces the wall thickness. In the case of a can, the cup is positioned so as to be manipulated by the stroke of a bodymaker ram. Here, the initial dome structure is formed at the end of each stroke of the bodymaker. Next, a set of dome tools form the dome shape while an outer domer die clamps and holds the metal taught while the ram stroke continues to form the dome. At this point, an inner domer, which is generally spherical in shape, and stretches the inner dome portion of the base profile.

(40) In a certain embodiment, the lightweight dome profile (110) geometries may be generated using a coining punch. This may be accomplished by using a triple action doming assembly in which the formation process may be assisted with vacuum drawing of the inner panel geometries. In combination with a coined feature defined by the “punch bolt” to improve the initial deflection panel edges and clarify the shape outline. These key aspects are unique to the form of the new profile using the punch bolt to define initial deflection panel formation. As shown generally in FIGS. 8-9, this punch bolt may create the definition of the circularity or shape of the initial panel tangential radii connecting the features to the initial deformation panel (110), buttressing structures (140), geometric panels (160) and/or a deformation panel boundary (113). This shaped punch bolt may be used as a coining feature to define and set the geometry properly for the desired strength and deflection/failure sequencing demonstrated in the lightweight dome profile's (100) ability to initiate a controlled sequential dome profile deformation.

(41) Compared to traditional dome profiles (10), the invention's lightweight dome profile (100) varies in the method of dome depth formation by utilizing unique tooling geometries. The lightweight dome profile (100) may form the depth of the dome shape at much lower depths than traditional dome profiles (10). This in turn provides metal savings, by using less material. The added shape and definition is provided by the unique geometric contoured shapes and the profile combinations as described herein to increase dome strength.

(42) As used herein, the term “includes” and “including” mean, but is not limited to, “includes” or “including” and “includes at least” or “including at least.” The term “based on” means “based on” and “based at least in part on.”

(43) As used herein, the terms “can,” “container,” “preform” and/or “bottle” may be used interchangeably and generally include shaped, ironed or formed metallic containers.

(44) As used herein, the term “about” or “approximately” generally refers to a range include a plus or minus value of up to a 15% variance.

(45) While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the lightweight dome profile invention as defined by the statements of invention. Indeed, as can be easily understood from the foregoing, the basic concepts of the present invention may be embodied in a variety of ways. It involves both lightweight dome profile designs, devices and methods to manufacturer the same. In this application, the lightweight dome profile designs, devices and methods of manufacturing the same, are disclosed as part of the results shown to be achieved by the various devices described and as steps which are inherent to utilization. They are simply the natural result of utilizing the devices as intended and described. In addition, while some devices are disclosed, it should be understood that these not only accomplish certain methods but also can be varied in a number of ways. Importantly, as to all of the foregoing, all of these facets should be understood to be encompassed by this disclosure.

(46) The discussion included in this application is intended to serve as a basic description. The reader should be aware that the specific discussion may not explicitly describe all embodiments possible; many alternatives are implicit. It also may not fully explain the generic nature of the invention and may not explicitly show how each feature or element can actually be representative of a broader function or of a great variety of alternative or equivalent elements. Again, these are implicitly included in this disclosure. Where the invention is described in device-oriented terminology, each element of the device implicitly performs a function. Apparatus claims may not only be included for the device described, but also method or process claims may be included to address the functions the invention and each element performs. Neither the description nor the terminology is intended to limit the scope of the claims that will be included in any subsequent patent application.

(47) It should also be understood that a variety of changes may be made without departing from the essence of the invention. Such changes are also implicitly included in the description. They still fall within the scope of this invention. A broad disclosure encompassing the explicit embodiment(s) shown, the great variety of implicit alternative embodiments, and the broad methods or processes and the like are encompassed by this disclosure and may be relied upon when drafting any claims. It should be understood that such language changes and broader or more detailed claiming may be accomplished at a later date (such as by any required deadline) or in the event the applicant subsequently seeks a patent filing based on this filing. With this understanding, the reader should be aware that this disclosure is to be understood to support any subsequently filed patent application that may seek examination of as broad a base of claims as deemed within the applicant's right and may be designed to yield a patent covering numerous aspects of the invention both independently and as an overall system.

(48) Further, each of the various elements of the invention and claims may also be achieved in a variety of manners. Additionally, when used or implied, an element is to be understood as encompassing individual as well as plural structures that may or may not be physically connected. This disclosure should be understood to encompass each such variation, be it a variation of an embodiment of any apparatus embodiment, a method or process embodiment, or even merely a variation of any element of these. Particularly, it should be understood that as the disclosure relates to elements of the invention, the words for each element may be expressed by equivalent apparatus terms or method terms—even if only the function or result is the same. Such equivalent, broader, or even more generic terms should be considered to be encompassed in the description of each element or action. Such terms can be substituted where desired to make explicit the implicitly broad coverage to which this invention is entitled. As but one example, it should be understood that all actions may be expressed as a means for taking that action or as an element which causes that action.

(49) Similarly, each physical element disclosed should be understood to encompass a disclosure of the action which that physical element facilitates. Regarding this last aspect, as but one example, the disclosure of a “buttress” should be understood to encompass disclosure of the act of “buttressing”—whether explicitly discussed or not—and, conversely, were there effectively disclosure of the act of “buttressing”, such a disclosure should be understood to encompass disclosure of a “buttress” and even a “method for manufacturing a buttress or buttressing structure.” Such changes and alternative terms are to be understood to be explicitly included in the description.

(50) Any patents, publications, or other references mentioned in this application, for example through a concurrently or later submitted Information Disclosure Statement, are hereby incorporated by reference. Any priority case(s) claimed by this application is hereby appended and hereby incorporated by reference. Thus, the applicant(s) should be understood to have support to claim and make a statement of invention to at least: i) each of the devices as herein disclosed and described, ii) the related methods disclosed and described, iii) similar, equivalent, and even implicit variations of each of these devices and methods, iv) those alternative designs which accomplish each of the functions shown as are disclosed and described, v) those alternative designs and methods which accomplish each of the functions shown as are implicit to accomplish that which is disclosed and described, vi) each feature, component, and step shown as separate and independent inventions, vii) the applications enhanced by the various systems or components disclosed, viii) the resulting products produced by such systems or components, ix) each system, method, and element shown or described as now applied to any specific field or devices mentioned, x) methods and apparatuses substantially as described hereinbefore and with reference to any of the accompanying examples, xi) the various combinations and permutations of each of the elements disclosed, xii) each potentially dependent claim or concept as a dependency on each and every one of the independent claims or concepts presented, and xiii) all inventions described herein.

(51) With regard to claims whether now or later presented for examination, it should be understood that for practical reasons and so as to avoid great expansion of the examination burden, the applicant may at any time present only initial claims or perhaps only initial claims with only initial dependencies. The office and any third persons interested in potential scope of this or subsequent applications should understand that broader claims may be presented at a later date in this case, in a case claiming the benefit of this case, or in any continuation in spite of any preliminary amendments, other amendments, claim language, or arguments presented, thus throughout the pendency of any case there is no intention to disclaim or surrender any potential subject matter. It should be understood that if or when broader claims are presented, such may require that any relevant prior art that may have been considered at any prior time may need to be re-visited since it is possible that to the extent any amendments, claim language, or arguments presented in this or any subsequent application are considered as made to avoid such prior art, such reasons may be eliminated by later presented claims or the like. Both the examiner and any person otherwise interested in existing or later potential coverage, or considering if there has at any time been any possibility of an indication of disclaimer or surrender of potential coverage, should be aware that no such surrender or disclaimer is ever intended or ever exists in this or any subsequent application.

(52) Limitations such as arose in Hakim v. Cannon Avent Group, PLC, 479 F.3d 1313 (Fed. Cir 2007), or the like are expressly not intended in this or any subsequent related matter. In addition, support should be understood to exist to the degree required under new matter laws—including but not limited to European Patent Convention Article 123(2) and United States Patent Law 35 USC 132 or other such laws—to permit the addition of any of the various dependencies or other elements presented under one independent claim or concept as dependencies or elements under any other independent claim or concept. In drafting any claims at any time whether in this application or in any subsequent application, it should also be understood that the applicant has intended to capture as full and broad a scope of coverage as legally available. To the extent that insubstantial substitutes are made, to the extent that the applicant did not in fact draft any claim so as to literally encompass any particular embodiment, and to the extent otherwise applicable, the applicant should not be understood to have in any way intended to or actually relinquished such coverage as the applicant simply may not have been able to anticipate all eventualities; one skilled in the art, should not be reasonably expected to have drafted a claim that would have literally encompassed such alternative embodiments.

(53) Further, if or when used, the use of the transitional phrase “comprising” is used to maintain the “open-end” claims herein, according to traditional claim interpretation. Thus, unless the context requires otherwise, it should be understood that the term “comprise” or variations such as “comprises” or “comprising”, are intended to imply the inclusion of a stated element or step or group of elements or steps but not the exclusion of any other element or step or group of elements or steps. Such terms should be interpreted in their most expansive form so as to afford the applicant the broadest coverage legally permissible. It should be understood that this phrase also provides support for any combination of elements in the claims and even incorporates any desired proper antecedent basis for certain claim combinations such as with combinations of method, apparatus, process, and the like claims.

(54) Furthermore, it should be noted that certain embodiments of the current invention may indicate a coupler, or the step of coupling or two or more items that may be coupled. It should be noted that these may indicate a direct, or in some cases an indirect connection and/or bring together of disparate or non-disparate elements in a functional, non-functional or desired configuration.

(55) Additionally, any claims set forth at any time are hereby incorporated by reference as part of this description of the invention, and the applicant expressly reserves the right to use all of or a portion of such incorporated content of such claims as additional description to support any of or all of the claims or any element or component thereof, and the applicant further expressly reserves the right to move any portion of or all of the incorporated content of such claims or any element or component thereof from the description into the claims or vice-versa as necessary to define the matter for which protection is sought by this application or by any subsequent continuation, division, or continuation-in-part application thereof, or to obtain any benefit of, reduction in fees pursuant to, or to comply with the patent laws, rules, or regulations of any country or treaty, and such content incorporated by reference shall survive during the entire pendency of this application including any subsequent continuation, division, or continuation-in-part application thereof or any reissue or extension thereon.