END CAP WITH SCORE LINE FOR CONTROLLED FLAP OPENING, AND METHOD AND TOOLING THEREFOR

Abstract

An assembly including an end cap having an end cap body having a rivet opening, a tab having a rivet opening, and a rivet extending through the rivet opening of the end cap body and the rivet opening of the tab, thereby coupling the tab to the end cap body. The end cap further includes a main score line formed in the end cap body and defining a flap. The main score line is configured to be torn along its length in a downstream direction to enable the flap to pivot about a hinge area. The main score line extends from a first side of at least one of the rivet openings to a second side of the at least one of the rivet openings in the downstream direction. A portion of the main score line, located on the second side of the at least one rivet opening, does not intersect a tangent line located at a bottom of the at least one rivet opening, or does not extend upwardly beyond the tangent line by more than 3/1000.

Claims

1. An assembly including an end cap comprising: an end cap body having a rivet opening; a tab having a rivet opening; a rivet extending through the rivet opening of the end cap body and the rivet opening of the tab, thereby coupling the tab to the end cap body; and a main score line formed in the end cap body and defining a flap, wherein the main score line is configured to be torn along its length in a downstream direction to enable the flap to pivot about a hinge area, wherein the main score line extends from a first side of at least one of the rivet openings to a second side of the at least one of the rivet openings in the downstream direction, and wherein a portion of the main score line, located on the second side of the at least one rivet opening, does not intersect a tangent line located at a bottom of the at least one rivet opening, or does not extend upwardly beyond the tangent line by more than 3/1000.

2. The assembly of claim 1 wherein the at least one rivet opening is the rivet opening of the tab, and wherein an entirety of the main score line located in the downstream direction of the tab rivet opening and on the second side of the tab rivet opening does not intersect the tangent line located at the bottom of the tab rivet opening.

3. The assembly of claim 1 wherein the at least one opening is the rivet opening of the tab, and wherein no portion of the main score line located in the downstream direction of the tab rivet opening and on the second side of the tab rivet opening is located above the tangent line.

4. The assembly of claim 1 wherein the at least one opening is the rivet opening of the tab, and wherein an entirety of the portion of the main score line located in the downstream direction of the tab rivet opening and on the second side of the tab rivet opening is located below the tangent line.

5. The assembly of claim 1 wherein the at least one opening is the rivet opening of the end cap.

6. The assembly of claim 5 wherein the portion of the main score line, located on the second side of the end cap rivet opening, does not extend upwardly beyond the tangent line by more than 3/1000.

7. The assembly of claim 5 wherein the portion of the main score line, located on the second side of the end cap rivet opening, does not extend upwardly beyond the tangent line by more than 1/1000.

8. The assembly of claim 1 wherein the main score line is in the shape of a generally closed loop, wherein the loop has a major axis oriented parallel to the tangent line.

9. The assembly of claim 8 wherein the first side and the second side are separated by a line extending through a center of the at least one rivet opening and oriented perpendicular to the major axis.

10. The assembly of claim 1 wherein the main score line is in the shape of a generally closed loop, and wherein the main score line has a first end and a second end that are spaced apart to define the hinge area about which the flap is pivotable when the main score line is torn along its length, wherein the first end and the second end are both located on the first side of the at least one rivet opening, and wherein the at least one rivet opening is circular.

11. The assembly of claim 10 wherein the first end and the second end are both located below the tangent line.

12. The assembly of claim 1 wherein the bottom of the at least one rivet opening is aligned with a center line of the end cap body and at least one of: a) is a location of the at least one rivet opening located closest to the main score line; or b) aligned with the center line that bisects a debossed section of the flap; c) is aligned with the center line that is aligned with a minor axis of the flap; or d) is aligned with the center line that bisects the length of the flap along a major axis thereof.

13. The assembly of claim 1 wherein the first side and the second side of the rivet opening are defined by a line passing through a center of the at least one rivet opening and that at least one of: a) bisects a debossed section of the flap; or b) is aligned with a minor axis of the flap; or c) bisects the length of the flap along a major axis thereof.

14. The assembly of claim 1 wherein an entirety or a majority of the main score line is located on a lower side of the tangent line.

15. The assembly of claim 1 wherein a portion of the main score line, located on the second side of the at least one rivet opening, does not intersect the tangent line, or does not extend upwardly beyond the tangent line by more than 3/1000.

16. The assembly of claim 1 wherein the main score line is configured to be torn along its length in the downstream direction to separate the flap from a remainder of the end cap body and enable the flap to pivot relative to the remainder of the end cap body about a hinge area, the tab has an end positioned adjacent to the flap, wherein the tab is pivotable about the rivet in a direction perpendicular to a plane of the end cap body such that the end of the tab is pressable into the flap to cause the main score line to tear along its length.

17. The assembly of claim 1 further including an anti-fracture score line formed in the end cap body and oriented substantially parallel to the main score line, and wherein the end cap body has a thickness of between about 8/1000 and about 8.5/1000.

18. The assembly of claim 1 wherein the flap has a length, extending in a direction parallel to the tangent line, that is greater than a height extending in a direction perpendicular to the tangent line.

19. The assembly of claim 1 further including a cylindrical container body configured to store a fluid therein, wherein the end cap is coupled to an end of the container body.

20. An assembly including an end cap comprising: an end cap body having a rivet opening; a tab having a rivet opening; a rivet extending through the rivet opening of the end cap body and the rivet opening of the tab, thereby coupling the tab to the end cap body; and a main score line formed in the end cap body and defining a flap, wherein the main score line is configured to be torn along its length in a downstream direction to enable the flap to pivot about a hinge area, wherein the main score line extends from a first side of at least one of the rivet openings to a second side of the at least one of the rivet openings in the downstream direction, and wherein a portion of the main score line, located on the second side of the at least one rivet opening, does not intersect a tangent line of the at least one rivet opening, or does not extend upwardly beyond the tangent line by more than 3/1000, wherein the tangent line is oriented parallel to a major axis of the flap and is positioned adjacent to the main score line relative to the rivet opening.

21. An assembly including an end cap comprising: an end cap body having a rivet opening; and a main score line formed in the end cap body and defining a flap, wherein the main score line is configured to be torn along its length in a downstream direction to enable the flap to pivot about a hinge area, wherein the main score line extends from a first side of the rivet opening to a second side of the rivet opening in the downstream direction, and wherein a portion of the main score line, located on the second side of the rivet opening, does not intersect a tangent line located at a bottom of the rivet opening, or does not extend beyond the tangent line by more than 3/1000.

22. A method for forming an end cap comprising: accessing an end cap body having a rivet opening; and forming a main score line in the end cap body defining a flap, wherein the main score line is configured to be torn along its length in a downstream direction to enable the flap to pivot about a hinge area, wherein the main score line extends from a first side of the rivet opening to a second side of the rivet opening in the downstream direction, and wherein the main score line, located on the second side of the rivet opening, does not intersect a tangent line located at a bottom of the rivet opening, or does not extend upwardly beyond the tangent line by more than 3/1000.

23. A method for forming an end cap comprising: accessing an end cap body having a rivet opening, wherein the end cap body has a main score line formed therein and defining a flap, wherein the main score line is configured to be torn along its length in a downstream direction to enable the flap to pivot about a hinge area; accessing a tab having rivet opening; and passing a rivet through the rivet opening of the end cap body and through the rivet opening of the tab to secure the tab to the end cap body, wherein the main score line is configured to extend from a first side of at least one of the rivet openings to a second side of the at least one of the rivet openings in the downstream direction, wherein a portion of the main score line, located on the second side of the at least one rivet opening, is configured to not intersect a tangent line located at a bottom of the at least one rivet opening, or to not extend upwardly beyond the tangent line by more than 3/1000.

24. The method of claim 23 wherein after the passing step an end of the tab is positioned adjacent to the flap and the tab is pivotable about the rivet in a direction perpendicular to a plane of the end cap body such that the end of the tab is pressable into the flap to cause the main score line to tear along its length.

25. A tool for making a main score line on an end cap, the end cap including an end cap body made of a relatively thin metal material and configured to have the main score line formed therein and defining a flap, wherein the end cap has or is configured to have a rivet opening and a tab coupled to the end cap body with an end positioned adjacent to the flap, the tab having a tab rivet opening, the tool comprising: a tool body having a protrusion positioned on an end thereof, the protrusion being configured to form a correspondingly-shaped and configured main score line in the end cap, wherein the main score line is configured to be torn along its length along downstream direction to enable the flap to pivot about a hinge area, wherein the main score line is configured to extend from a first side of at least one of the rivet openings to a second side of the at least one of the rivet openings in the downstream direction, and wherein a portion of the main score line, located on the second side of the at least one rivet opening, is configured to not intersect a tangent line located at a bottom of the at least one rivet opening, or to not extend upwardly beyond the tangent line by more than 3/1000.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0005] FIG. 1 is a perspective view of a can with an end cap;

[0006] FIG. 2 is a top view of the end cap of the can of FIG. 1;

[0007] FIG. 3 is a cross section of the end cap, taken along line 3-3 of FIG. 2;

[0008] FIG. 4 is a top view of the end cap of FIG. 2, with the tab removed;

[0009] FIG. 5 is a detail view of the area indicated in FIG. 4;

[0010] FIG. 6 is a top view of the end cap of FIG. 2, with the tab and tab rivet opening shown in broken lines;

[0011] FIG. 7 is a detail view of the area indicated in FIG. 6;

[0012] FIG. 8 is a detail view of the main score line and anti-fracture score line of the end cap of FIG. 4;

[0013] FIG. 9 is a detail view of the area indicated in FIG. 4, showing an anti-score line;

[0014] FIG. 10 is a cross section taken along line 10-10 of FIG. 9;

[0015] FIG. 11 is a cross section taken along line 11-11 of FIG. 9;

[0016] FIG. 12 is a side view of a tool that can be used to form the main score line and anti-facture score line of FIGS. 1, 2, 4, 6 and 8;

[0017] FIG. 13 is an end view of the tool of FIG. 12; and

[0018] FIG. 14 is a detail cross section taken along line 14-14 of FIG. 13.

DETAILED DESCRIPTION

[0019] FIG. 1 illustrates a container body 10, such as a can or the like, having a tubular (cylindrical in one case) main portion 12, with a circular lid or end cap 14 coupled thereto. In one case the end cap 14 is formed separately and coupled to the main portion 12 of the container body 10 such that the lid or end cap 14 is coupled to and/or forms part of the container body 10, as will be described in greater detail below. The end cap 14 can include or constitute an end cap body 16 made of a relatively flat, sheet-like thin piece of material, including metals such as aluminum, steel, aluminum alloys, steel alloys and the like. The end cap body 16 can be relatively thin and planar, in one case having a thickness of between about 8/1000 and about 8.5/1000. The end cap 14/end cap body 16 can be generally circular in top view so that the end cap 14 can be coupled to the generally cylindrical main portion 12 of the container body 10, but can have other shapes as desired.

[0020] The end cap 14/end cap body 16 can in one case have a center panel 18, a tapered countersink groove 20 extending about an outer perimeter thereof, and an outer curl portion 22 configured to fit about and be coupled to an upper flange (not shown) of the container body 10. The end cap 14/end cap body 16 can further have a debossed panel or depressed area 24, defined by a downwardly angled chamfer portion or edge 26.

[0021] The end cap 14 can have a main score line 28 and an anti-fracture score line 30 formed therein. The main score line 28 extends in a nearly or generally closed loop shape in top view, having a generally oval shape in the illustrated embodiment and defining a flap or flap area 32 therein. With reference to FIG. 2, the flap 32 can have a major axis 34, oriented along the greatest length of the flap 32, and a minor axis 36 oriented along the shortest length of the flap 32 and/or oriented perpendicular to the major axis 34 and aligned with a center of the flap 32/end cap 14 (and/or aligned with the center of the rivet 48 and/or rivet opening 50). The flap 32 can also include a debossed section, or down bead 38, located in a center area of the flap 32 to provide increased stiffness to the flap 32.

[0022] In the illustrated embodiment the main score line 28 does not form a complete loop but leaves a gap, landed area or hinge area 40 through which the main score line 28 does not extend. The main score line 28 has a first end (at 67 of FIG. 4) and a second end (at 29 of FIG. 4) that are spaced apart to define the hinge area 40 about which the flap 32 is pivotable relative to a remainder of the end cap 14/end cap body 16. The main score line 28 in one case extends circumferentially between about 330 to about 350, such that the hinge area 40 in one case extends circumferentially between about 10 and about 30.

[0023] With reference to FIG. 10, the main score line 28 can be a cut or area of displaced/deformed/removed material formed in the thickness of the end cap 14. The main score line 28 is shown as having angled side walls and a straight/flat bottom edge, but can have other shapes as desired, including straight side walls in one case. The main score line 28 can have a generally constant depth, but in some cases, the main score line 28 can have a shallower depth (and greater/thicker residual) in certain areas, for example in one case to define a check slot region (not shown) which slows the propagation of the tearing of the main score line 28, and can also have varying depths at other areas. In one case, where the end cap 14 has a thickness of between about 8/1000 and about 8.5/1000, the main score line 28 can have an average and/or median depth of between about 4/1000 and about 6/1000. The main score line 28 can in one case, extend an average and/or median depth between about 50% and about 75% of a thickness of the end cap 14/end cap body 16, in that case leaving a residual thickness of between about 25% and about 50%.

[0024] With reference for example to FIG. 4, the anti-fracture score line 30 is formed in the end cap 14/end cap body 16, and can extend parallel or generally parallel to the main score line 28 in top view. In the illustrated embodiment the anti-fracture score line 30 is positioned radially inside the main score line 28, but in other cases the anti-fracture score line 30 can be located radially outside the main score line 28, or in yet another case multiple anti-fracture score lines 30 can be located both radially inside and outside the main score line 28. The anti-fracture score line 30 is, in one case, maintained a generally constant distance from the main score line 28 to be parallel to the main score line 28 and does not intersect the main score line 28. The anti-fracture score line 30 extends in one case along the main score line 28 at least about 90% of a length of the main score line 28, and extends along the entirety of the length of the main score line 28 in the illustrated embodiment. The main score line 28 and anti-fracture score line 30 can extend to a score loop 64 (FIG. 4), and join/meet at an intersection point 67.

[0025] With reference to FIG. 10, the anti-fracture score line 30 can be a cut or area of displaced, deformed or removed material formed in the thickness of the end cap 14. In the illustrated embodiment the anti-fracture score line 30 has angled side walls and a straight/flat bottom edge, but can have other shapes as desired, including straight side walls. The anti-fracture score line 30 can have a generally constant depth, but in some cases, can have a shallower depth (and thicker residual), or vice versa, in certain areas as desired. The anti-fracture score line 30 can be formed at the same time as formation of the main score line 28, and can be provided to reduce stresses in the end cap 14 and/or main score line 28 during formation of the main score line 28.

[0026] In one case, where the end cap 14 has a thickness of between about 8/1000 and about 8.5/1000, the anti-fracture score line 30 can have an average and/or median depth of between about 4/1000 and about 4.5/1000. In one case, the anti-fracture score line 30 has a lesser depth (and thus greater residual thickness) than the main score line 28, and in one case extends (average and/or median) between about 40% and about 60% of a thickness of the end cap 14 material, leaving a residual thickness of between about 40% and about 60%. The anti-fracture score line 30 can in some cases have an average and/or median depth that is between about 50% and about 80% of the depth of the main score line 28.

[0027] With reference for example to FIG. 2-4, the container body 10 and/or end cap 14 can have a generally oval-shaped tab 42 having a front end/tip 44 and an opposed back end/tip 46. With reference to FIG. 3, the tab 42 can be coupled to the end cap body 16 via a rivet 48 extending through a circular (in one case) tab rivet opening 50 (formed in the tab 42) and extending through end cap rivet opening 60 (formed in the end cap body 16). However it should be understood that the tab 42 can be coupled to the end cap body 16 by various other devices and mechanisms. In one case, the radially outer surface of the shaft 47 of the rivet 48 has a size/diameter slightly larger than the size/diameter of the tab rivet opening 50 to form an interference fit therebetween. The back end 46 of tab 42 is configured to be manually raised and thereby pivot the tab 42 about the rivet 48, pivoting the tab 42 about an axis parallel to the plane of the end cap body 16 (such that the tab 42 is pivotable at least partially in in a direction perpendicular to a plane of the end cap body 16), pushing or pressing the forward tip/end 44 of the tab 42 downwardly into the flap area 32.

[0028] With reference to FIGS. 4 and 6, during opening of the flap 32, the main score line 28 is torn along its length in a downstream direction 66 to enable the flap 32 to pivot about the hinge area 40. The flap 32 is then formed and folded downwardly about the hinge area 40 into the container body 10, as the main score line 28 tears or fractures along its length, thereby forming an opening through which the contents of the container body 10 can be dispensed. The main score line 28 thus extends from a first side 68 of the rivet 46/rivet opening(s) 50, 60 (the left side, in the illustrated embodiment) to a second side 70 of the rivet 46/rivet opening(s) 50, 60 (the right side, in the illustrated embodiment) in the downstream direction 66.

[0029] With reference to FIG. 2, the tab 42 can include a back opening 52 formed through a back portion (adjacent the back end 46) and a front opening 54 formed through a front portion (adjacent the forward end 44). The openings 52, 54 can provide material saving and weight reduction. The tab 42 can include a peninsula 56 positioned in/adjacent to the front opening 54, and the tab rivet opening 50 can be formed in the peninsula 56. As best shown in FIG. 3, the tab 42 can include a rolled portion 62 about an outer perimeter thereof to provide stiffening to the tab 42 and reduce exposure of sharp edges of the tab 42. The tab 42 can be made of or include a relatively flat, sheet-like thin piece of sheet-like material, including metals such as aluminum and aluminum alloys, or steel and steel alloys and the like, and can have a thickness of between about 9/1000 and about 9.5/1000 in one case, or less than about 10.5/1000 in one case and/or greater than about 8.5/1000 in another case.

[0030] As noted above, the tab rivet opening 50 (FIG. 2) is configured to receive the rivet 48, which also extends through and/or is fixedly coupled to, the end cap 14, to thereby couple the tab 42 and the end cap 14 together. The end cap 14/end cap body 16 can also include an end cap rivet opening 60 (FIG. 4) through which the rivet 48 is received. The end cap rivet opening 60 in one case has a size/diameter that is slightly larger than the size/diameter of the shaft 47 of rivet 48 received therein. The end cap rivet opening 60 can also or instead be larger in size/diameter than the size/diameter the tab rivet opening 50 so that the shaft 47 of the rivet 48 is cleanly (or more cleanly) received through the end cap rivet opening 60 as compared to the tab rivet opening 50, which can form an interference fit with the rivet 48. In one case, the shaft 47 of the rivet 48 has a diameter of about 0.130 inches; the tab rivet opening 50 has a diameter of about 0.130 inches, or between about 0.1290 and about 0.1295 inches in another case; and the end cap rivet opening 60 has a diameter of about 0.132 inches.

[0031] With reference to FIG. 7, the tab rivet opening 50 has a tangent line 72 at its bottom, and with reference to FIG. 5, the end cap rivet opening 60 has a tangent line 76 at its bottom. The bottom of the rivet opening(s) 50, 60 can be defined as, in one case, a bottom of the rivet opening(s) 50, 60 in top view of the end cap 14 in the orientation as shown in FIGS. 5 and 7, e.g. when the tab 42 is centered over and/or aligned with the flap 32. The bottom of the rivet opening(s) 50, 60 can also or instead be defined as, in one case, a portion of the rivet opening(s) 50, 60 that is aligned (in one case, along a radial line) with a center of the end cap 14, and/or aligned with the minor axis 36 of the flap 32, and/or a location of the rivet opening(s) 50, 60 located closest to the main score line 28, and/or aligned with a line that bisects the debossed panel 24 of the flap 32, and/or aligned with a line that bisects the length of the flap 32 along the major axis 34. The tangent lines 72, 76 can be parallel to the major axis 34 and/or can be positioned adjacent to the main score line 28 relative to the rivet opening(s) 50, 60. In general, the frame of reference for the bottom of the end cap 14 can be that side of the end cap 14 in which an entirety or a majority of the flap 32 is located, as opposed to the top or upper side or half of the end cap 14, as shown for example with the frame of reference shown in FIGS. 2, 4 and 6.

[0032] In one embodiment a portion or an entirety of the main score line 28, located on the second side 70 of the rivet opening(s) 50, 60, does not intersect one or both tangent lines 72, 76. For example, in the embodiment of FIG. 7 there is a gap 78 between the tangent line 72 of tab rivet opening 50 and a downstream portion of the main score line 28, where the gap 78 extends in a direction perpendicular to the tangent line 72 (the size of the gap 78 may be smaller than that actually shown, and the size/scale of the gap 78 is increased in FIG. 7 for ease of visibility).

[0033] In another embodiment, the downstream portion of the main score line 28, located on the second side 70 of the rivet opening(s) 50/60, does intersect one or both tangent lines 72, 76, but does so by only a limited amount. For example, in the embodiment of FIG. 5, the main score line 28 intersects the tangent line 76, in a direction perpendicular to the tangent line 76, by an amount/distance 80. The distance 80 may extend in a direction perpendicular to the tangent line 76, and may be smaller than that actually shown, increased for visibility. The distance 80 is less than 1/1000 in one case, or less than 3/1000 in another case, or less than 10% of a radius of the rivet opening(s) 50/60 in one case, or less than 5% of the radius in another case, and less than 1% in yet another case of the radius of the rivet opening(s) 50/60 in another case. In another embodiment a portion of the main score line 28, located on the second side 70 of the rivet opening(s) 50, 60, does not intersect a tangent line 72, 76 by more than a predetermined amount (e.g. more than 1/1000 in one case, or more than 3/1000 in another case, or the other parameters outlined above relating to the distance 80).

[0034] The first side 68 and the second side 70 of the rivet opening(s) 50, 60 can be defined, in one case, as opposite sides of a line 84 (FIG. 4) passing through a center of the rivet opening(s) 50, 60 and also passing through the bottom of the rivet opening(s) 50, 60, as defined above. The line 84 can be oriented perpendicular to the major axis 34 and/or tangent lines 72, 76 and/or parallel to the minor axis 36. The first 68 and second 70 sides of the rivet opening(s) 50, 60 can also or instead be defined as opposite sides of a line 84 passing through the center of the rivet opening(s) 50, 60 and bisecting the debossed section 38 of the flap 32, and/or bisecting the length of the flap 32 along the major axis 34. As shown for example in FIG. 4, in one embodiment the first end 67 and the second end 29 of the main score line 28 are both located on the first side 68 of the rivet opening(s) 50, 60, and both ends 67, 29 are located below one or both tangent lines 72, 76.

[0035] In the illustrated embodiment the first side 68 is the left side and the second side 70 is the right side, and the path of tearing of the main score line 28 in the downstream direction 66 is left-to-right. However it should be understood that the orientation of score lines 28, 30 can be reversed from the configuration shown, and the first side 68 would be on the right side and the second side 70 would be the left side, and the path of original tearing of the main score line/downstream direction 66 would be right-to-left.

[0036] Thus, as noted above, the main score line 28, located on the second side 70 of the rivet opening(s) 50/60, in one case, is not positioned above and/or does not intersect one or both tangent lines 72, 76. Thus in one case, as shown in FIG. 7 an entirety of the main score line 28, located in the downstream direction 66 of the tab rivet opening(s) 50, 60 and on the second side 70 of the opening 50, 60, does not intersect one or both the tangent lines 72, 76 (or intersects one or both tangent lines 72, 76 by a limited amount). Stated differently, in one case no portion of the main score line 28 located in the downstream direction 66 of the tab rivet opening(s) 50, 60, and on the second side 70 of the opening(s) 50, 60 is located above one or both tangent lines 72, 76 (or is located above one or both tangent lines 72, 76 by a limited amount). Stated yet even more differently, a portion and/or the entirety of the main score line 28 located in the downstream direction 66 of the rivet opening(s) 50, 60 and on the second side 70 of the rivet opening(s) 50, 60 is located below one or both the tangent lines 72, 76.

[0037] By arranging the main score line 28 such that the portion of the main score line 28 does not intersect the tangent line(s) 72, 76 at all, or in another case extends past the tangent lines 72, 76 only by a sufficient amount (e.g. more than 1/1000 in one case, or more than 3/1000 in another case, or other parameters as set forth above) means, in one case, the main score line 28 does not extend beyond the tangent line 72, 76 in a direction perpendicular to the tangent line (e.g. in one case providing gap 78 of FIG. 7). The upper sides of the tangent line 72, 76 (e.g. in one case, in the context of the main score line 28 not extending sufficiently upwardly beyond the tangent line 72, 76) can be the side of the tangent line 72, 76 on which the rivet 48 and rivet opening(s) 50, 60 (and/or a majority of the rivet and opening(s) 50, 60) are located. Stated differently the lower side of the tangent lines 72, 76 can be the side on which an entirety or a majority of the main score line 28 is located. In other cases, as outlined above and shown in FIG. 5, the main score line 28 may extend beyond the tangent line 72, 76, but only to a limited extent 80.

[0038] It should be noted that in some cases, the main score line 28 extends beyond the tangent line 76 of the end cap rivet opening 60, but does not touch, intersect or extend beyond the tangent line 72 of the tab rivet opening 50, as can be seen in comparing FIGS. 5 and 7. This is because, even though the openings 50, 60 may be aligned, the end cap rivet opening 60 can have a larger size/diameter than the size/diameter of the tab rivet opening 50, as outlined above.

[0039] The shape/configuration/positioning of the main score line 28 as described herein, and in particular not extending past the tangent line(s) 72, 76, or extending past the tangent line(s) 72, 76 by only a limited amount, can reduce the tendency of the flap 32 to lift upwardly/outwardly during the opening process. In particular, during initial opening/tearing of the main score line 28, pressure forces in the container body 10 are at their highest, and internal, pressurized fluids can escape through the initially cracked main score line 28 at relatively high velocities as the fluid is forced through a relatively small orifice.

[0040] With reference to FIG. 8, one embodiment of the main score line 28, anti-fracture score line 30 and end cap rivet opening 60 as described above are shown in solid lines, and a traditional main score line, anti-fracture score line and end cap rivet opening are shown in dashed lines. The oval 90 shown in a dash dot line indicates an area upon which relatively high pressures act during initial tearing of the main score line 28/initial formation of the flap 32. Thus it can be seen that the conventional score line provides significant surface area of the flap 32 inside the oval 90, leading to a relatively high force acting upon the flap 32 during initial opening.

[0041] In contrast, the main score line 28 does not extend into the oval 90 nearly as much as the conventional main score line. Thus the main score line 28 disclosed herein provides a flap 32 with a significantly reduced surface area in the oval 90, leading to reduced force acting upon the flap 32. In other words, since the force exerted on the flap 32 is a function of pressure and area (Force=pressure x area), the shape, configuration and positioning of the main score line 28 disclosed herein reduces the amount of flap area 32 exposed to the higher pressures, thereby reducing the force on the flap 32, which reduces any tendency of the flap 32 to open upwardly (away from the container body 10), rather than downwardly (into the container body 10). The lack of intersection of the main score line 28 with the tangent line(s) 72, 76), or only extending slightly past, the tangent line(s) 72, 76, thus improves the opening characteristics of the container 10/ flap 32.

[0042] It should be noted that it also may be desired for the main score line 28 to extend at least partially and/or significantly in the lateral (left-to-right) direction in the vicinity of the rivet 48 and rivet opening(s) 50, 60. In particular, the flap 32 can be desired to have a relatively high aspect ratio, which can be defined as the ratio of the length of the flap 32 along the major axis 34 and/or the axis extending in the right-to-left direction of FIG. 2 and/or parallel to one or both tangent lines 72, 76; as compared to height/length of the flap 32 along the minor axis 36 and/or the axis extending in the top-to-bottom direction of FIG. 2 and/or perpendicular to one or both tangent lines 72, 76. The aspect ratio can be greater than 1:1 in one case, and greater than about 1.2:1 in another case, and about 1.4:1 in another case, and less than 2:1 in yet another case.

[0043] This configuration of the flap 32, in one case with the stated aspect ratios, provides a big mouth opening and enables liquid to be more quickly and effectively poured out of the container body 10. The relatively high aspect ratio also matches the wider left-to-right opening size/aspect ratio of a consumer's mouth to provide ease of drinking directly from the container body 10. The wider aspect ratio opening/flap 32 also enables liquids to be more quickly and effectively poured out of the container body 10 when the container body 10 is not full/approaching empty, since gravity pulls the liquid toward the bottom of the container body 10 where it spread out laterally. It has been found that positioning the main score 28 line below the tangent lines 72, 76, and/or only slightly protruding past the tangent lines 72, 76 as described herein, provides a good balance of reducing pressure forces, but also providing a wide opening with the desired aspect ratio.

[0044] With reference to FIG. 9, the end cap 14/end cap body 16/center panel 18 can include a control score line 92 positioned adjacent to the main score line 28 and/or anti-fracture score line 30. Like the main score line 28 and the anti-fracture score line 30, and with reference to FIGS. 10 and 11, the control score line 92 can be a cut or area of displaced or removed material formed in the thickness of the end cap 14, and can have angled and/or straight side walls and a flat bottom edge, but can have other shapes as desired. In one case, where the end cap 14 has a thickness of between about 8/1000 and about 8.5/1000, the control score line 92 can have a fixed, average, deepest and/or median depth of between about 1/1000 and about 2/1000. In one case, the control score 92 has a lesser depth (and thus greater residual thickness) than the main score line 28 and/or anti-fracture score line 30, and in one case has a fixed, average, deepest and/or median depth between about 10% and about 30% of a thickness of the end cap 14, and in another case have an average and/or median depth of between about 20% and about 40% of the depth of the main score line 28.

[0045] The control score line 92 can be positioned adjacent to the main score line 28 such that, in one case, the shortest distance between the main score line 28 and the control score line 92 is less than about 40/1000, or in another case less than about 30/1000, or in yet another case less than about 20/1000. On the other hand the control score line 92 can be positioned such that the shortest distance between the main score line 28 and the control score line 92 is greater than about 5/1000 in one case, or greater than about 10/1000 in another case. The control score line 92 should be positioned sufficiently close to the main score line 28 so that the control score line 92 can provide the retarding effect upon tearing of the main score line 28 as described in greater detail below, but should not be positioned so close to the main score line 28 as to risk any tearing of the main score line 28 propagating into the control score line 92. The control score line 92 can also be spaced away from any check slot region (not shown) of the main score line 28.

[0046] In the illustrated embodiment the control score line 92 intersects the anti-fracture score line 30 (twice) and extends transversely (twice) across the anti-fracture score line 30. In other words in one case differing portions of the control score line 92 are located on both sides of the anti-fracture score line 30, and the control score line 92 extends from one side of the anti-fracture score line 30 to the other side of the anti-fracture score line 30. In the illustrated embodiment the control score line 92 does not intersect the main score line 28.

[0047] The control score line 92 can, in one case, have a width (in a direction parallel to a plane of the end cap 14, at the top of the control score line 92 adjacent the plane of the end cap 14) that is greater than the width of main score line 28 and/or anti-fracture score line 30. In particular, in one case the control score line 92 has a width between about 8/1000 and about 12/1000. The control score line 92 can have a width that is at least about 1.5 times greater in one case, or at least about double in another case, the width of the main score line 28 and/or anti-fracture score line 30.

[0048] As shown in FIG. 9, the control score line 92 can be curved (including oval or elliptical) or circular/arcuate in top view along at least part or an entirety of its length in top view. In the illustrated embodiment the control score line 92 is curved or arcuate along its entire or substantially its entire length (e.g. at least about 75% of its length in one case, and along at least about 90% of its length in another case). In the illustrated embodiment the control score line 92 is semi-circular or substantially semicircular (extending at least about 90 degrees in one case, or at least about 120 degrees in another case, or at least about 180 degrees in another case) in top view, having spaced apart end portions (or tangents thereof) 92a, 92b that can be parallel or substantially parallel (in one case, within about +/10 degrees of parallel). In one case the control score line 92 can have a radius (when the control score line 92 is semicircular) of between about 0.02 inches and about 0.15 inches and have a length in one case between about 0.06 inches and about 0.47 inches.

[0049] Having a control score line 92 that is semi-circular or substantially semi-circular, and/or with parallel or substantially parallel ends, can provide certain advantages. In particular, the control score line 92 defines a stub portion 94 therein (having a substantially hemispherical shape in the illustrated embodiment). In some cases it may be desired to ensure the stub portion 94 is relatively defined and stiff to ensure that the areas of the end cap 14/end cap body 16 adjacent to the stub portion 94 do not flex during tearing along the main score line 28. If the control score line 92 were not semi-circular or substantially semi-circular, and/or has ends that are not parallel or substantially parallel, and in one case has ends that flare sufficiently outwardly, the stiffness of the stub portion 94 can be compromised and decreased since the stub portion 94 is not well contained/defined. This means that areas adjacent to the main score line 28 are weaker and can lead to undesired tearing at areas propagating away from the main score line 28 and/or less controlled tearing along the main score line 28 may result.

[0050] In the embodiment of FIG. 9, the control score line 92 is positioned generally or at least partially radially inside the anti-fracture score line 30 and entirely radially inside the main score line 28, and configured such that a tangent line 96 of a center 98 (along the length) of the semicircle is oriented parallel or substantially parallel (e.g. in one case within +/10 of parallel) to the portion of the anti-fracture score line 30 and/or main score line 28 adjacent or closest to the center 98 of the semicircle/the tangent line 96 (where in one case, for making parallel determinations, curved/nonlinear segments of the score lines 28, 30 can be defined by a best fit straight line (using a least square model in one case) extending about 25% of a length of the control score line 92, or in another case extending about 10% of a length of the control score line 92). Thus each end 92a, 92b of the control score line 92 can be oriented perpendicular or substantially perpendicular (e.g. in one case within +/10 of perpendicular, or within +/5 or +/1) using best fit methods as noted above to measure the appropriate angles) to the associated adjacent (closest) portion of the anti-fracture score line 30 and/or main score line 28 and/or tangent line 96. However, if desired in some cases the control score line 92 can be rotated about its center point, from the illustrated configuration, to vary the effect of the control score line 92 upon tearing of the main score line 28. In addition, while the control score line 92 is shown positioned radially inside the main score line 28, if desired and if the end cap 14 geometry so permits, the control score line 92 can be positioned radially outside the main score line 28.

[0051] As best shown in FIGS. 10 and 11, the control score line 92 can have a tapered depth portion at or forming one or both ends 92a, 92b thereof. The tapered depth portions 92a, 92b can be arranged such that the control score line 92 has a shallower depth at the ends 92a, 92b thereof and tapers (relatively to an upper/planar surface of the end cap 14/end cap body 16), at a relatively sharp and then relatively shallow angle in one case (which can reduce stress induced into the material of the end cap 14 of the formation of the control score line 92 over a relatively broad area), to a deeper depth at a center portion of the control score line 92. In one case the average/total angle of taper along the length of the ends 92a, 92b is between about 1 and about 10, but the angle can vary as desired.

[0052] The tapered depth portions at the ends 92a, 92b can extend in one case a length of between about twenty five percent and about forty percent of an entire length of the control score line 92. The tapered depth portions 92a, 92b of the control score line 92 can aid in formation of the control score line 92 by reducing tension induced into the surrounding areas of the end cap 14/end cap body 16. However tapered depth portions 92a, 92b are optional and can be omitted if desired.

[0053] During opening of the flap area 32, the end cap 14/end cap body 16/flap area 32 is designed to tear along the main score line 28. In particular, the main score line 28 is typically initially severed at location aligned (in the left-to-right direction of FIGS. 2, 4, and 6) with at the front tip 44 of the tab 42 and/or the rivet 48, and (primarily) initially moves in a left-to-right direction, as shown by the arrow 66 of FIG. 4. As the fracturing or tearing of the main score line 28 approaches the control score line 92, it is believed that material of the end cap 14 is urged at least partially toward and/or into the main score line 28 by the nature and positioning of the control score line 92, which slows tearing along the main score line 28, without entirely stopping tearing along the main score line 28. The greatest amount of deformation of material into the main score line 28 by the control score line 92 can occur at the location adjacent/aligned with the center 98, and/or the location of the main score line 28 closest to the control score line 92. The relatively shallow depth and/or relatively wide width of the control score line 92 helps to ensure that the control score line 92 does not compromise the strength of the end cap 14 in the area of the control score line 92, but allows sufficient material to be deformed into the main score line 28 during opening of the flap 32.

[0054] In this manner, as the tearing of the main score line 28 propagates in the downstream direction, the control score line 92 smoothly and progressively slows the tearing of the main score line 28 to a maximum value at location 98, and thereafter smoothly and progressively removes the slowing effect. Thus the control score line 92 provides smooth, efficient, controlled and predictable slowing of tearing of the main score line 28, reducing any undesired upward deflection of the flap 32. In particular, without the control score line 92 the flap 32 may tend to project upwardly (instead of downwardly) when internal pressure in the container body 10 is rapidly released, causes rapid tearing along the length of the main score line 28, instead of the desired downward deflection of the flap 32.

[0055] The tapered end portions 92a, 92b of the control score line 92 can also contribute to smooth and controlled slowing of the tearing of the main score line 28. The shallower ends at the tapered end portions 92a, 92b are more easily deformed and thus can lead to a cascading or rolling effect where the control score line 92 is deformed greater amounts along its length with a lesser force compared to a situation where the tapered end portions 92a, 92b were not present. As noted above, the tapered nature of the end portions 92a, 92b can also reduce stresses caused by the formation of the control score line 92 over a relatively broad surface area, and increases the effective stiffness of the flap 32.

[0056] The control score line 92 can be positioned relatively close to the end/tip 44 of the tab 42, so that the control score line 92 interacts with the main score line 28 relatively early in the opening process. Thus in one case the portion of the main score line 28 positioned closest to the control score line 92 is located within the first 25% of fracturing or tearing of the main score line 28 when the flap 32 is opened.

[0057] The use of the control score line 92, in conjunction with the shape of the main score line 28 as outlined above and shown for example in FIGS. 1, 2, 4, 6 and 8, work together to provide improved performance/opening of the flap 32. In particular, both of those features address two issues that can cause rapid, outward opening of the flap 32. In particular, the control score line 92 increases the stiffness of the flap 32, since the deformed/displaced material adjacent the control score line 92, formed during formation of the control score line 92, creates an area(s) of increased thickness. In addition the shape of the main score line 28 as outlined above reduces the area of the flap 32 that is affected by the pressure of escaping gas during initial opening. The two features thus cooperate together to provide more controlled opening of the flap 32.

[0058] FIGS. 12-14 illustrate a tool 100, in the form of a punch, that can be used to form the main score line 28 (and/or anti-fracture score line 30) shown in FIGS. 1, 2, 4, 6 and 8. The tool 100 includes a tool body in one case in the form of generally cylindrical stem 102 and a generally cylindrical, enlarged head 104. The head 104 carries a pair of protrusions 108, 110 thereon shaped to correspond to the main score line 28 and control score line 30, respectively, described above. Thus in one case the protrusions 108, 110 extend in a generally or nearly closed loop shape in top view, having a generally oval shape in the illustrated embodiment with the various features as described above and shown in FIGS. 1, 2, 4, 6, and 8. As shown in FIG. 14, in one case the protrusions 108, 110 are generally triangular in side view/cross section, having an included angle X of about 50 degrees (+/5 degrees) in one case.

[0059] During formation of the main score line 28, the end cap 14 can be positioned on a generally flat supporting surface or anvil surface as the punch 100 is moved into contact with the upper side of the end cap 14 to form the main score line 28 and control score line 30. The protrusions 108, 110 can thus have properties to enable formation of the main score line 28 and control score line 30, in its various embodiments as described above.

[0060] In order to form the end cap of FIGS. 1-11, a starting piece of sheet-like material can be provided. The end cap body 16 can be stamped, molded, machined, or otherwise modified to have the countersink groove 20, outer curl portion 22 and debossed panel 24, and other components/properties outlined above. The main score line 28 and anti-fracture score line 30 can then be formed in the end cap 14/end cap body 16, such as by using tools/punches having protrusions in the shape of the main score line 28 and anti-fracture score line 30 as outlined above. The control score line 92, if utilized, can be formed in the end cap 14, in one case using a punch with a protrusion in the shape of the control score line 92. Of course, the order of operations of forming one or more components of the end cap 14 can be varied from that outlined above.

[0061] Once the end cap 14 is formed, it can be coupled to the container body 10, such as by seaming the outer curl portion 22 to the upper edge/flange of the container body 10. A bottom may then be coupled to the container body 10, if not already coupled to the container body 10, and the container can be filled with a fluid and sealed.

[0062] Having described the invention in detail and by reference to certain embodiments, it will be apparent that modifications and variations thereof are possible without departing from the scope of the invention.