METHOD AND APPARATUS FOR FORMING A CAN SHELL USING A DRAW-STRETCH PROCESS

Abstract

A shell includes a body with a center panel, a countersink, a chuck wall, and a draw-stretched outer portion. The countersink has a base thickness. The outer portion has a reduced thickness. The shell countersink has substantially the same thickness as the sheet material prior to forming. In this configuration, the shell maintains the buckle resistance of a standard shell but uses less material.

Claims

1. A shell comprising: a body including a center panel, a countersink, a chuck wall, a can fit radius, a crown radius, and a curl; wherein said center panel and said countersink have a base thickness; and wherein said body has a reduced volume.

2. The shell of claim 1 wherein said crown radius is a draw-stretched crown radius.

3. The shell of claim 2 wherein said shell body has one of a reduced profile or a maximum reduced profile

4. The shell of claim 1 wherein: said body is aluminum; said countersink has a general thickness of between about 0.0104 inch and about 0.0078 inch; said center panel has a general thickness of between about 0.0104 inch and about 0.0078 inch; and said draw-stretched crown radius has a general thickness of between about 0.009 inch and about 0.0064 inch.

5. The shell of claim 4 wherein: said countersink has a general thickness of about 0.0086 inch; said center panel has a general thickness of about 0.0086 inch; and said crown radius has a general thickness of about 0.0076 inch.

6. The shell of claim 1 wherein: said body is steel; said countersink has a general thickness of between about 0.0065 inch and about 0.0090 inch; said center panel has a general thickness of between about 0.0065 inch and about 0.0090 inch; and said crown radius has a general thickness of between about 0.0050 inch and about 0.0090 inch.

7. The shell of claim 6 wherein: said countersink has a general thickness of about 0.0080 inch; said center panel has a general thickness of about 0.0080 inch; and said crown radius has a general thickness of about 0.0080 inch.

8. A press assembly structured to form a shell from a blank cut from sheet material, said sheet material having a base thickness, said press comprising: a frame; a number of press stations including a first forming station; said first forming station including an upper tooling assembly and a lower tooling assembly; said first forming station upper tooling assembly structured to move between an upper, first position, wherein said first forming station upper tooling assembly is spaced from said first forming station lower tooling assembly, and a lower, second position, wherein said first forming station upper tooling assembly is immediately adjacent said first forming station lower tooling assembly; wherein when said first forming station upper tooling assembly and said first forming station lower tooling assembly are structured to form a shell body including a center panel, a countersink, a chuck wall, and a crown radius; wherein said first forming station upper tooling assembly and said first forming station lower tooling assembly are further structured to draw-stretch said crown radius to create a crown radius with a reduced thickness; and wherein said first forming station upper tooling assembly and said first foil ling station lower tooling assembly are further structured to form said center panel and said countersink at said base thickness.

9. The press assembly of claim 8 wherein: said first forming station upper tooling assembly includes a blank & draw die punch, an upper piston, and a die center punch; said first forming station lower tooling assembly includes an lower piston, a die core ring, and a panel punch; said first forming station upper blank & draw die punch including an inner radius; wherein said first forming station upper blank & draw die punch inner radius is a reduced radius; said first forming station lower die core ring including an outer radius; and wherein said first forming station lower die core ring outer radius is a diminished radius.

10. The press assembly of claim 9 wherein: said first forming station upper blank & draw die punch inner radius is about a 0.019 inch radius; and said first forming station lower die core ring outer radius is about a 0.022 inch radius.

11. The press assembly of claim 9 wherein, when said upper tooling assembly is in said second position, said first forming station upper blank & draw die punch and said first forming station lower piston clamp said blank.

12. The press assembly of claim 11 wherein, when said upper tooling assembly is in said second position, said first forming station upper piston and said first forming station lower die core ring apply a force of between about 100 psi and about 600 psi to said blank.

13. The press assembly of claim 12 wherein, when said upper tooling assembly is in said second position, said first forming station upper piston and said first forming station lower die core ring apply a force of about 110 psi to said blank.

14. A method of forming a shell comprising: providing a sheet material, said sheet material having a base thickness; cutting a blank from said sheet material, said blank including a countersink portion, a chuck wall portion, and a crown radius portion; providing a press assembly including a frame, a number of press stations including a first forming station, said first forming station including an upper tooling assembly and a lower tooling assembly, said first forming station upper tooling assembly structured to move between an upper, first position, wherein said first forming station upper tooling assembly is spaced from said first forming station lower tooling assembly, and a lower, second position, wherein said first forming station upper tooling assembly is immediately adjacent said first forming station lower tooling assembly, wherein when said first forming station upper tooling assembly and said first forming station lower tooling assembly are in said second position, said first forming station upper tooling assembly and said first forming station lower tooling assembly are structured to form a shell body including a center panel, a countersink, and a crown radius; disposing said blank between said upper tooling assembly and said lower tooling assembly; clamping said crown radius portion between said first forming station upper tooling assembly and said first forming station lower tooling assembly; performing forming operations including: draw-stretching said crown radius portion to form a draw-stretched crown radius; forming said countersink portion into a counter sink; and draw-stretching said chuck wall portion into a draw-stretched chuck wall.

15. The method of claim 14 wherein said counter sink has a thickness corresponding to said sheet material base thickness.

16. The method of claim 13 wherein providing a press assembly includes: providing a first forming station upper tooling assembly that includes a blank & draw die punch, an upper piston, and a die center punch; providing a first forming station lower tooling assembly that includes a lower piston, a die core ring, and a panel punch; wherein said first forming station upper blank & draw die punch includes an inner radius; wherein said first forming station upper blank & draw die punch inner radius is a reduced radius; wherein said first forming station lower die core ring includes an outer radius; and wherein said first forming station lower die core ring outer radius is a diminished radius.

17. The method of claim 16 wherein providing a press assembly includes: providing said first forming station upper blank & draw die punch wherein said inner radius is about a 0.019 inch radius; and providing said first forming station lower die core ring wherein outer radius is about a 0.022 inch radius.

18. The method of claim 14 wherein draw-stretching said crown radius portion to form a draw-stretched crown radius include applying a force of between about 100 psi and about 600 psi to said blank.

19. The method of claim 18 wherein draw-stretching said crown radius portion to form a draw-stretched crown radius include applying a force of about 110 psi.

20. The method of claim 14 wherein cutting a blank from said sheet material includes cutting a blank with a reduced volume.

21. The method of claim 20 wherein performing forming operations includes forming said blank into a standard beverage shell.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] 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:

[0014] FIG. 1 is a schematic cross-sectional side view of a prior art shell.

[0015] FIG. 2 is a partial cross-sectional side view of an uncurled shell.

[0016] FIG. 3 is a partially schematic side view and partially cross-sectional side view of a press.

[0017] FIG. 4 is a partially schematic side view and partially cross-sectional side view of a first forming station.

[0018] FIGS. 5A-15A are detail cross-sectional side views of one embodiment of a first forming station at sequential configurations during the forming of a shell. FIGS. 5B-15B are detail cross-sectional side views of another embodiment of a first forming station at sequential configurations during the forming of a shell. FIG. 15C is a schematic cross-sectional view comparing the profiles of the tooling in FIGS. 5A and 5B.

[0019] FIG. 16 is a flow chart of the disclosed method.

[0020] FIG. 17A is a schematic cross-sectional side view of a shell having a reduced profile. FIG. 17B is a schematic cross-sectional side view of a shell having a maximum reduced profile.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] 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.

[0022] 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.

[0023] As used herein, the singular form of a, an, and the include plural references unless the context clearly dictates otherwise.

[0024] 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].

[0025] 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.

[0026] As used herein, a coupling assembly includes two or more couplings or coupling components. The components of a coupling or coupling assembly are generally not part of the same element or other component. As such, the components of a coupling assembly may not be described at the same time in the following description.

[0027] As used herein, a coupling or coupling component(s) is one or more component(s) of a coupling assembly. That is, a coupling assembly includes at least two components that are structured to be coupled together. It is understood that the components of a coupling assembly are compatible with each other. For example, in a coupling assembly, if one coupling component is a snap socket, the other coupling component is a snap plug, or, if one coupling component is a bolt, then the other coupling component is a nut.

[0028] As used herein, a fastener is a separate component structured to couple two or more elements. Thus, for example, a bolt is a fastener but a tongue-and-groove coupling is not a fastener. That is, the tongue-and-groove elements are part of the elements being coupled and are not a separate component.

[0029] As used herein, the statement that two or more parts or components are coupled shall mean that the parts are joined or operate together either directly or indirectly, i.e., through one or more intermediate parts or components, so long as a link occurs. As used herein, directly coupled means that two elements are directly in 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. Accordingly, when two elements are coupled, all portions of those elements are coupled. A description, however, of a specific portion of a first element being coupled to a second element, e.g., an axle first end being coupled to a first wheel, means that the specific portion of the first element is disposed closer to the second element than the other portions thereof. Further, 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.

[0030] As used herein, the phrase removably coupled or temporarily coupled means that one component is coupled with another component in an essentially temporary manner. That is, the two components are coupled in such a way that the joining or separation of the components is easy and would not damage the components. For example, two components secured to each other with a limited number of readily accessible fasteners, i.e., fasteners that are not difficult to access, are removably coupled whereas two components that are welded together or joined by difficult to access fasteners are not removably coupled. A difficult to access fastener is one that requires the removal of one or more other components prior to accessing the fastener wherein the other component is not an access device such as, but not limited to, a door.

[0031] As used herein, temporarily disposed means that a first element(s) or assembly (ies) is resting on a second element(s) or assembly(ies) in a manner that allows the first element/assembly to be moved without having to decouple or otherwise manipulate the first element. For example, a book simply resting on a table, i.e., the book is not glued or fastened to the table, is temporarily disposed on the table.

[0032] As used herein, operatively coupled means that a number of elements or assemblies, each of which is movable between a first position and a second position, or a first configuration and a second configuration, are coupled so that as the first element moves from one position/configuration to the other, the second element moves between positions/configurations as well. It is noted that a first element may be operatively coupled to another without the opposite being true.

[0033] As used herein, correspond indicates that two structural components are sized and shaped to be similar to each other and may be coupled with a minimum amount of friction. Thus, an opening which corresponds to a member is sized slightly larger than the member so that the member may pass through the opening with a minimum amount of friction. This definition is modified if the two components are to fit snugly together. In that situation, the difference between the size of the components is even smaller whereby the amount of friction increases. If the element defining the opening and/or the component inserted into the opening are made from a deformable or compressible material, the opening may even be slightly smaller than the component being inserted into the opening. With regard to surfaces, shapes, and lines, two, or more, corresponding surfaces, shapes, or lines have generally the same size, shape, and contours.

[0034] As used herein, a path of travel or path, when used in association with an element that moves, includes the space an element moves through when in motion. As such, any element that moves inherently has a path of travel or path. Further, a path of travel or path relates to a motion of one identifiable construct as a whole relative to another object. For example, assuming a perfectly smooth road, a rotating wheel (an identifiable construct) on an automobile generally does not move relative to the body (another object) of the automobile. That is, the wheel, as a whole, does not change its position relative to, for example, the adjacent fender. Thus, a rotating wheel does not have a path of travel or path relative to the body of the automobile. Conversely, the air inlet valve on that wheel (an identifiable construct) does have a path of travel or path relative to the body of the automobile. That is, while the wheel rotates and is in motion, the air inlet valve, as a whole, moves relative to the body of the automobile.

[0035] As used herein, the statement that two or more parts or components engage one another means that the elements exert a force or bias against one another either directly or through one or more intermediate elements or components. Further, as used herein with regard to moving parts, a moving part may engage another element during the motion from one position to another and/or may engage another element once in the described position. Thus, it is understood that the statements, when element A moves to element A first position, element A engages element B, and when element A is in element A first position, element A engages element B are equivalent statements and mean that element A either engages element B while moving to element A first position and/or element A either engages element B while in element A first position.

[0036] As used herein, operatively engage means engage and move. That is, operatively engage when used in relation to a first component that is structured to move a movable or rotatable second component means that the first component applies a force sufficient to cause the second component to move. For example, a screwdriver may be placed into contact with a screw. When no force is applied to the screwdriver, the screwdriver is merely temporarily coupled to the screw. If an axial force is applied to the screwdriver, the screwdriver is pressed against the screw and engages the screw. However, when a rotational force is applied to the screwdriver, the screwdriver operatively engages the screw and causes the screw to rotate. Further, with electronic components, operatively engage means that one component controls another component by a control signal or current.

[0037] As used herein, the word unitary means a component that 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.

[0038] As used herein, the term number shall mean one or an integer greater than one (i.e., a plurality). That is, for example, the phrase a number of elements means one element or a plurality of elements.

[0039] As used herein, in the phrase [x] moves between its first position and second position, or, [y] is structured to move [x] between its first position and second position, [x] is the name of an element or assembly. Further, when [x] is an element or assembly that moves between a number of positions, the pronoun its means [x], i.e., the named element or assembly that precedes the pronoun its.

[0040] As used herein, about in a phrase such as disposed about [an element, point or axis] or extend about [an element, point or axis] or [X] degrees about an [an element, point or axis], means encircle, extend around, or measured around. When used in reference to a measurement or in a similar manner, about means approximately, i.e., in an approximate range relevant to the measurement as would be understood by one of ordinary skill in the art.

[0041] As used herein, a radial side/surface for a circular or cylindrical body is a side/surface that extends about, or encircles, the center thereof or a height line passing through the center thereof. As used herein, an axial side/surface for a circular or cylindrical body is a side that extends in a plane extending generally perpendicular to a height line passing through the center. That is, generally, for a cylindrical soup can, the radial side/surface is the generally circular sidewall and the axial side(s)/surface(s) are the top and bottom of the soup can.

[0042] As used herein, a product side means the side of a construct used in a container that contacts, or could contact, a product such as, but not limited to, a food or beverage. That is, the product side of the construct is the side of the construct that, eventually, defines the interior of a container.

[0043] As used herein, a customer side means the side of a construct used in a container that does not contact, or could not contact, a product such as, but not limited to, a food or beverage. That is, the customer side of the construct is the side of the construct that, eventually, defines the exterior of a container.

[0044] As used herein, generally curvilinear includes elements having multiple curved portions, combinations of curved portions and planar portions, and a plurality of planar portions or segments disposed at angles relative to each other thereby forming a curve.

[0045] As used herein, generally means in a general manner relevant to the term being modified as would be understood by one of ordinary skill in the art.

[0046] As used herein, substantially means for the most part relevant to the term being modified as would be understood by one of ordinary skill in the art.

[0047] As used herein, at means on and/or near relevant to the term being modified as would be understood by one of ordinary skill in the art.

[0048] As used herein, standard, as used in standard container or standard shell, means a construct used in association with a specific product and which is used by more than one product manufacturer. As noted above, for a product such as soda, pop, and/or beer, many manufacturers use an aluminum twelve fluid ounce container. Thus, such a container, as well as the components therefore (e.g., the shell, can end, and can body), is a standard container, a standard shell, a standard can end, and a standard can body. Standard containers, as well as the components therefore, are well known in the art.

[0049] As used herein, to draw-stretch means that a portion of a metal blank is clamped between forming constructs and pulled therebetween. This action both draws the metal and stretches the metal. As used herein, to draw metal means that the metal is thinned by pulling the metal between two dies that are spaced by a distance thinner than the metal. As used herein, to stretch metal means that the metal is held at a plurality of locations and pulled. This action results in the metal thinning between the held points. Thus, to draw-stretch a blank combines these two actions. Further, as used herein, draw-stretching is not the same as any of drawing, stretching, or ironing the metal. Further, as used herein, clamp(ed) means that a blank is disposed between two forming constructs and a bias is applied to the blank sufficient to prevent the formation of wrinkles but not sufficient to prevent the metal from moving between the forming constructs.

[0050] The following description provides for forming a shell 20, shown in FIG. 2, including an inner portion 24 and an outer portion 26 that are divided by boarder B. The shell 20 is made from a reduced volume of material and having a draw-stretched outer portion 26. That is, as used herein, the outer portion 26 includes a chuck wall 34, a can fit radius 35, a crown radius 36, and a curl 38. As used herein, a chuck wall 34, a draw-stretched can fit radius 35, draw-stretched crown radius 36, draw-stretched curl 38 are thinned via draw-stretch forming, or that collectively all elements, i.e., the outer portion 26 is thinned via draw-stretch forming.

[0051] As is known, the shell 20 is initially a blank 10 (FIG. 3) cut from sheet material 1. The sheet material 1, and therefore the blank 10, have a base thickness. Unless altered by forming operations, as described below, portions of the blank 10 and the shell 20, and therefore the resulting can end (not shown), maintain the base thickness. That is, as shown in FIG. 3, the blank 10 includes a center panel portion 11, a countersink portion 12, a chuck wall portion 14, a can fit radius portion 15, a crown radius portion 16, and a curl portion 18 which, following forming operations, become a center panel 30, a countersink 32, a draw-stretched chuck wall 34, a draw-stretched can fit radius 35, a draw-stretched crown radius 36, and a curl 38, respectively, as discussed below. The draw-stretched chuck wall 34, draw-stretched can fit radius 35, draw-stretched crown radius 36 are, as used herein, collectively identified as the draw-stretched outer portion 26

[0052] Further, the following discussion and the Figures use a generally cylindrical shell 20 as an example. It is understood that the disclosed and claimed concept is operable with shells 20 of any shape and the cylindrical shape discussed and shown is exemplary only. Further, in an exemplary embodiment and for the dimensions described below, the shell is made from aluminum and is structured to be coupled to a beverage can; that is, a can structured to contain a beverage such as beer or carbonated beverages, i.e., a soda or pop. As used herein, such shell is identified as a beverage container shell 20. One non-limiting example of a beverage can having a beverage container shell 20 is a twelve ounce beverage container. The standard volume, as defined above, for a blank 10 and the subsequent beverage container shell 20 is substantially about 0.0546 in.sup.3. As is known, such a standard blank (not shown) was formed into a shell with the following characteristics. One embodiment of a standard volume beverage container shell 20 (FIG. 1) has the following characteristics.

TABLE-US-00001 Volume 0.0546 in.sup.3 Base Thickness 0.0086 in. Structured to Resist a Pressure of 90 psi

[0053] It is understood that shells 20 for other standard containers (none shown) have different characteristics that are well known in the art.

[0054] The blank 10 is formed into a shell 20 including a body 22 with a center panel 30, a countersink 32, a draw-stretched chuck wall 34, a draw-stretched can fit radius 35, a draw-stretched crown radius 36, and/or a draw-stretched curl 38. As used herein, draw-stretched means that the identified element has been draw-stretched so as to be thinner than in the prior art. As the draw-stretched element(s) is/are thinner, the blank 10 requires less metal, i.e., has a reduced volume, relative to the prior art. This solves the problems stated above. Further, a draw-stretched element has a thickness that is thinner than the base thickness of the sheet material and/or the blank 10. Thus, as used herein, a term such as draw-stretched crown radius 36 recites the characteristics such as, but not limited to, thickness of the crown radius and does not recite a product-by-process.

[0055] The inner portion 24, center panel 30 and the countersink 32 have a base thickness that generally corresponds to the sheet material 1 base thickness. The draw-stretched outer portion 26, i.e., the draw-stretched chuck wall 34, the draw-stretched can fit radius 35, the draw-stretched crown radius 36, and/or the draw-stretched curl 38 has/have a reduced thickness or a specific reduced thickness. That is, as used herein, a reduced thickness means that the draw-stretched chuck wall 34, the draw-stretched can fit radius 35, the draw-stretched crown radius 36, and/or the draw-stretched curl 38 have a thickness that is between about 5% to about 21% thinner than the base gauge. As used herein, a specific reduced thickness means that the draw-stretched chuck wall 34, draw-stretched can fit radius 35, the draw-stretched crown radius 36, and/or the draw-stretched curl 38 have a thickness that is about 11% thinner than the base gauge. As used herein, a shell 20 that includes the draw-stretched chuck wall 34, the draw-stretched can fit radius 35, the draw-stretched crown radius 36, and/or the draw-stretched curl 38 is made from a reduced volume of material but maintains the buckle resistant characteristics of a standard shell. That is, a beverage container shell 20 made from a reduced volume of material and which includes a draw-stretched outer portion 26 has the following characteristics:

TABLE-US-00002 Volume 0.0533 in.sup.3 Base Thickness 0.0086 in. Structured to Resist a Pressure of 90 psi

[0056] Further, a beverage container shell 20 according to this disclosure is shown in FIG. 17A which shows the percentage decrease in the thickness of the metal (relative to base thickness) at the draw-stretched chuck wall 34, the can fit radius 35, the draw-stretched crown radius 36, and the curl 38, e.g., the outer portion 26. In this embodiment, the volume of metal in the draw-stretched crown radius 36 is reduced (relative to a standard volume container shell) between about 5% to about 20%, or about 11%. Stated alternately, in a reduced volume shell 20 (or reduced volume shell body 22), the draw-stretched chuck wall 34, the can fit radius 35, the draw-stretched crown radius 36, and the curl 38, have a reduced profile. That is, as used herein, a reduced profile means that the thickness of the metal relative to base thickness at the draw-stretched chuck wall 34, the can fit radius 35, the draw-stretched crown radius 36, and the curl 38 is reduced as described in the next sentence. The thickness of the metal relative to base thickness at the draw-stretched chuck wall 34 is reduced about 8.9% and 13.2%, the can fit radius 35 is reduced between about 13.2% to about 8.9%, the thickness of the metal relative to base thickness at the draw-stretched crown radius 36 is reduced between about 8.9% and about 13.2%, and the thickness of the metal relative the base thickness at the curl 38 is reduced between about 4.9% and about 10.3%.

[0057] Further, a shell 20 made from a reduced volume of material and which includes the draw-stretched chuck wall 34, the draw-stretched can fit radius 35, the draw-stretched crown radius 36, the draw-stretched curl 38, and/or a draw-stretched solves the problems stated above. As used herein, a reduced volume of material for the shell 20 is measured relative to a standard shell and means that volume of the blank 10/shell 20 is between about 2% to about 4% less, or about 2.4% less, than the volume of a blank for a similar blank/shell (i.e., a blank/shell structured to be coupled to the same size can body) that does not have a draw-stretched chuck wall 34, a draw-stretched can fit radius 35, a draw-stretched crown radius 36, and/or a draw-stretched curl 38. Further, such a blank 10, or such a shell 20, is, as used herein, a reduced volume blank 10 or a reduced volume shell 20.

[0058] In another exemplary embodiment, as shown in FIG. 17B, the beverage container shell 20 (or reduced volume shell body 22) has a maximum reduced profile. As used herein, a maximum reduced profile means that the thickness of the metal relative to the base thickness at the draw-stretched chuck wall 34, the draw-stretched can fit radius 35, the draw-stretched crown radius 36, and/or the draw-stretched curl 38 is reduced as shown in FIG. 17B. As shown, the thickness of the metal relative to base thickness at the draw-stretched chuck wall 34 is reduced between about 25% to about 27%, can fit radius 35 is reduced between about 25% to about 27%, the thickness of the metal relative to base thickness at the draw-stretched crown radius 36 is reduced about 27%, and the thickness of the metal relative to the base thickness at the curl 38 is reduced about 25%. Thus, a reduced volume shell 20 (or reduced volume shell body 22) has one of a reduced profile or a maximum reduced profile.

[0059] For example, for a beverage container shell 20 the shell body 22 is aluminum, the countersink 32 has a general thickness of between about 0.0082 inch and about 0.0106 inch or about 0.0086 inch. The draw-stretched chuck wall 34 has a general thickness of between about between about 0.0056 inch and about 0.0090 inch or about 0.0086 inch. The draw-stretched can fit radius 35 has a thickness of between about 0.0056 inch or about 0.0090 inch, or about 0.0078 inch. The draw-stretched crown radius 36 has a general thickness of between about 0.0056 inch and about 0.0090 inch or about 0.0078 inch. The draw-stretched curl 38 has a thickness of between about 0.0060 inch or about 0.0094 inch, or about 0.0082 inch. As used herein, the general thickness means the thickness of the material measured along a line generally perpendicular to the surface of the identified portion of the shell 20 at a specific location. Thus, for example, the general thickness of the countersink 32 does not mean the width of the countersink 32. Such a beverage container shell 20 has, generally, the same dimensions as a standard beverage shell and, as such, the beverage container shell 20 is structured to be processed in a manner substantially similar to a standard beverage shell. That is, the beverage container shell 20 does not require the use of new processing equipment and, as such, solves the problems stated above. Further, the beverage container shell 20 is structured to be coupled to a beverage can body (not shown) and is structured to have a standard can end buckle resistance.

[0060] As another example, a shell for a steel container (not shown), such as, but not limited to an 18.6 ounce soup container, includes a steel shell body 22 formed from a steel sheet material with a base thickness of about 0.0079 inch. A shell 20 for such a container includes a countersink 32 that has a general thickness of between about 0.0088 inch and about 0.0075 inch, or about 0.0079 inch. Further, in this embodiment, the draw-stretched elements further include the draw-stretched chuck wall 34, the draw-stretched can fit radius 35, the draw-stretched crown radius 36, and/or the draw-stretched curl 38. For such a steel shell 20, the draw-stretched chuck wall 34 has a general thickness of between about 0.0056 inch and about 0.0084 inch, or about 0.0072 inch, the draw-stretched can fit radius 35 has a thickness of between about 0.0056 inch or about 0.0084 inch, or about 0.0072 inch. The draw-stretched crown radius 36 has a general thickness of between about 0.0056 inch and about 0.0084 inch or about 0.0072 inch. The draw-stretched curl 38 has a thickness of between about 0.0060 inch or about 0.0088 inch, or about 0.0076 inch. It is again noted that the specific reductions in thickness in this paragraph are exemplary and that the specific thickness of a draw-stretched element varies with the original base thickness of the material.

[0061] The shell 20 made from a reduced volume of material and which includes the draw-stretched chuck wall 34, the draw-stretched can fit radius 35, the draw-stretched crown radius 36, and/or the draw-stretched curl 38 is formed in a press assembly (or press) 500, as shown in FIGS. 2-14. In another embodiment, a shell 20 made from a reduced volume of material and which includes the draw-stretched chuck wall 34, the draw-stretched can fit radius 35, and/or the draw-stretched crown radius 36 is formed in a press assembly (or press) 500. That is, compared to the prior embodiment, the draw-stretched curl 38 is not formed in the press 500, but is formed at another station 502 or another press (not shown). Thus, the press 500 is structured to, and does, form a reduced volume shell 20.

[0062] As noted above, in one embodiment, the press 500 includes a single station that both cuts the blank 10 from a sheet material 1 and forms the blank 10 into a shell 20. In another embodiment, the press 500 includes a number of stations 502 (some shown schematically) each of which perform a number of forming operations on the shell 20 (as shown in the Figures, stations are generically identified by reference number 502). For example, in one embodiment, a station 502 cuts a generally circular, disk-like blank 10, which is a reduced volume blank 10, from the sheet material 1. Alternatively, a pre-cut reduced volume blank 10 is fed into the press 500. Thus, the press 500 is structured to, and does, form a shell 20 from a blank 10 wherein the blank 10 is cut from a sheet material 1. Whether the press 500 cuts the blank 10 from the sheet material 1 is not relevant to this disclosure. Further, in one exemplary embodiment, the sheet material 1 has forming operations performed thereon prior to cutting the blank 10 from the sheet material 1, or, prior to forming operations by a first forming station 530, discussed below. Thus, as used herein, the blank 10 is also a shell 20. Accordingly, the following discussion addresses a press 500 acting on either a blank 10 or a shell 20.

[0063] As noted above, the shell 20 is, in one embodiment, formed in a one-stage process. That is, as used herein, a one-stage process means that all forming operations occur at a single station. Stated alternately, for a one-stage process the number of stations 502 includes only a single station, which is identified herein as the first forming station 530.

[0064] In another embodiment, the blank 10, and/or shell 20, moves through the press 500 on a conveyor 504, shown schematically in FIG. 3 that is structured to, and does, move with an intermittent, or indexed, motion. In an exemplary embodiment, the conveyor 504 is a belt 506 (shown schematically) including a number of recesses, not shown. The belt 506 moves a set distance then stops before moving the set distance again. As the belt 506 moves, the blank 10/shell 20 is moved sequentially through the conversion press number of stations 502 where, as noted above, each station 502 performs a single forming operation, or a number of forming operations, on the blank 10/shell 20.

[0065] The press 500 also includes a frame 508 and a drive assembly (not shown) as well as a number of upper tooling assemblies 510 and a number of lower tooling assemblies 520. In an exemplary embodiment, each lower tooling assembly 520 is movably coupled, movably and directly coupled, or fixed to the press frame 508 and is generally stationary. Each upper tooling assembly 510 is structured to, and does, move between a first position, wherein the upper tooling assembly 510 is spaced from the lower tooling assembly 520, and a second position, wherein the upper tooling assembly 510 is closer to, and in an exemplary embodiment, immediately adjacent, the lower tooling assembly 520. As used herein, immediately adjacent means that the upper tooling assembly 510 is spaced from the lower tooling assembly 520 so that the tooling assemblies 510, 520 form, i.e., change the shape of, the blank 10/shell 20. In an exemplary embodiment, each of the upper tooling assembly 510 and a lower tooling assembly 520 for multiple stations 502 are unitary or coupled and support the dies, punches and other elements of each station. In this configuration, the upper tooling assemblies 510 for the stations move at the same time and are driven by a single drive assembly (not shown). Further, and as is known, the upper tooling assembly 510 and the lower tooling assembly 520 include separately movable elements, e.g., punches, dies, spacers, pads, risers and other sub-elements (collectively hereinafter, sub-elements) discussed below, that are structured to, and do, move separately from each other. All elements, however, generally move with the upper tooling assembly 510 between first and second positions. That is, generally, the motions of the sub-elements are relative to each other but as a whole, the upper tooling assembly 510 moves between the first position and the second position as described above. Further, it is understood that the drive assembly includes cams, linkages, and other elements that are structured to move the sub-elements of the upper tooling assembly 510 and the lower tooling assembly 520 in the proper order. That is, selected sub-elements of the upper tooling assembly 510 and the lower tooling assembly 520 are structured to move independently of other selected sub-elements. For example, one selected sub-element is structured to move into, and dwell, at the second position while another sub-element moves into and out of the second position. Such selective motion of the sub-elements is known in the art. For the purpose of this disclosure, only a first forming station 530, or a single forming station 530, is relevant and hereinafter the upper tooling assembly 510 and the lower tooling assembly 520 are identified as the first forming station upper tooling assembly 510 and the first forming station lower tooling assembly 520. The first forming station 530 is structured to, and does, form the shell body 22 to have the center panel 30, the countersink 32, the draw-stretched chuck wall 34, and the draw-stretched crown radius 36, as discussed above. Stated alternately, the first forming station upper tooling assembly 510 and the first forming station lower tooling assembly 520 are structured to, and do, form the shell body 22 to have the center panel 30, the countersink 32, the draw-stretched chuck wall 34, the draw-stretched can fit radius 35, and the draw-stretched crown radius 36. That is, the first forming station upper tooling assembly 510 and the first forming station lower tooling assembly 520 are structured to, and do, form the countersink portion 12 into a countersink 32, the chuck wall portion 14 into the draw-stretched chuck wall 34, the can fit radius portion 15 into the draw-stretched can fit radius 35, and the crown radius portion 16 into the draw-stretched crown radius 36. Thus, the first forming station upper tooling assembly 510 and the first forming station lower tooling assembly 520 are structured to, and do, draw-stretch the chuck wall portion 14/can fit radius portion 15/crown radius portion 16 to create an outer portion 26, or a crown radius 36, with a reduced thickness. Further, the press 500 is structured to form the center panel 30 and the countersink 32, or inner portion 24, while substantially maintaining the base thickness of the sheet material 1. In this configuration, the blank 10/shell 20 with a reduced volume and with a draw-stretched outer portion 26 solves the problems stated above.

[0066] In an exemplary embodiment, the first forming station upper tooling assembly 510 includes a blank & draw die punch 512, an upper piston 514, and a die center punch 516. The forming station upper tooling assembly blank & draw die punch 512 (hereinafter first forming station upper blank & draw die punch 512) includes a generally toroid body 531. The first forming station upper blank & draw die punch body 531 includes an axial surface 532 and an inner radial surface 534. The inner intersection of the first forming station upper blank & draw die punch toroid body axial surface 532 and the first forming station upper blank & draw die punch toroid body inner radial surface 534 is curvilinear and this transition area is, as used herein, the inner radius 536. That is, the term inner radius does not mean the radius that defines the first forming station upper blank & draw die punch toroid body inner radial surface 534. Moreover, in an exemplary embodiment, the first forming station upper blank & draw die punch inner radial surface 536 is a reduced radius (hereinafter, also identified as the first forming station upper blank & draw die punch reduced inner radial surface 536). As used herein, a reduced radius means that the radius is reduced between about 68% and about 88%, or about 80% relative to the radius of a comparable first forming station upper blank & draw die punch inner radial surface structured to make a similar shell.

[0067] FIGS. 5A-15A show an embodiment of the press 500 wherein the first forming station upper tooling assembly 510 includes a die center punch 516A. FIGS. 5B-15B show an embodiment of the press 500 wherein the first forming station upper tooling assembly 510 includes a die center punch 516B. FIG. 15C shows a comparison between the die center punch 516A and the die center punch 516B. The motions of the elements of the first forming station 530 would be understood by one of ordinary skill in the art as shown in FIGS. 5A-15A and 5B-15B.

[0068] Further, in an exemplary embodiment, the first forming station lower tooling assembly 520 includes a lower piston 522 (alternately hereinafter, first forming station lower piston 522), a die core ring 524, and a panel punch 526. The first forming station lower tooling assembly die core ring 524 (hereinafter, the first forming station lower die core ring 524) includes a generally toroid body 540 with and axial surface 542 and an outer radial surface 544. The intersection of the first forming station lower die core ring toroid body axial surface 542 and the first forming station lower die core ring toroid body outer radial surface 544 is curvilinear and this transition area is, as used herein, the outer radius 546; that is, the term outer radius does not mean the radius that defines the first forming station upper blank & draw die punch toroid body outer radial surface 544.

[0069] Moreover, in an exemplary embodiment, the first forming station lower die core ring outer radius 546 is a diminished radius (hereinafter, also identified as the first forming station lower die core ring diminished outer radius 546). As used herein, a diminished radius means that the radius is reduced between about 30% and about 60%, or about 50% relative to the radius of a comparable first forming station lower die core ring radial surface structured to make a similar shell.

[0070] In an exemplary embodiment, wherein the press is structured to form a beverage container shell 20, the first forming station upper blank & draw die punch inner radial surface 536 is about a 0.019 inch radius, and the first forming station lower die core ring outer radius 546 is about a 0.022 inch radius.

[0071] Further, the draw-stretched outer portion 26 is formed by draw-stretching as defined above. Accordingly, the press 500 is structured to, and does, clamp the crown radius portion 16 of the blank 10, as defined above. Thus, when the first forming station upper tooling assembly 510 is in the second position, the first forming station upper blank & draw die punch 512 and the first forming station lower piston 522 apply a force of between about 60 psi and about 250 psi, or about 110 psi, to the blank 10/shell 20. Stated alternately, the pressure relative to the prior art pressure of 50 psi for these components, is increased between about 20% to about 400% or about 200%. Further, the upper piston 514 and the first forming station lower die core ring 524 apply a force of between about 100 psi and about 600 psi, or about 110 psi. Stated alternately, the pressure relative to the prior art pressure of 50 psi for these components is increased between about 100% to about 1100% or about 800%.

[0072] As used herein, the pressure ranges noted in the prior paragraph are a draw-stretching pressure range for the identified components. That is, a force of between about 60 psi and about 250 psi is the draw-stretching pressure range for the first forming station upper blank & draw die punch 512 and the first forming station lower piston 522. The press 500 is structured to, and does, apply the draw-stretching pressure range to each pair of components. Further, the specific pressure noted in the prior paragraph is the draw-stretching pressure for the identified components. The press 500 is structured to, and does, apply the draw-stretching pressure to each pair of components.

[0073] As noted above, the terms blank 10 and the shell 20 are interchangeable; thus, as used herein when discussing the press 500, the terms blank 10 or shell 20 are interchangeable and mean the construct that is being formed.

[0074] It is understood that the combination of the first forming station upper blank & draw die punch reduced inner radial surface 536, the first forming station lower die core ring diminished outer radius 546, and the increased pressure of the first forming station upper blank & draw die punch 512 and the first forming station lower piston 522 that are structured to, and do, form the draw-stretched outer portion 26 and solve the problems stated above.

[0075] As shown in FIG. 16, a method of forming the shell 20 with a draw-stretched outer portion 26 includes providing 1000 a sheet material 1, the sheet material 1 having a base thickness, cutting 1002 a blank 10 from the sheet material 1, the blank 10 including a countersink portion 12, a chuck wall portion 14, and a crown radius portion 16, providing 1004 a press assembly 500 including a frame 508, a number of press stations 502 including a first forming station 530, the first forming station 530 including an upper tooling assembly 510 and a lower tooling assembly 520, the first forming station upper tooling assembly 510 structured to move between an upper, first position, wherein the first forming station upper tooling assembly 510 is spaced from the first forming station lower tooling assembly 520, and a lower, second position, wherein the first forming station upper tooling assembly 510 is immediately adjacent the first forming station lower tooling assembly 520, wherein when the first forming station upper tooling assembly 510 and the first forming station lower tooling assembly 520 are in the second position, the first forming station upper tooling assembly 510 and the first forming station lower tooling assembly 520 are structured to form a shell body 22 including a center panel 30, a countersink 32, a chuck wall 34, a can fit radius 35, a crown radius 36, and a curl 38, disposing 1006 the blank between the first forming station upper tooling assembly 510 and the first forming station lower tooling assembly 520, clamping 1008 any of the can fit radius portion 15, the crown radius portion 16, and the curl portion 18 between the first forming station upper tooling assembly 510 and the first forming station lower tooling assembly 520, and performing 1010 forming operations. Performing 1010 forming operations includes draw-stretching 1020 any, or all, of the chuck wall portion 14, can fit radius portion 15, the crown radius portion 16, the curl portion 18, and/or the outer portion 26 to form any of a draw-stretched chuck wall 34, draw-stretched can fit radius 35, a draw-stretched crown radius 36, and/or a draw-stretched curl 38 (or a draw-stretch outer portion 26), and forming 1022 the countersink portion 12 into a counter sink 32. As described above, following the formation 1022 of the counter sink 32, the center panel 30 has a thickness corresponding to the blank 10 which, in turn, has a thickness corresponding to the sheet material 1.

[0076] Further providing 1004 a press assembly 500 includes providing 1030 a first forming station upper tooling assembly 510 that includes a blank & draw die punch 512, an upper piston 514, and a die center punch 516, providing 1032 a first forming station lower tooling assembly 520 that includes a lower piston 522, a die core ring 524, and a panel punch 526, wherein the first forming station upper blank & draw die punch 512 includes an inner radial surface 536, wherein the first forming station upper blank & draw die punch inner radial surface 536 is a reduced radius, wherein the first forming station lower die core ring 524 includes an outer radius 546, wherein the first forming station lower die core ring outer radius 546 is a diminished radius. Further, providing 1004 a press assembly 500 includes providing 1034 the first forming station upper blank & draw die punch 512 wherein the inner radial surface 536 is about a 0.019 inch radius, and, providing 1036 the first forming station lower die core ring 524 wherein outer radius 546 is about a 0.022 inch radius.

[0077] Further, draw-stretching 1020 the chuck wall portion 14, can fit radius portion 15, the crown radius portion 16, and/or the curl portion 18 to form a draw-stretched can fit radius 35, a draw-stretched crown radius 36, and/or a draw-stretched curl 38 (or a draw-stretch outer portion 26) includes applying 1040 a force of between about 1,153 lbf and about 3,890 lbf to the blank 10, and/or, applying 1042 a force of about 2,442 lbf to the blank 10.

[0078] In an exemplary embodiment, cutting 1002 a blank 10 from the sheet material 1 includes cutting 1050 a blank 10 with a reduced volume. As noted above, cutting a blank 10 is equivalent to providing a blank; thus, as used herein, cutting 1050 a blank with a reduced volume is the same as providing a blank 10 with a reduced volume. Further, in an exemplary embodiment, performing 1010 forming operations includes forming 1060 the blank 10 into a standard beverage shell 20.

[0079] As noted above, the example used is generally an aluminum standard beverage shell 20. It is understood, however, that the concept disclosed above is also applicable to can ends made of other materials such as, but not limited to, steel and steel alloys. It is further understood that steel cans and can ends are typically made from material with a base thickness thinner than aluminum can ends. Thus, a steel can end that includes the down-gauging concept disclosed herein would have a thinner base thickness than the dimensions for an aluminum can, as described below, and a thinner base thickness than the metal used to make the can ends that do not include the concept disclosed herein.

[0080] 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 invention which is to be given the full breadth of the claims appended and any and all equivalents thereof.