U.S. patent application number 10/433465 was filed with the patent office on 2007-08-02 for metal container suitable to accommodate a heating or cooling component method and for manufacturing it.
Invention is credited to David N. Bowen.
Application Number | 20070175258 10/433465 |
Document ID | / |
Family ID | 9904341 |
Filed Date | 2007-08-02 |
United States Patent
Application |
20070175258 |
Kind Code |
A1 |
Bowen; David N. |
August 2, 2007 |
Metal container suitable to accommodate a heating or cooling
component method and for manufacturing it
Abstract
A method of producing a metal container from a low carbon steel
strip or sheet coated on at least one of its surfaces with a
coherent laminated coating of a thermoplastic polymer material
includes one or more redrawing stages which reduce the thickness of
the side walls by a drawing/stretching operation, and a partial
reverse redrawing stage to produce an initial internal chamber
whose depth is produced by a reduction of its height. The initial
internal chamber is then redrawn to produce two chambers of
differing diameter and depth, the diameter of the initial chamber
being decreased by the redraw operation and inserting by base
reforming the final chamber with a new internal diameter and depth
produced by a reduction in the container height.
Inventors: |
Bowen; David N.; (Swansea,
GB) |
Correspondence
Address: |
BLANK ROME LLP
600 NEW HAMPSHIRE AVENUE, N.W.
WASHINGTON
DC
20037
US
|
Family ID: |
9904341 |
Appl. No.: |
10/433465 |
Filed: |
November 26, 2001 |
PCT Filed: |
November 26, 2001 |
PCT NO: |
PCT/GB01/05187 |
371 Date: |
November 25, 2003 |
Current U.S.
Class: |
72/347 |
Current CPC
Class: |
B21D 22/30 20130101;
B65D 81/3484 20130101; B21D 22/24 20130101; B65D 1/165
20130101 |
Class at
Publication: |
072/347 |
International
Class: |
B21D 22/00 20060101
B21D022/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 4, 2000 |
GB |
0029459.5 |
Claims
1. Method of producing a metal container from a low carbon steel
strip or sheet coated on at least one of its surfaces with a
coherent laminated coating of a thermoplastics polymer material in
which a blank produced from the coated steel strip of sheet to a
drawing operation to produce a cup, the method being comprised of
the following steps: (i) subjecting the cup to at least one drawing
and stretching operation to reduce the thickness of the cup wall
and to increase the cup height without ironing of the wall surface;
(ii) subjecting the stretched cup to at least on partial reverse
redrawing operation to produce within the stretched cup a first
internal chamber whose depth is produced by a reduction of its
height without any reduction in wall thickness; (iii) subjecting
the first internal chamber to a reverse redrawing operation to
produce a second internal chamber whose diameter and depth differs
from those of the first internal chamber; and (iv) subjecting the
cup base to a reforming operation to produce a third internal
chamber whose diameter and depth differ from those of the first and
second chamber and whose depth is produced by a reduction in the
cup height.
2. Method according to claim 1 wherein the thermoplastic polymer
has good formability and comprises an internal coating which
prevents corrosion of the container by its contents and an external
coating which prevents corrosion of the container by its
heating/cooling solution, the laminate coating being applied to the
metal surface by means of direct extrusion or lamination.
3. Metal container produced by a method as claimed in claim 1
having a combination of internal chambers of differing depths and
diameters.
4. Metal container as claimed in claim 3 produced from a double
reduced high strength high ductility low carbon steel having a
proof strength in the range 490 to 720 N/mm.
5. Metal container as claimed in claim 3 wherein the maximum carbon
level for the steel is 0.050% by weight.
6. Metal container as claimed in claim 4 wherein the steel
comprises by weight %: C 0.01-0.10; S 0.02 max.; P 0.015 max.; Mn
0.15-0.30; Ni 0.04 max.; Cu 0.06 max.; Sn 0.02 max.; As 0.01 max.;
Mo 0.01 max.; Cr 0.06 max.; Al 0.02-0.09 and N 0.003 max.
7. Metal container as claimed in claim 4 wherein the steel is
reduced by hot or cold rolling to a gauge of between 0.12' mm and
0.3 mm.
Description
[0001] The invention relates to a metal container and its
manufacture. The metal container comprises a plurality of internal
chambers of various depths and diameters, the design of which can
be varied dependent on the respective application. The internal
chamber or chambers may be filled with appropriate substances and
used to heat or cool via a chemical reaction the contents of
another chamber. The container according to the invention can thus
be used to accommodate a heating or cooling component to heat or
cool the contents, although it could also be used for alternative
applications, e.g. where food products need to be kept
separate.
[0002] This invention also relates to a method of manufacturing
such a metal container, incorporating a combination of internal
chambers, suitable to accommodate a heating or cooling component,
used for heating or cooling its contents.
[0003] The method of manufacture used in producing the metal
container may involve a combination or a series of the following
processes, cupping, draw redraw (DRD) and/or draw stretch redraw
(DSRD), reverse (partial) redraw, redraw of the reverse chamber and
base reform depending on application and container size. Examples
of such methods are disclosed in U.S. Pat. No. 5,088,870 and WO
99/61326.
[0004] For a typical design the process developed is as follows:
The original cup is redrawn in sequential stages until a container
of correct diameter is produced. The container is then subjected to
a reverse (partial) redraw in order to insert an internal chamber.
The next stage involves redraw of the internal chamber, hence
producing two internal chambers of different diameter and depth.
The final chamber is produced by means of base reform which
produces a container of correct external diameter and height and,
hence, a finished container of correct internal chamber diameters
and depths.
[0005] For this invention, the configuration of internal chambers
of the metal container consists of three internal chambers, with
the following typical dimensions: 61.6 mm diameter at 4 mm deep,
53.7 mm diameter at 15 mm deep and 45 mm diameter at 73 mm deep.
The starting material is conventionally a double reduced product of
high strength high ductility low carbon steel with a proof strength
of 480-720 N/mm.sup.2, and coated with a polymer coated film on one
or each surface. The use of DR products for the metal container is
not exclusive to the design, as it is possible that a range of SR
tin mill products can be used for the application.
[0006] This invention concerns a method of producing a typical
metal container used to accommodate a heating or cooling component,
used in the heating or cooling of the contents of the metal
container.
[0007] The feed stock for the method of manufacture for the metal
containers to be produced in accordance with the invention is a
double reduced high strength high ductility low carbon steel with a
proof strength of 480-720 N/mm.sup.2. The maximum carbon level for
the steel is typically 0.05% by weight. A typical specification for
this steel is by weight %: C 0.01-0.04; S 0.02 max.; P 0.015 max.;
Mn 0.15-0.30; Ni 0.04 max.; Cu 0.06 max.; Sn 0.02 max.; As 0.01
max.; Mo 0.01 max.; Cr 0.06 max.; A 0.02-0.09 and N 0.003 max. The
steel is reduced by hot or cold rolling to a gauge typically of
between 0.12 mm and 0.30 mm and is processed by known appropriate
heating cycles and continuous annealing. The steel has a minimum
earing quality.
[0008] As an example, the feed stock used is DR 580 CA 0.24 mm,
coated with a PET laminate coating of 0.025 mm (white) on one side
and a PET laminate coating of 0.020 mm (clear) on the other.
[0009] The specification for this steel is by weight %: C
0.012-0.04; S 0.02 max.; P 0.015 max.; Mn 0.15-0.30; Al 0.025-0.055
and N 0.003 max., plus trace elements: Ni 0.04 max.; Cu 0.06 max.;
Sn 0.02 max.; As 0.01 max.; Mo 0.01 max.; Cr 0.06 max.
[0010] Strip produced from the feed stock is subjected to an
electrolytic coating process. In this process, the steel strip is
cleaned and pickled before being passed through a plating bath in
which it is coated with a thin layer of chromium metal, typically
of 0.010 mm thickness followed by a thin layer of chromium oxide,
again typically of 0.010 mm thickness. Alternatively, tinplate or
other suitable substrate could be employed.
[0011] The strip is then coated with a polymer material. In this
process a layer of PET (polyethylene terephthalate) and/or PP
(polypropylene) is bonded to the surface of the metallic coated
steel strip or sheet using heat and pressure.
[0012] The films are co-extruded so that the bonding layer of 0.002
mm first makes contact with the steel and forms a strong bond.
After the bond is formed with the substrate the polymer films are
melted and held above the recrystallisation temperatures for a few
seconds before being rapidly quenched to below their softening
temperatures.
[0013] This produces an amorphous structure in the PET and a
minimal crystalline structure in the PP. The method of coating the
strip can be a direct extrusion or laminating process. Typically
the thickness of the external polymer is in the order of 0.025 mm
thickness and the internal polymer is between 0.015 and 0.030 mm.
Laminating processes and polymer films of a different structure and
composition other than those discussed may be employed.
Cupping
[0014] The strip, either in sheet or coil form is fed to a cupper
in a pre-waxed condition or is passed through a waxer on entry to
the cupping system. The wax may be edible and petroleum based with
film weights in the range 5-20 mg/ft.sup.2. Discs are stamped from
the sheet or strip. The cup is drawn in one operation using a die
with a diameter typically in the range 150 mm to 300 mm.
[0015] This diameter is dependent (with gauge) upon the required
can size and type of application. The draw ratio (i.e. ratio of the
diameter of the disc to that of the cup) is typically in the range
1.0-2.0:1. The geometry of the tooling is designed in combination
with the correct blank holding load to give a reduction in wall
thickness at the cupping stage of up to 20%, however this can be
produced with a smaller or greater reduction depending on
application.
[0016] This is accomplished with a die radius typically between 0.5
mm and 6.5 mm and a parallel land length of up to 10 mm. The blank
holding load is achieved by use of a boosted air pressure of up to
200 psi fed into a series (typically three) of internal multiplying
pistons. The punch/die gap is important and is controlled by the
feed stock gauge and coating and gaps of 1.20-2.50 times the
starting total laminate thickness are typically used.
[0017] The punch nose radius is carefully controlled to achieve the
required draw/stretch whilst minimising subsequent can wall marking
which could lead to laminate rupture. Punch nose radii in the range
of 0.5 mm to 10 mm are generally required.
First Redraw Processing
[0018] The cupper cup is passed into the draw/stretch redraw press
which contains tooling for both first and second redraw operations.
The diameter of the cup is reduced in the first redraw operation
with a draw ratio in the range 1.0-1.7:1, and with a wall thickness
reduction typically 25% of the in going cup wall thickness, however
this can be produced with a smaller or greater reduction (in the
range of 10-60%) depending on application.
[0019] The wall thickness reduction is achieved by a stretching
technique. The wall thickness reduction is balanced with the draw
ratio and is achieved by use of pressure sleeve and die geometry in
combination with controlled blank holding loads.
[0020] The tooling geometry typically is as follows: pressure
sleeve diameter up to 0.66 mm smaller than the cupper cup internal
diameter; pressure sleeve radius up to 2.0 mm; die radius up to 2
mm with a parallel land length up to 5 mm.
[0021] The blank holding load is achieved by use of air pressure of
up to 100 psi fed into a stack of two or more internal multiplying
pistons.
[0022] Location of the cup on the die is effected by means of a
nest recess with a diameter matched to the cupper cup, allowing for
the thickness of the actual laminate. The radius of the nest
diameter with the die at the base of the nest is in the range
0.10-2.00 mm.
[0023] The punch is parallel along its length and the gap between
the punch diameter and die (per side) is generally controlled to
between 1.20 and 1.50 times the starting laminate thickness. The
punch radius is important to achieve the required stretch whilst
minimising subsequent en wall marking which could lead to laminate
rupture. Punch nose radii in the range 1 mm to 3 mm are typically
used.
Second Redraw Processing
[0024] The first redraw cup is passed back into the stretch redraw
press a station containing the second redraw tooling. The cup
diameter is reduced in this operation to the final metal container
diameter, typically 211, however, may vary depending on
application. The draw ratio is generally in the range 1.0-1.7:1,
and with a wall thickness reduction typically 25% of the ingoing
cup wall thickness, however this can be produced with a smaller or
greater reduction (in the range 10-60%) depending on
application.
[0025] The wall thickness reduction is again achieved by a
stretching technique using a combination of pressure sleeve and die
geometry with controlled blank holding loads. The correct choice of
diameter reduction ratio to achieve the finished can is also
important in enabling the stretch process to be successful. The
tooling geometry used typically is as follows: pressure sleeve
diameter up to 0.30 mm smaller than the first redraw cup internal
diameter; pressure sleeve radius up to 2.0 mm; die radius up to 2
mm with a parallel land length up to 5 mm.
[0026] The blank holding load is achieved by use of air pressure of
up to 100 psi fed into a stack of two or more internal multiplying
pistons. Location of the cup on the die is effected by means of a
nest recess with a diameter matched to the cupper cup, allowing for
the thickness of the actual laminate. The radius of the nest
diameter with the die at the base of the nest is in the range
0.10-2.00 mm.
[0027] The punch is parallel along its length and the gap between
the punch diameter and die (per side) is generally controlled to
between 1.00 and 1.20 times the starting laminate thickness. The
punch radius is important to achieve the required stretch whilst
minimising subsequent can wall marling which could lead to laminate
rupture. Punch nose radii in the range 1 mm to 3 mm are typically
used.
[0028] Gap control or arrested draw is employed at the redraw
stages to eliminate high spot clip off or the generation of
laminate "whiskers". When gap control is used, gaps of 0.10 to 0.15
mm between the pressure sleeve and die face are generally used
depending upon the laminate feed stock used. The overall metal
container wall thinning employed is 5-40% dependent upon the end
use of the container.
[0029] The second redraw container (i.e. final container diameter)
is transferred to a different redraw press, which can accommodate
tooling for the reverse draw for the internal chamber, redraw of
the reverse chamber and base reform operations.
Reverse Draw Operation
[0030] The container undergoes a reverse draw operation, in order
to produce an initial internal chamber. The draw ratio for the
initial internal chamber is generally in the range 1.0-1.7:1, with
no (or limited) wall thickness reduction instead the internal depth
is achieved by a reduction of the in going second redraw container
height. To prevent wall thickness reduction correct choice of die
radius, punch radius and controlled blank holding pressure are
required. The tooling geometry typically is as follows: die
external diameter up to 0.60 mm smaller than the second redraw can
internal diameter; die external radius up to 2.0 mm; die radius up
to 5 mm with a parallel land length up to 5 mm.
[0031] The blank holding load is achieved by use of air pressure of
up to 100 psi fed into a stack of two or more flexible pressure
chambers. Location of the container on the pressure sleeve is
effected by means of a nest recess with a diameter matched to the
second redraw can, allowing for the thickness of the actual
laminate. The radius of the nest diameter with the die at the base
of the nest is in the range 0.10-2.00 mm.
[0032] The punch is parallel along its length and the gap between
the punch diameter and die (per side) is generally controlled to
between 1.10 and 1.40 times the starting laminate thickness. The
punch radius is important to prevent 1 limit wall thickness
reduction, instead it is used to draw the container wall to produce
the internal chamber. The punch nose radius in the range 2 mm to
7.5 mm is typically used, Depth of the reverse draw is controlled
out by the means of a mechanical stop. The depth of the reverse
draw is dependent on the application, typically between 10-100
mm.
Redraw of the Reverse Chamber
[0033] The reverse redraw container is transferred to the next
operation station, where redraw of the reverse chamber is
performed. The container's internal chamber is redrawn to a smaller
diameter for a portion of it's depth, i.e. two different chamber
diameters and depths. The draw ratio used in the reduction of the
internal chamber is generally in the range 1.0-1.7:1. The increase
in height of the internal chambers is caused by a reduction of the
reverse redrawn can base diameter and base thickness reduction.
[0034] Base thickness reduction is again achieved by a stretching
technique using a combination of pressure sleeve, punch and die
geometry with controlled blank holding loads. The correct choice of
internal diameter reduction ratio to achieve the required internal
parameters is important in enabling the process to be
successful.
[0035] The tooling geometry used typically is as follows: die
external diameter up to 0.60 mm smaller than the second redraw can
internal diameter; die radius up to 5 mm with a parallel land
length up to 5 mm.
[0036] The blank holding load is achieved by use of air pressure of
up to 100 psi fed into a stack of two or more flexible pressure
chambers. Location of the container on the pressure sleeve is
controlled by means of the internal chamber from the reverse redraw
operation with a diameter 0.60 mm smaller than the internal chamber
for can location, allowing for the thickness of the laminate to be
taken into account.
[0037] The punch is parallel along its length and the gap between
the punch diameter and die (per side) is generally controlled to
between 1.10 and 1.40 times the starting laminate thickness. The
punch radius is important to achieve the required stretch. The
punch nose radii in the range 2 mm to 7.5 mm is typically used.
[0038] Depth of the redraw is controlled by the means of a
mechanical stop. The depth of the redraw operation is dependent on
the application, typically between 10-100 mm.
Base Reform
[0039] The redraw container is transferred to the final operation
station for this application, where base reform is performed. The
final internal chamber is reformed to the largest diameter chamber
for a specified depth (i.e. three different chamber diameters and
depths). The draw ratio used in the reduction of the internal
chamber is generally in the range of 1.0-1.4:1; with no wall
thickness reduction, instead the internal depth for this final
chamber is achieved by a reduction from the ingoing second redraw
container height.
[0040] To prevent wall thickness reduction, a correct choice of die
and punch radius is required. The tooling geometry typically is as
follows: punch external diameter up to 0.60 mm smaller than the
second redraw can internal diameter; punch external radius up to
2.0 mm; punch internal radius up to 2.0 mm; die radius up to 2.0 mm
with a parallel land length up to application requirement;
[0041] The base reform load is applied by the reaction between the
punch and die that is used to apply the base design.
[0042] Location of the container on the die is effected by means of
a nest recess with a diameter matched to the second redraw
container, allowing for the thickness of the actual laminate. The
radius of the nest diameter with the die at the base of the nest is
perpendicular.
[0043] Depth of the redraw is controlled by the means of a
mechanical stop. The punch bottoms out on the die face at the
specified depth for the application requirements.
[0044] After the final operation the container is trimmed (this can
occur after the second redraw operation) and passed through an
oven. This oven is typically held at 200-230' C and the pass time
is typically between 1 and 3 minutes. This facilitates the removal
of petroleum wax lubricant to such a level so that it does not
interfere with the lay down of printing inks used to decorate the
can. It also raises the surface energy of the PET coating to at
least 38 dynes/cm, which increases the wettability of the PET
surface to printing inks. The temperature cycle in the oven is
chosen to minimise recrystallisation of the PET by rapid
temperature rise and cooling cycles.
[0045] Printing is currently carried out using conventional
machinery, which applies thermally curing inks onto the external
surface of the can. Again, recrystallisation of the PET is
minimised as above. Alternatively, a shrink wrap sleeve may be
applied at lower temperatures.
[0046] The invention will now be further described with reference
to the accompanying diagrammatic drawings, in which:
[0047] FIG. 1 illustrates five stages of a cupping operation of the
method of the present invention;
[0048] FIG. 2 illustrates five stages of a first draw 1 stretch
redraw operation of the method of the present invention;
[0049] FIG. 3 illustrates five stages of a second draw/stretch
redraw operation of the method of the present invention;
[0050] FIG. 4 illustrates six stages of a reverse redraw operation
of the method of the present invention;
[0051] FIG. 5 illustrates six stages of a redraw operation of the
method of the present invention;
[0052] FIG. 6 illustrates five stages of a base reform operation of
the method of the present invention;
[0053] FIG. 1 shows five stages of a cupping operation of the
method of the present invention. The five stages are labelled A to
E. Stage 1A shows a feed stock strip 1 of laminated steel strip
held between a draw pad 2 and a blank and draw die 3. A disc of the
required diameter is cut from the strip, by downward movement of a
cutter 5 (see FIG. 1B). A punch 6 (FIGS. 1C and 1D) is then moved
downwardly with the disc edges trapped between the opposed surfaces
of the draw pad 2 and draw die 3. A cup 7 is thereby formed which
is removed from the die by air pressure (see FIG. 1E).
[0054] As will be seen from FIG. 2, the cup is then placed on a die
for first redraw purposes. This stage is illustrated in FIG. 2A.
The die is formed with a shaped lip 9 and has a curved annular
projection 10 protruding inwardly from its upper surface. As seen
in FIG. 2B, a pressure sleeve 11 and punch move downwardly and
within the side wall of the cup 7. The outer rim of the cup base
seats between the opposed surfaces of the pressure sleeve 11 and
the die 8. The gap between these members is sufficient only to
restrict movement of the cup 7, not to impose a force sufficient to
deform or iron the cup. As the punch is moved downwardly, so the
cup wall is stretched to increase the cup height.
[0055] This stretching process can be seen more clearly from FIG.
5. It will be seen that the cup wall between the projection 10 and
the punch lower face is not in contact with either the die 8 or the
side wall of the punch 12. Movement of the cup between the pressure
sleeve 11 and the die 8 and over the curvilinear projection 10 is
restricted to cause stretching of the cup wall. After stretching,
the cup is ejected by air pressure (see FIG. 2E).
[0056] Turning to FIG. 3, the second redraw operation uses the same
or similar pressure sleeve and die as those used in the first
redraw operation. These have been accordingly been given the same
numerical reference. In FIG. 3, the cup 7 is again shown in
positioned on the die 8, see FIG. 3A. The pressure sleeve 11 is
moved downwardly as shown in FIG. 3B to position the sleeve within
the cup 7. Again, the spacing between the sleeve 11 and the die 8
is to restrict movement of the cup, not to preclude such movement.
A punch 14 is moved downwardly into engagement with the cup base to
once again stretch the cup side wall and effect elongation thereof.
This stretching operation being as described above in relation to
FIG. 2. This stretching operation is shown in FIGS. 3C and 3D. The
fully stretched and formed cup is ejected by air pressure (see FIG.
3E).
[0057] FIG. 4 concerning the reverse redraw operation illustrates
how the initial internal chamber is applied. Cup 7 is placed on the
pressure sleeve 15 for the reverse redraw for the initial internal
chamber. This stage is illustrated in FIG. 4A. As seen in FIG. 4B,
the die 14 moves downwardly and locates in the cup 7. The die 14
continues its downward movement and clamps the cup 7 between itself
and the pressure sleeve 15, see FIG. 4C. The die 14 continues the
downward motion, and in doing so, forces the pressure sleeve 15 to
move in the same direction, hence, causing the cup 7 to be drawn
over the fixed punch 16, resulting a reduction in the height of the
second redraw cup (i.e. material is not thinned, but moved to new
position, due to minimal blank holding pressure to be applied). The
depth of the internal chamber is controlled by a mechanic stop at a
described displacement. This operation applies the initial internal
chamber, see FIG. 4D. The die 14 begins its upward motion as
illustrated in FIG. 4E. After the reverse redraw operation the cup
7 is ejected by air pressure, see FIG. 4F.
[0058] In FIG. 5, the redraw of the initial internal chamber is
illustrated, which produces two internal chambers of different
diameters and depths. Cup 7 is placed on the pressure sleeve 18 for
the redraw of the initial internal chamber. This stage is
illustrated in FIG. 5A. As seen in FIG. 5B, the die 17 moves
downwardly and locates in the cup 7. The die 17 continues it
downward movement and clamps the cup 7 between itself and the
pressure sleeve 18, see FIG. 5C. The die 17 continues the downward
motion, and in doing so, forces the pressure sleeve 17 to move in
the same direction, hence, causing the cup 7 to be drawn over the
fixed punch 19. As the die 17 moves downwardly the cup base is
reduced in diameter, producing two internal chambers of different
diameters and depths, see FIG. 5D. The depth of the internal
chamber is controlled by a mechanic stop at a described
displacement. The die 17 begins its upward motion as illustrated in
FIG. 5E. After the reverse redraw operation the cup 7 is ejected by
air pressure, see FIG. 5F.
[0059] FIG. 6, describes the process of base reform, this is
whereby the final internal chamber (for this application) is
applied to the can. In FIG. 6, the cup is located in the die 21 for
the base reform operation to occur see FIG. 6A. As seen in FIG. 6B,
the punch 20 moves downwardly and locates in the cup 7. The punch
20 continues it downward movement into engagement between the cup
7, itself and the die 21. With the third recess applied, due to a
reduction, once again, from the ingoing cup height, as explained in
relation to FIG. 4. This base reform operation is shown in FIGS. 6C
and 6D. The punch 20 begins its upward motion, and the fully formed
cup 7 is ejected by air pressure, see FIG. 6E.
[0060] It will be appreciated that the foregoing is merely
exemplary of methods and apparatus in accordance with this
invention and that modifications can readily be made thereto
without departing from the true scope of the invention.
[0061] The advantage of such a two piece can over the three piece
version is that there is no seaming of the heat exchange unit to
the welded cylinder, which removes the problem of corrosion
encountered at the seaming of the cylinder to the heat exchange
unit.
* * * * *