End closure with double anti-missile score

Abstract

An end closure for food and beverage containers provides controlled opening characteristics to prevent the unintentional missiling of a tear panel. The end closure comprises a score line that defines a portion of the tear panel, and the end closure may comprise one or more anti-missile features that inhibit the propagation of a fracture down a score line, which reduces the likelihood that a tear panel will inadvertently detach from the end closure and injure the user or another.

Claims

1. A method of forming a metallic end closure with an anti-missile feature, comprising: providing a blank metallic material; forming an end closure comprising a peripheral curl, a central panel, and a countersink positioned therebetween; forming a first score line on said central panel, wherein said first score line substantially defines a tear panel; providing a tool with at least one shaped feature disposed on a distal end of said tool; pressing said tool into at least one of said central panel and said tear panel such that said at least one shaped feature contacts said at least one of said central panel and said tear panel at a location proximate said first score line to form a first anti-missile feature positioned proximate a second anti-missile feature in said end closure, wherein said first and second anti-missile features have a shallower depth than said first score line, and wherein said first anti-missile feature and said second anti-missile feature are disposed on said tear panel and oriented substantially parallel to each other; and interconnecting a pull tab to said central panel of said end closure, wherein a nose of said pull tab is positioned over said tear panel to facilitate opening of said end closure when a downward force is applied to said tear panel with said nose of said pull tab.

2. The method of claim 1, further comprising: forming a second score line substantially parallel to said first score line, wherein said second score line has a shallower depth than said first score line.

3. The method of claim 2, wherein said first and second anti-missile features are disposed over said second score line.

4. The method of claim 1, wherein said first and second anti-missile features have longitudinal axes which are oriented at an acute angle relative to said first score line.

5. The method of claim 4, wherein said angle is between approximately 15 and 60 degrees.

6. The method of claim 1, wherein said first and second anti-missile features have a shape of at least one of a rectangle, a circle, an ovoid, a polygonal, a trapezium, and an arc shape.

7. A method of forming a metallic end closure with an anti-missile feature, comprising: providing a blank metallic material; forming an end closure comprising a peripheral curl, a central panel, and a countersink positioned therebetween; forming a first score line on said central panel, wherein said first score line substantially defines a tear panel, and said first score line comprises a check slot having a first end and a second end; providing a tool with at least one shaped feature disposed on a distal end of said tool; pressing said tool into at least one of said central panel and said tear panel such that said at least one shaped feature contacts said at least one of said central panel and said tear panel at a location proximate to said first score line to form a first anti-missile feature positioned proximate a second anti-missile feature in said end closure, and wherein an end of said first anti-missile feature is positioned proximate to said check slot between said ends of said check slot, and an end of said second anti-missile feature is positioned proximate to said check slot between said ends of said check slot; and interconnecting a pull tab to said central panel of said end closure, wherein a nose of said pull tab is positioned over said tear panel to facilitate opening of said end closure when a downward force is applied to said tear panel with said nose of said pull tab.

8. The method of claim 7, further comprising: forming a second score line substantially parallel to said first score line, wherein said second score line has a shallower depth than said first score line.

9. The method of claim 8, wherein said first and second anti-missile features are disposed over said second score line.

10. The method of claim 7, wherein said first and second anti-missile features have longitudinal axes which are oriented at an acute angle relative to said first score line.

11. The method of claim 10, wherein said angle is between approximately 15 and 60 degrees.

12. The method of claim 7, wherein said first and second anti-missile features have a shape of at least one of a rectangle, a circle, an ovoid, a polygonal, a trapezium, and an arc shape.

13. The method of claim 7, wherein said first and second anti-missile features are disposed on the tear panel side of said first score line.

14. The method of claim 7, wherein said first and second anti-missile features have a shallower depth than said first score line.

15. A method of forming a metallic end closure with anti-missile features, comprising: providing a blank metallic material; forming an end closure comprising a peripheral curl, a central panel, and a countersink positioned therebetween; forming a first score line on said central panel, wherein said first score line substantially defines a tear panel; providing a tool with a first shaped feature and a second shaped feature disposed on a distal end of said tool, wherein an end of said first shaped feature is offset from an end of said second shaped feature by a first offset distance, and a longitudinal axis of said first shaped feature is offset from a longitudinal axis of said second shaped feature by a second offset distance; pressing said tool into at least one of said central panel and said tear panel such that said first shaped feature forms a first anti-missile feature and said second shaped feature forms a second anti-missile feature in said end closure; and interconnecting a pull tab to said central panel of said end closure, wherein a nose of said pull tab is positioned over said tear panel to facilitate opening of said end closure when a downward force is applied to said tear panel with said nose of said pull tab.

16. The method of claim 15, wherein said first offset distance is between approximately 0.026 and 0.022 inches.

17. The method of claim 15, wherein said second offset distance is approximately 0.029 inches.

18. The method of claim 15, wherein a direction of said second offset distance is substantially perpendicular to a direction of said first offset distance.

19. The method of claim 15, wherein said first and second anti-missile features have a shallower depth than said first score line.

20. The method of claim 15, wherein said first and second anti-missile features are disposed on the tear panel side of said first score line.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Those of skill in the art will recognize that the following description is merely illustrative of the principles of the present invention, which may be applied in various ways to provide many different alternative embodiments. This description is made for illustrating the general principles of the teachings of this invention and is not meant to limit the inventive concepts disclosed herein.

(2) The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of the invention.

(3) FIG. 1 is a top plan view of one embodiment of an end closure with anti-missile features;

(4) FIG. 2 is an enlarged top plan view of the anti-missile features shown in FIG. 1;

(5) FIG. 3 is a top plan view of an alternative embodiment of an end closure with a dimple-shaped anti-missile feature;

(6) FIG. 4 is a top plan view of an alternative embodiment of an end closure with a trapezium-shaped anti-missile feature;

(7) FIG. 5 is a top plan view of an alternative embodiment of an end closure with a U-shaped anti-missile feature;

(8) FIG. 6A is a top plan view of an alternative embodiment of an end closure with a single, wide anti-missile feature;

(9) FIG. 6B is another top plan view of the embodiment shown in FIG. 6A where reference lines C, D, and E are visible;

(10) FIG. 6C is a cross-sectional elevation view of the embodiment shown in FIG. 6B taken at line C-C;

(11) FIG. 6D is a cross-sectional elevation view of the embodiment shown in FIG. 6B taken at line D-D;

(12) FIG. 6E is a cross-sectional elevation view of the embodiment shown in FIG. 6B taken at line E-E;

(13) FIG. 7 is an isometric view of an embodiment of an insert tool;

(14) FIG. 8 is front elevation view of the insert tool of FIG. 7;

(15) FIG. 9 is a side elevation view of the insert tool of FIG. 7; and

(16) FIG. 10 is an enlarged side elevation view showing shaped features of the insert tool of FIG. 7.

(17) To assist in the understanding of the embodiments of the present invention the following list of components and associated numbering found in the drawings is provided herein:

(18) TABLE-US-00001 Number Component 96 Container Body 100 End Closure 104 Central Panel 108 Panel Radius 112 Peripheral Curl 116 Countersink 120 Rivet 124 Deboss Area 128 Main Score 130 Main Score Depth 132 Anti-Fracture Score 134 Anti-Fracture Score Depth 136 Score Loop 140 Pour Opening 144 Check Slot 145 First Check Slot End 146 Second Check Slot End 148 First Anti-Missile 149 First Anti-Missile Length 150 Missile-Fracture Intersection 151 First Anti-Missile Depth 152 Second Anti-Missile 156 Main Score Residual 160 Anti-Fracture Score Residual 200 Insert Tool 204 Body 208 First End 212 Second End 216 Flange 220 First Shaped Feature 224 Second Shaped Feature 228 Body Outer Diameter 232 Flange Outer Diameter 236 Flat Side Dimension 238 Shaped Feature Width 240 First Horizontal Offset 244 Second Horizontal Offset 248 Overall Length 252 Flange Length 256 Shaped Feature Length 260 First Body Radius 264 Second Body Radius 268 Shaped Feature Height 272 Angle 276 First Transition 280 Second Transition 284 First Centerline 288 Second Centerline 292 First Transition Distance 296 Second Transition Distance

(19) It should be understood that the drawings are not necessarily to scale, and various dimensions may be altered. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

(20) Those of skill in the art will recognize that the following description is merely illustrative of the principles of the disclosure, which may be applied in various ways to provide many different alternative embodiments. This description is made for illustrating the general principles of the teachings of this disclosure invention and is not meant to limit the inventive concepts disclosed herein.

(21) The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosure and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosures.

(22) It should be understood that the drawings are not necessarily to scale, and various dimensions may be altered. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

(23) FIG. 1 shows a top plan view of the public side of an end closure 100 which is interconnected to the neck of container body 96. The end closure 100 in this embodiment generally comprises a central panel 104 that represents the central area of the end closure 100 in FIG. 1. A panel radius 108 defines the outer edge of the central panel 104. Moving outward from the panel radius 108 is a countersink 116 that leads from the central panel 104 to a chuckwall, which is interconnected to peripheral curl 112, and the peripheral curl 112 allows for interconnection to the container body 96. The central panel 104, the panel radius 108, the countersink 116, the chuckwall, and the peripheral curl 112 are generally circular in shape as depicted in FIG. 1. One skilled in the art will appreciate that any one of these features may have general modifications in shape or dimensions without deviating from the scope of the invention.

(24) Also shown in FIG. 1 are two lines that pass through the center of a rivet 120, wherein the two lines may be used to reference the location of other features disposed on the end closure 100. One line passes vertically through the rivet 120, and one line passes horizontally through the rivet 120. These lines provide reference to planes that pass through the longitudinal axis of the container 96. In this embodiment, the rivet 120 is centered on the end closure 100, but in other embodiments, the rivet 120 may be off center and the reference lines will not necessarily partition the enclosure 100 into halves.

(25) The rivet 120 provides a location for a pull tab (not shown) to be disposed. A user may engage the rear portion of the pull tab to provide a force on the nose portion to a tear panel defined by a main score 128. As the user continues to engage and pivot the pull tab, the main score 128 fractures and the tear panel is disposed into the container 96 to define a pour opening 140. In FIG. 1, the tear panel is located proximate the rivet 120 and is defined by two score lines. The outer score line is the main score 128, and the inner score line is the anti-fracture score 132. Typically, the anti-fracture score 132 has a shallower depth than the main score 128. In other words, the anti-fracture score 132 has a larger score residual, or larger amount of material underneath the score, than the main score 128. The anti-fracture score 132 is located proximate to the main score 128 to relieve stress areas around the main score 132 and prevent accidental opening of the main score 128.

(26) The two score lines 128, 132 may join together at a score loop 136, which is located proximate to the rivet 120. In the embodiment depicted in FIG. 1, the score loop 136 is located to the lower left of the rivet 120, and the score loop 136 is where the end closure 100 begins to fracture as a user engages the pull tab. As the user continues to engage and pivot the pull tab, the fracture propagates down the main score 128, defining the tear panel. As the main score 128 continues to fracture around the perimeter of the tear panel, the main score 128 may simply terminate at a location proximate to the score loop 136 such that a small portion of the end closure 100 does not fracture, and thus the tear panel that passes through the pour opening 140 remains attached to the end closure 100 via a hinge. One skilled in the art will appreciate a variety of configurations of the terminus of the main score 128 including, but not limited to, a second score loop.

(27) In the embodiment shown in FIG. 1, the rivet 120, the score lines 128, 132, and the pour opening 140 are disposed on a deboss area 124, which is an area of the central panel 104 that is slightly depressed or lower than the rest of the central panel 104. The deboss area 124 aids in the prevention of interference with the pull tab during production, storage, or stacking of the containers 96, where such interference may lead to accidental opening of the container 96. One skilled in the art will appreciate a deboss area 124 of varying depths, sizes, shapes, and locations, or end closure which are void of a deboss area 124.

(28) As mentioned above, complications can arise during opening of the end closure 100 such as rapid fracture of the main score 128 that results in the tear panel becoming a missile or inadvertently detached. One feature that aids in mitigation of this problem is the check slot 144. The check slot 144 in FIG. 1 is located on the main score 128 on the opposite side of the rivet 120 from the score loop 136. Typically, the check slot 144 is cut to a shallower depth than the main score 128. In other words, the check slot 144 has a larger score residual. The purpose of the check slot 144 is to inhibit propagation of the fracture along the main score 128. The fracture begins in the score loop 136, then travels to the check slot 144 where the fracture is temporarily stopped or slowed down. This configuration allows the pressure inside the container 96 to equalize with the pressure of the atmosphere before the fracture continues to propagate past the check slot 144. One skilled in the art will appreciate check slots 144 of varying depths, lengths, and locations that may prove advantageous.

(29) Also disposed on the central panel 104 are a first anti-missile feature 148 and a second anti-missile feature 152. The anti-missile features 148, 152 push material of the central panel towards the main score 128, which deforms a portion of the main score 128. In some embodiments this deformation is the pinching together of the two sides of the main score 128. When the two sides of the main score 128 are pinched, the propagation of the fracture is inhibited, temporarily stopped, or otherwise impeded. In some embodiments, the anti-missile features 148, 152 allow for the reduction in size of the check slot 144, and in some embodiments the anti-missile features 148, 152 allow for the complete elimination of the check slot 144.

(30) FIG. 2 depicts a top plan view of the end closure 100 shown in FIG. 1, and wherein the anti-missile features 148, 152 are enlarged for clarity. In this embodiment, the anti-missile features 148, 152 are both oriented at an angle of approximately 45 degrees from a horizontal plane. The second anti-missile feature 152 is offset from the first anti-missile feature 148 by approximately 0.026 inches in the horizontal direction, and approximately 0.030 inches in the vertical direction. The anti-missile features 148, 152 are disposed proximate the check slot 144 portion of the main score 128. The inclusion of the second anti-missile feature 152 provides a second location of deformation or distortion of the material of the main score 128. Further, there is deformation or distortion of the material along the main score 128 between the first anti-missile feature 148 and the second anti-missile feature 152.

(31) One skilled in the art will appreciate various angles and configurations of anti-missile features 148, 152 that provide various benefits. In some embodiments, anti-missile features 148, 152 are disposed on either side of the main score 128 at a common point on the main score 128. If the anti-missile features 148, 152 are oriented substantially perpendicular to the main score 128, then the main score 128 is deformed from both sides instead of only one side. This anti-missile configuration results in a more thorough deformation of the end closure 100 and the main score 128. In some embodiments, the deformation is a more complete and robust deformation or distortion of the two sides of the main score 128. Therefore, as the fracture propagates down the main score 128 the fracture will more abruptly slow down before resuming down the main score 128. This produces a different feel for the user and a different venting response for the end closure 100, all while reducing the risk of the tear panel turning into a missile.

(32) In a further embodiment, the anti-missile features are substantially parallel to the main score 128. This exposes a greater length of the main score 128 to the deformations in the end closure 100 produced by the anti-missile features 148, 152. In this parallel orientation, anti-missile features 148, 152 may be disposed in series along the main score 128. This configuration will produce a deformation that has a less pronounced effect on the main score 128 but affects a greater length of the score 128. Therefore, this configuration will provide a smoother feel to the user as he or she opens the container and will provide a different venting response for the end closure 100, again, all while reducing the risk of the tear panel turning into a projectile or missile.

(33) In other embodiments, two anti-missile features 148, 152 are substantially parallel with one feature disposed on each side of the main score 128 at a common location on the main score 128. This configuration will produce a more robust deformation of the main score 128 since the anti-missile features 148, 152 are disposed on either side, and the deformation is along a length of the main score 128. As mentioned above, this provides a different feel to the user and a different venting response.

(34) Further, the anti-missile features 148, 152 need not be disposed proximate to a common point on the main score 128. Other embodiments of the present invention have anti-missile features 148, 152 that are disposed on either side of the main score 128 but at different locations along the main score 128. Depending on the offset between the anti-missile features 148, 152, the deformation of the end closure 100 and the resulting effect may be a twisting or similar distortion of the main score 128, which provides yet another feel for the user and a difference in performance of the end closure 100.

(35) Embodiments of the present invention may comprise any number of anti-missile features. Some embodiments of the present invention utilize one anti-missile feature, while other embodiments utilize two or more anti-missile features. In the embodiment where the two anti-missile features 148, 152 are disposed on either side of the main score 128, substantially perpendicular to the main score 128, and located at a common point on the main score 128; a series of these pairs of anti-missile features may be disposed along the length of the main score 128 to provide a series of abrupt slow-downs in the propagation of the fracture along the main score 128. Alternatively, some embodiments may have asymmetric combinations of anti-missile features 148, 152 wherein the anti-missile features 148, 152 are disposed on either side of the main score 128 but never at a common location on the main score 128. This configuration of the main score 128 may provide a deformation that is a twisting or distortion of the main score 128 that produces a particular effect on the propagation of the main score 128.

(36) In some embodiments, the shape of the main score 128 drives the location, shape, orientation, and number of anti-missile features 148, 152. When viewed in cross-section, the main score 128 may be shaped as a V or a U. Further, the main score 128 may have a bottom surface that is substantially perpendicular to the two side walls of the main score 128. The main score 128 may have any number of profiles that are commonly known in the art. The profiles that have a large distance between the two sides may necessitate a more aggressive or robust anti-missile 148, 152 configuration. Whereas a narrow V with relatively close sides may require a less aggressive or robust anti-missile 148, 152 configuration.

(37) FIGS. 3-6E show examples of the various shapes of the anti-missile features 148, 152. These are only exemplary in nature and are not meant to be limiting. The various shapes provide different deformations or distortions to the main score 128, and thus varying opening characteristics of the end closure 100. FIG. 3 shows a top plan view of an end closure 100 where the first anti-missile feature 148 is circular or dimple-shaped. In this embodiment, the first anti-missile feature 148 pushes material radially from the center of the first anti-missile feature 148. This allows for a greater length of the main score 128 to be deformed or distorted.

(38) FIG. 4 shows a top plan view of an end closure 100 where the first anti-missile feature 148 is trapezium-shaped. In other words, the first anti-missile feature 148 has four sides, and no two sides are parallel. The side of the first anti-missile feature 148 proximate the main score 128 is substantially parallel to the main score 128. This allows the first anti-missile feature 148 to deform or distort as much of the main score 128 as possible while retaining a similar angle from horizontal as the first anti-missile feature 148 depicted in FIG. 2. Further, the trapezium shape of the first anti-missile feature 148 allows for a greater area of the central panel 104 to be pushed toward the main score 128, which provides a more through deformation or distortion of the main score 128.

(39) FIG. 5 shows a top plan view of an end closure 100 where the first anti-missile feature 148 has an arcuate shape and wherein the ends of the legs of the U are pointing away from the main score 128. This orientation of the U allows a greater portion of the first anti-missile feature 148 to be located proximate the main score 128. In turn, a greater portion of the main score 128 is deformed or distorted, and the propagation of the fracture during opening of the end closure 100 is slowed down or temporarily stopped. The two legs of the first anti-missile feature 148 in FIG. 5 are not substantially parallel. Rather, the two legs are offset at an angle from a plane that traverses the anti-missile feature 148 in the longitudinal direction. One skilled in the art will appreciate other embodiments of the present invention that have an offset angle between approximately 180 degrees and approximately 15 degrees.

(40) FIG. 6A shows a top plan view of an end closure 100 that has a relatively wide first anti-missile feature 148. In this embodiment, the width of the first anti-missile feature 148 is approximately twice the width of the first anti-missile feature 148 depicted in FIG. 2. The double width means there is twice as much area of the central panel 104 that is being pushed. This allows for a more thorough deformation or distortion of the main score 128, which results in a slow down or temporary stop in the propagation of the fracture of the main score 128.

(41) FIG. 6B shows an enlarged plan view of the end closure 100 of FIG. 6A including a first check slot end 145 that is disposed proximate the rivet 120 and a second check slot end 146 that is disposed on the end of the check slot 144 opposite the first check slot end 145. Also shown in FIG. 6B is reference line C-C, reference line D-D, and reference line E-E. Reference line C-C traverses the longitudinal length of the first anti-missile feature 148 and is perpendicular to the central panel 104. reference line D-D traverses the lateral dimension of the first anti-missile feature 148 at the end of the first anti-missile feature 148 that is proximate the anti-fracture score 132. Reference line D-D is also oriented perpendicular to the central panel 104. Reference line E-E is substantially perpendicular to the main score 128 and the anti-fracture score 132, and the reference line E-E is oriented perpendicular to the central panel 104.

(42) FIG. 6C shows a cross-sectional view of the end closure 100 at reference line C-C. In the background of this view is the rivet 120. The anti-fracture score 132 intersects the first anti-missile feature 148 at the missile-fracture intersection 150, and the anti-fracture score 132 continues to travel to the left in FIG. 6C as shown by a dashed line. Similarly the check slot 144 is shown on the right side of FIG. 6C. Traveling leftward, the check slot 144 terminates at the first check slot end 145. The main score 128 continues to travel to the left of the check slot 144 in FIG. 6C as shown by a dashed line.

(43) Finally, the first anti-missile feature 148 is shown in FIG. 6C, which is disposed across the anti-fracture score 132 but not the main score 128. The first anti-missile feature 148 has a first anti-missile feature length 149, which is 0.1 inches in this embodiment.

(44) FIG. 6D shows a cross-sectional view of the end closure 100 at reference line D-D. The main score 128 is disposed on the left side of FIG. 6D, and the main score 128 has a main score depth 130. In this embodiment, the main score depth 130 is approximately 0.0045 inches. Next, FIG. 6D shows a view down the longitudinal direction of the first anti-missile feature 148. The first anti-missile feature 148 has a first anti-missile depth 151. In preferred embodiments, the first anti-missile depth 151 is between approximately 0.0070 inches and 0.0010 inches. In more preferred embodiments, the first anti-missile depth 151 is between approximately 0.0030 inches and 0.0050 inches. In a most preferred embodiment, the first anti-missile feature depth 151 is approximately 0.0040 inches. Therefore, the anti-missile features, such as the first anti-missile feature 148, can have a shallower depth than the main score 128. Lastly, the anti-fracture score 132 is disposed to the right of the first anti-missile feature 148 in FIG. 6. The anti-fracture score 132 has an anti-fracture score depth 134, which is approximately 0.0035 inches in this embodiment of the present invention.

(45) FIG. 6E shows a cross-sectional view of the main score 128 and the anti-fracture score 132 at reference line E-E. From this view, the anti-fracture score 132 is located on the left and the main score 128 is located on the right. The top side of the end closure is the public side of the container and the bottom side of the end closure is the content side of the container. An anti-fracture score residual 160 is measured from the bottom of the end closure to the bottom of the anti-fracture score 132. Likewise, a main score residual 156 is measured from the bottom of the end closure to the bottom of the main score 128. Thus, while the anti-fracture score 132 has a shallower depth than the main score 128, the anti-fracture score residual 160 is larger than the main score residual 156 by approximately 0.002 inches.

(46) FIG. 7 shows an isometric front perspective view of an insert tool 200 used to make an anti-missile feature. In one embodiment, the insert tool 200 has a cylinder-shaped body 204 with a first end 208 and a second end 212. The first end 208 comprises a flange 216 such that the insert tool 200 may be secured during the manufacturing process of the anti-missile features. The flange 216 in this embodiment is shaped like a flat cylinder. The second end 212 of the insert tool 200 comprises a first shaped feature 220 and a second shaped feature 224. The shaped features 220, 224 are what form the anti-missile features, and the shaped feature 220, 224 may be configured to generate any anti-missile features described elsewhere herein.

(47) FIG. 8 shows a front elevation view of the insert tool 200 where the working end of the insert tool is visible. In this embodiment, an outer diameter 228 of the body 204 is between approximately 0.1700 and 0.1698 inches, with a position tolerance of approximately 0.0004 inches. An outer diameter 232 of the flange 216 is approximately 0.25 inches with a position tolerance of approximately 0.1 inches. Further, the outer diameter 232 of the flange 216 has a flat side. The flat side dimension 236 can be referenced from a central plane of the flange 216. In this embodiment, the flat side dimension 236 is between approximately 0.0853 and 0.0855 inches.

(48) FIG. 8 also shows the two shaped features 220, 224, which are substantially the same size in this embodiment. The shaped features 220, 224 have a rectangular shape in FIG. 8, where the longer, width dimension 238 of the shaped features 220, 224 is between approximately 0.101 and 0.099 inches. Further, this longer dimension is substantially parallel with the flat side of the flange 216.

(49) The shaped features' 220, 224 horizontal position, as shown in FIG. 8, can be expressed in terms of offset from a vertical plane through the center of the body 204. The first horizontal offset 240 is measured from the left edge of the first shaped feature 220 to the vertical plane. In this embodiment, the first horizontal offset 240 is between approximately 0.027 and 0.025 inches. The second horizontal offset 244 is measured from the left edge of the second shaped feature 224 to the vertical plane. In this embodiment, the second horizontal offset 244 is between approximately 0.051 and 0.049 inches.

(50) FIG. 9 shows a side elevation view of the insert tool 200. The insert tool 200 has an overall length 248 measured from the top of the flange 216 down to the working edge of the shaped features 220, 224. In this embodiment, the overall length 248 is approximately 0.688 inches. The flange 216 also has a length 252 in FIG. 9, which is between approximately 0.065 and 0.063 inches. Finally, the shaped features 220, 224 have a length 256 measured from the end of the tool body 204 to the tip of the shaped features 220, 224. The shaped feature length 256 is between approximately 0.0095 and 0.0085 inches.

(51) Also shown in FIG. 9 are two radiuses of the body 204 of the tool insert 200. The first radius 260 of the body 204 extends from the body 204 at the first end 208 and blends into the bottom surface of the flange 216. The first body radius 260 in this embodiment has a radius of curvature of approximately 0.03 inches. The second radius 264 of the body 204 is a radiused edge located at the second end 212 of the body 204. The second radius 264 in this embodiment has a radius of curvature of approximately 0.005 inches.

(52) The surface of the flange 216 in this embodiment comprises a burrless etch to remove any leftover burrs from previous manufacturing. In other embodiments of the present invention, the flange 216 does not comprise a burrless etch. In further embodiments, other components of the insert tool 200 may also comprise a burrless etch. One skilled in the art will appreciate which components to apply a burrless etch to in order to enhance the performance of the present invention.

(53) FIG. 10 shows an enlarged detailed view of the second end 212 of the tool insert 200. The detailed view is at a scale of approximately 20:1. FIG. 10 shows the size of the shaped features 220, 224. As shown in FIG. 9, the shaped feature length 256 is between approximately 0.0095 and 0.0085 inches. The shaped features 220, 224 are flat at the end of the shaped feature length 256, and this flat surface may be defined as a shaped feature height 268. In this embodiment, the shaped feature height 268 is between approximately 0.0125 and 0.0115 inches, with a position tolerance of approximately 0.0005 inches.

(54) The shaped features 220, 224 taper from the flat surface to the second end 212 of the body 204 at an angle 272, which is measured between the edge that tapers from the above the shaped features 220, 224 and the edge that tapers from below the shaped features 220, 224. The angle 272 in this embodiment is approximately 50 degrees. Further, there is a first transition 276 between the flat surface and the two edges that taper away from the flat surface. In this embodiment, the first transition 276 is a radiused edge that has a radius of curvature between approximately 0.003 and 0.001 inches. There is also a second transition 280 between the two edges that taper away from the flat surface and the second end 212 of the body 204. In this embodiment, the second transition 280 is a radiused edge that has a radius of curvature between approximately 0.003 and 0.001 inches.

(55) FIG. 10 also shows the positions of the shaped features 220, 224 expressed in terms of offset from a horizontal plane through the center of the body 204. The first shaped feature 220 has a first centerline dimension 284 between the centerline of the first shaped feature 220 and the horizontal plane. In this embodiment, the first centerline dimension 284 is approximately 0.033 inches. Likewise, the second shaped feature 224 has a second centerline dimension 288 between the centerline of the second shaped feature 224 and the horizontal plane. In this embodiment, the second centerline dimension 288 is approximately 0.062 inches.

(56) The positions of the shaped features 220, 224 may also be expressed in terms of the first transitions 276. The distance between the uppermost first transition 276 of the first shaped feature 220 and the horizontal plane may be identified as the first transition distance 292, which is 0.0264 inches in this embodiment. Similarly, the distance between the uppermost first transition 276 of the second shaped feature 224 and the horizontal plane may be identified as the second transition distance 296, which is approximately 0.0554 inches in this embodiment. As mentioned above, the dimensions of the shaped features 220, 224, and the spatial relationship among shaped features 220, 224 can vary to produce any of the anti-missile features described herein.

(57) The material of the insert tool 200 in this embodiment is CPM REX M4 tool steel that has been hardened and grinded. The finish of the tool insert 200 is a titanium nitride coating that is 2 microns thick, or 0.00008 inches. When coating the tool insert 200, the temperature must not exceed 800 degrees Fahrenheit. One skilled in the art will appreciate that not all components of the insert tool 200or anynecessarily have to be the above tool steel or titanium nitride coating. Different combinations of materials and coatings will provide different attributes to the insert tool 200 that one skilled in the art may find advantageous.

(58) The phrases at least one, one or more, and and/or, as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions at least one of A, B, and C, at least one of A, B, or C, one or more of A, B, and C, one or more of A, B, or C, and A, B, and/or C means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together. Further, the term anti-missile features as used herein may also refer to a single anti-missile feature or at least one anti-missile feature.

(59) Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification, drawings, and claims are to be understood as being modified in all instances by the term about or approximately.

(60) The term a or an entity, as used herein, refers to one or more of that entity. As such, the terms a (or an), one or more and at least one can be used interchangeably herein.

(61) The use of including, comprising, or having, and variations thereof, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms including, comprising, or having and variations thereof can be used interchangeably herein.

(62) It shall be understood that the term means as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112(f). Accordingly, a claim incorporating the term means shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts, and the equivalents thereof, shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.

(63) The foregoing description of the present invention has been presented for illustration and description purposes. However, the description is not intended to limit the invention to only the forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.

(64) Consequently, variations and modifications commensurate with the above teachings and skill and knowledge of the relevant art are within the scope of the present invention. The embodiments described herein above are further intended to explain best modes of practicing the invention and to enable others skilled in the art to utilize the invention in such a manner, or include other embodiments with various modifications as required by the particular application(s) or use(s) of the present invention. Thus, it is intended that the claims be construed to include alternative embodiments to the extent permitted by the prior art.