U.S. patent application number 13/023990 was filed with the patent office on 2012-02-09 for shaped, threaded metal can.
Invention is credited to Gerald Baker, Jianwen Hu, William Kapolas, Steve Manne, Seth Moore.
Application Number | 20120031913 13/023990 |
Document ID | / |
Family ID | 40094910 |
Filed Date | 2012-02-09 |
United States Patent
Application |
20120031913 |
Kind Code |
A1 |
Moore; Seth ; et
al. |
February 9, 2012 |
Shaped, Threaded Metal Can
Abstract
A food or drink container kit includes a metal container
including a round threaded neck having at least one integrally
formed thread. The kit also includes a metal press-on, twist-off
closure comprising a round skirt including a gasket material 5
located on at least a portion of the interior of the skirt, a seal
forming between the neck and skirt when the closure is placed on
the container and heated.
Inventors: |
Moore; Seth; (Oconomowoc,
WI) ; Baker; Gerald; (Wauwatosa, WI) ;
Kapolas; William; (Des Plaines, IL) ; Manne;
Steve; (Oconomowoc, WI) ; Hu; Jianwen;
(Nashotah, WI) |
Family ID: |
40094910 |
Appl. No.: |
13/023990 |
Filed: |
February 9, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11811362 |
Jun 8, 2007 |
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13023990 |
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Current U.S.
Class: |
220/610 |
Current CPC
Class: |
B65D 41/0457 20130101;
B65D 7/04 20130101; B65D 53/06 20130101; B65D 41/17 20130101 |
Class at
Publication: |
220/610 |
International
Class: |
B65D 8/04 20060101
B65D008/04 |
Claims
1. A two piece container, comprising: a can end having an outside
end diameter; a can body formed from single sheet of metal joined
with a seam to form a cylinder having a top end and a bottom end,
the seam extending from the top end to the bottom end, the can body
including a neck portion formed at the top end and a body portion;
the neck portion defining a can opening surrounded by a curled
portion of the sheet metal and a threaded portion including at
least one thread formed from the sheet metal adjacent to the curled
portion; the body portion having a variable-diameter side-wall
extending from the neck portion to the bottom end, the side wall
including a first lobe portion, a second lobe portion and a
transition portion joining the lobed portions wherein the side-wall
has a first diameter at the first lobe portion which is between 100
and 120% of the end diameter, a second diameter at the second lobe
portion which is between 95 and 110% of the end diameter, and a
third diameter at the transition portion which is between 80 and
95% of the end diameter; and a double seam which hermetically seals
the can end to the body portion.
2. The container of claim 1, wherein the body portion has a length
defined by the distance between the neck portion and the bottom
end, the length being between 165 and 230% of the end diameter.
3. The container of claim 2, wherein the curled portion is formed
by curling an end portion of the sheet metal outwardly.
4. The container of claim 2, wherein the curled portion is formed
by curling an end portion of the sheet metal inwardly.
5. The container of claim 3, wherein the curled portion forms a
hollow toroid surrounding the opening.
6. The container of claim 4, wherein the curled portion forms a
hollow toroid surrounding the opening.
7. The container of claim 5, wherein the toroid is a torus.
8. The container of claim 2, wherein the thread wraps around the
neck portion at least 11/2 times.
9. The container of claim 8, including a metal closure having a
generally cylindrical side wall integrally formed with an end wall
and integrally formed with a rim at the end of the side wall
opposite the end wall, the closure further including a gasket
material disposed within the closure to form a hermetic seal
between the neck and closure when the closure is joined to the
threaded portion, heated and then cooled.
10. The container of claim 9, wherein the gasket material is
disposed within the closure to permit the closure to be pressed
onto the threaded portion to form a vacuum or hermetic seal between
the closure and the neck portion when the container wall and
closure are heated.
11. The container of claim 10, wherein the gasket material hardens
and forms around the first end when it is heated and then
cooled.
12. A two piece container, comprising: a can end having an outside
end diameter; a can body formed from single sheet of metal joined
with a seam to form a cylinder having a top end and a bottom end,
the seam extending from the top end to the bottom end, the can body
including a neck portion formed at the top end and a body portion;
the neck portion defining a can opening surrounded by a toroid
formed from the sheet metal and a threaded portion including at
least one thread from the sheet metal adjacent to the toroid; the
body portion having a variable-diameter side-wall extending from
the neck portion to the bottom end, the side wall including a first
lobe portion, a second lobe portion and a transition portion
joining the lobed portions wherein the side-wall has a first
diameter at the first lobe portion which is between 100 and 120% of
the end diameter, a second diameter at the second lobe portion
which is between 95 and 110% of the end diameter, and a third
diameter at the transition portion which is between 80 and 95% of
the end diameter; wherein the body portion has a length defined by
the distance between the neck portion and the bottom end, the
length being between 165 and 230% of the end diameter; and a double
seam which hermetically seals the can end to the body portion.
13. The container of claim 12, wherein the toroid is hollow and has
a generally circular cross-section.
14. The container of claim 12, wherein the toroid is hollow and has
a generally elongated cross-section.
15. The container of claim 12, wherein the threaded portion is a
single thread which wraps around the neck portion at least 11/2
times.
16. The container of claim 12, including a metal closure having a
generally cylindrical side wall integrally formed with an end wall
and integrally formed with a rim at the end of the side wall
opposite the end wall, the closure further including a gasket
material disposed within the closure to form a hermetic seal
between the neck and closure when the closure is joined to the
threaded portion, heated and then cooled.
17. The container of claim 16, wherein the gasket material is
disposed within the closure to permit the closure to be pressed
onto the threaded portion to form a vacuum or hermetic seal between
the closure and the neck portion when the container wall and
closure are heated.
18. The container of claim 17, wherein the gasket material hardens
and forms around the first end when it is heated and then
cooled.
19. A two piece container, comprising: a can end having an outside
end diameter; a can body formed from single sheet of metal joined
with a seam to form a cylinder having a top end and a bottom end,
the seam extending from the top end to the bottom end, the can body
including a neck portion formed at the top end and a body portion;
the neck portion defining a can opening surrounded by a toroid
formed from the sheet metal and a threaded portion including at
least one thread formed from the sheet metal adjacent to the toroid
which wraps around the neck portion at least 11/2 times, the body
portion having a variable-diameter side-wall extending from the
neck portion to the bottom end; the side wall including a first
lobe portion, a second lobe portion and a transition portion
joining the lobed portions wherein the side-wall has a first
diameter at the first lobe portion which is between 100 and 120% of
the end diameter, a second diameter at the second lobe portion
which is between 95 and 110% of the end diameter, and a third
diameter at the transition portion which is between 80 and 95% of
the end diameter; wherein the body portion has a length defined by
the distance between the neck portion and the bottom end, the
length being between 165 and 230% of the end diameter; and a double
seam which hermetically seals the can end to the body portion.
20. The container of claim 19, wherein the toroid is hollow and has
a generally circular cross-section.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of prior U.S. application
Ser. No. 11/811,362, filed Jun. 8, 2007 that is currently pending,
which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] The application generally relates to metal food containers.
The application relates more specifically to shaped metal food
containers with screw-top closures and methods of making the
same.
SUMMARY
[0003] One embodiment relates to a two piece container. The two
piece container includes a can end, can body, neck portion, body
portion and a double seam. The can end has an outside diameter. The
can body is formed from a single sheet of metal joined with a seam
to form a cylinder having a top end and a bottom end. The seam
extends from the top end to the bottom end. The can body includes a
neck portion formed at the top end and a body portion. The neck
portion defines the can opening surrounded by a curled portion of
the sheet metal and a threaded portion including at least one
thread formed from the sheet metal adjacent to the curled portion.
The body portion has a variable-diameter side-wall that extends
from the neck portion to the bottom end. The side-wall has a first
lobe portion with a diameter between 100% and 120% of the end
diameter, a second lobe portion with a diameter between 95% and
110% of the end diameter and a transition portion joining the lobed
portions with a diameter between 80% and 95% of the end diameter.
The double seam hermetically seals the can end to the body
portion.
[0004] Another embodiment relates to a two piece container. The two
piece container includes a can end, can body, neck portion, body
portion and a double seam. The can end has an outside diameter. The
can body is formed from a single sheet of metal joined with a seam
to form a cylinder having a top end and a bottom end. The seam
extends from the top end to the bottom end. The can body includes a
neck portion formed at the top end and a body portion. The neck
portion defines a can opening surrounded by a toroid formed from
the sheet metal and a threaded portion including at least one
thread from the sheet metal adjacent to the toroid. The body
portion has a variable-diameter side-wall that extends from the
neck portion to the bottom end. The side-wall has a first lobe
portion with a diameter between 100% and 120% of the end diameter,
a second lobe portion with a diameter between 95% and 110% of the
end diameter and a transition portion joining the lobed portions
with a diameter between 80% and 95% of the end diameter. The body
portion has a length defined by the distance between the neck
portion and the bottom end that is between 165% and 230% of the end
diameter. The double seam hermetically seals the can end to the
body portion.
[0005] Yet another embodiment relates to a two piece container. The
two piece container includes a can end, can body, neck portion,
side-wall and a double seam. The can end has an outside diameter.
The can body is formed from a single sheet of metal joined with a
seam to form a cylinder having a top end and a bottom end. The can
body includes a neck portion formed at the top end and a body
portion. The neck portion defines a can opening surrounded by a
toroid formed from the sheet metal and a threaded portion including
at least one thread which wraps at least 11/2 times around the neck
portion and is formed from the sheet metal adjacent to the toroid.
The body portion has a variable-diameter side-wall that extends
from the neck portion to the bottom end. The side-wall has a first
lobe portion with a diameter between 100% and 120% of the end
diameter, a second lobe portion with a diameter between 95% and
110% of the end diameter and a transition portion joining the lobed
portions with a diameter between 80% and 95% of the end diameter.
The body portion has a length defined by the distance between the
neck portion and the bottom end that is between 165% and 230% of
the end diameter. The double seam hermetically seals the can end to
the body portion.
BRIEF DESCRIPTION OF THE FIGURES
[0006] The application will become more fully understood from the
following detailed description, taken in conjunction with the
accompanying figures, wherein like reference numerals refer to like
elements, in which:
[0007] FIG. 1 is a perspective view of a metal container having a
threaded neck, according to an exemplary embodiment;
[0008] FIG. 2 is a side profile view of a metal container having a
threaded neck, according to an exemplary embodiment;
[0009] FIG. 3 is a close-up side profile view of the threaded neck,
according to an exemplary embodiment;
[0010] FIG. 4 is a close-up side profile view of the threaded neck
having a press-on twistoff closure installed, according to an
exemplary embodiment;
[0011] FIG. 5 is a partial sectional view of the container
threading having the closure installed, according to an exemplary
embodiment;
[0012] FIG. 6 is a partial sectional view of the container
threading having the closure installed, according to an alternative
embodiment;
[0013] FIG. 7A is a side profile view of a threaded neck, according
to an alternative embodiment;
[0014] FIG. 7B is a side profile view of a threaded neck having a
closure installed, according to an alternative embodiment;
[0015] FIG. 8 is a flow chart of a method of making the metal
container, according to an exemplary embodiment.
[0016] FIG. 9 is a side profile view of a metal container during
manufacturing, prior to forming threading into the container neck,
according to an exemplary embodiment.
[0017] FIG. 10 is a side profile view of a metal container with the
improved shaped having a threaded neck, according to an exemplary
embodiment.
[0018] FIG. 11 is a side profile view of a metal container with the
improved shaped having a threaded neck, according to an alternative
embodiment.
[0019] FIG. 12 is a side profile view of a metal container with the
improved shaped having a threaded neck, according to an alternative
embodiment.
[0020] FIG. 13 is a side profile view of a metal container with the
improved shaped having a threaded neck, according to an alternative
embodiment.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0021] Before turning to the figures which illustrate the exemplary
embodiments in detail, it should be understood that the application
is not limited to the details or methodology set forth in the
following description or illustrated in the figures. It should also
be understood that the phraseology and terminology employed herein
is for the purpose of description only and should not be regarded
as limiting.
[0022] Referring generally to the figures, a metal container (i.e.,
a can) is shown having a threaded neck integrally formed from the
metal of the container body. The threads are formed to fit a
screw-top closure and the closure is a press-on, twist-off closure.
The container is suitable for use with a thermal retort process
with or without over-pressure. Referring still to the figures in
general, a process of making a metal container is provided so that
the integrally formed threads are formed from a relatively unworked
or un-thinned portion of metal once the majority of the container
body has been formed.
[0023] Referring to FIG. 1, a perspective view of metal container 1
is shown, according to an exemplary embodiment. Metal container 1
includes a top end 2, a body 4, and a bottom end 6. Container 1 and
body 4 are shown as substantially cylindrical (i.e., the container
walls or piece forming body 4 are curvilinear). According to
various other embodiments, container 1 may take any number of other
container shapes as may be desirable for different applications or
aesthetic qualities. For example, container 1 may be formed to have
one or more angles that create a polygonal cross-section such as a
rectangular cross-section. Container 1 and body 4 could also be
formed to have any number of edges, curves and/or beads as may be
desirable for end-users and/or for structural integrity purposes.
Metal container 1 may be sized to store about eight ounces of
liquid contents or may be sized differently (e.g., less than eight
ounces, more than eight ounces, twelve ounces, sixteen ounces,
thirty-two ounces, etc.).
[0024] According to an exemplary embodiment, the metal of container
1 is about 0.008 inches thick and is primarily made of tin plated
steel. According to various other exemplary embodiments, the metal
of container 1 is formed from steel having a working gauge range
from about 0.006 inches thick to about 0.013 inches thick, or other
available working ranges. According to various other alternative
embodiments, container 1 may be formed of aluminum, tin free steel
and/or another metal material that may be used to form metal food
containers. The material of container 1 may also be more or less
thick along certain structures or locations of body 4. For example,
in the middle of the side walls of container body 4, the material
may be more thin than material closer to the top end or bottom
end.
[0025] The top of container 1 and container body 4 angles inward to
create a frusto-conical portion 8. A threaded neck 10 extends from
the frusto-conical portion 8. According to an exemplary embodiment,
frusto-conical portion 8 is angled around thirty-seven degrees from
the vertical surfaces of body 4 and sized so that the diameter of
the neck with a closure installed thereon is smaller than the
diameter of body 4. According to various other embodiments,
frusto-conical portion 8 is angled more or less than thirty-seven
degrees from vertical. This sizing and structure may create an
aesthetically pleasing container top, provide a user with increased
leverage for opening the screw-top and/or prevent the container
top, threads, and closure from experiencing some amount of the
unavoidable contact that containers typically have with adjacent
containers or other structures during manufacture, shipping and/or
use. According to other various exemplary embodiments,
frusto-conical portion 8 may not be present on the container, may
be characterized as a cone-shaped shoulder area, or may take any
other shape or size.
[0026] Referring to FIG. 2, a side view of metal container 1 is
shown, according to an exemplary embodiment. At bottom end 6 of
metal container 1, one or more bottom seal structures 21 may
fixably seal a bottom end piece to container body 4. According to
an exemplary embodiment, bottom seal structures 21 are a double
seam including folds of metal adjoining a container flange (e.g.,
92 shown in FIG. 9) and a bottom end piece (i.e., sanitary end) so
that a substantially hermetic seal is created.
[0027] Referring to FIGS. 2 and 3, detail of threaded neck 10 is
shown, according to an exemplary embodiment. Threaded neck 10 is
integrally formed from the metal of container 1, container body 4
and/or frusto-conical portion 8. Threaded neck 10 extends upward
from frusto-conical portion 8 along the vertical axis of container
body 4. The radius and height of threaded neck 10 is generally
determined based on the radius and depth of the closure with which
the threaded neck will be used. A lower ring 12 and one or more
threads 14 extend from threaded neck 10.
[0028] According to an exemplary embodiment, thread 14 is a single
thread conforming to the Glass Packaging Institute's (GPI) glass
finish designation number 465, last revised Feb. 5, 1999. According
to other alternative embodiments, different thread designations or
specifications may be used to create the container's threads (e.g.,
GPI glass finish designation number 2215, etc.). Furthermore, as
shown in the Figures, thread 14 may wrap around the neck portion
more than 1 time. Preferably between 11/2 and 21/2 times.
[0029] Neck edge 16 will generally be curled or rounded to provide
a suitable sealing surface (e.g., uniform and having some
substantial diameter relative to the gauge of the container walls).
Neck edge 16 may also be curled or rounded to provide a suitable
surface for mouth contact or drinking. For example, neck edge 16 is
shown as a curled neck edge, curling to the exterior of threaded
neck 10. The exterior diameter of the neck and structures of the
neck may be appropriately sized to allow the closure to function
properly. According to an exemplary embodiment, the neck is sized
per certain threading specifications (e.g., GPI glass finish
designation number 2215,465, etc.).
[0030] Referring to FIG. 4, a side view of metal container 1 is
shown, metal container 1 having closure 40 (e.g., cap, cover, top,
etc.) shown installed on a round threaded neck 10 of the previous
FIGS., according to an exemplary embodiment. Closure 40 includes a
closure top end 42, a round closure skirt portion 44 and a closure
bottom rim 46. When closure 40 is installed onto threaded neck 10,
closure bottom rim 46 is adjacent lower ring 12. Closure 40 may
have a diameter of 40 millimeters (e.g., shown as diameter "D" on
FIG. 4), but may be sized differently to fit differently sized or
configured threaded necks. According to one alternative embodiment,
closure 40 is a 48 millimeter diameter closure. According to an
exemplary embodiment, relatively deep closures may be desirable for
use with threaded necks having a single thread. According to an
exemplary embodiment, closure 40 has a closure style of "40 DER"
that may be described as having a diameter of 40 millimeters, a
deep closure skirt, and a vacuum safety button that requires a 20
inch Hg vacuum to verify the seal is intact. According to various
other exemplary embodiments, the closure may include other tamper
evidencing features or no tamper evidencing features.
[0031] Referring to FIG. 5, a sectional view of threaded neck 10
and closure 40 are shown, according to an exemplary embodiment.
Closure 40 is a press-on, twist-off type metal closure (i.e.,
push-on/twist-off cap, etc.). A press-on, twist-off closure refers
to a closure that is initially coupled to a body by a press-on
(i.e., push-on) movement, but then is later removed or reattached
by a twisting motion. According to an exemplary embodiment, closure
skirt portion 44 is smooth such that closure skirt portion does not
have any threads or other metal structures that would prevent
closure 40 from being pressed onto the threaded neck or threads of
a container. According to various alternative embodiments, closure
40 may be a plastic closure or another closure other than
metal.
[0032] According to an exemplary embodiment, the metal of closure
40 is between about 0.006 inches and 0.008 inches thick. Closure
underside or interior surface 41, along at least some of the
closure skirt portion 44, is coated with a gasket or gasket
material 50. According to an exemplary embodiment, gasket 50 is a
plastisol material or compound applied to the top and side surfaces
of closure underside 41. Materials other than plastisol may serve
as the gasket. Plastisol may provide sufficient resistance to acids
of food products that may come into contact with the plastisol, may
permit hot-fill processes to produce a vacuum seal, and may
withstand a heat-based sterilization or cooking process. A
sufficient amount of the gasket material coats closure underside 41
such that the outer diameter of thread 14 is larger than the inner
diameter of gasket 50. The plastisol compound does not contain
preformed thread indents or receiving structures. Rather, steam or
another application of heat is used to soften the plastisol
material prior to pushing the material onto the threaded neck of
the container. The difference between the diameter of the gasket
material and the structures of threaded neck 10 cause the softened
gasket 50 to move and flow around thread 14 so that many portions
of threaded neck 10 are surrounded by gasket 50 such that the
interface(s) between threaded neck 10 and gasket 50 form a hermetic
seal. Following cooling of the plastisol, the plastisol stiffens or
hardens to create a resilient foam that may act to maintain the
hermetic seal with threads 14. The cooled plastisol may have a
semi-permanent or permanent impression of the structures of the
threaded neck such that the closure may be removed and/or reclosed
or resealed with a twist-off or twist-on motion.
[0033] According to an exemplary embodiment, gasket 50 specifically
comprises a plastisol compound that may be characterized as a "508
compound" or similar material. Gasket 50 may be a liquid applied
gasket or any other suitable gasket material.
[0034] Referring to FIG. 6, a sectional view of a threaded neck and
closure 40 is shown, according to an alternative exemplary
embodiment. In the embodiment shown in FIG. 6, neck edge 16 is
curled to the interior of the threaded neck. Sealing compound 61
may prevent a raw metal edge from exposure to moisture that may
rust and/or corrode the raw metal.
[0035] Referring to FIGS. 7A and 7B, a side view of a threaded
container neck having multiple independent threads is shown,
according to an alternative embodiment. Multiple independent
threads may allow the height of a closure to be decreased.
[0036] Referring to FIG. 8, a flow chart of a process of making and
using a metal container such as metal container 1 shown in the
previous FIGS. is shown, according to an exemplary embodiment.
Metal container 1 may be made using a variety of methods. For
example, metal container 1 may be formed using a drawn and ironed
manufacturing process, a drawn and redrawn manufacturing process
and/or a variety of alternative manufacturing processes. According
to the embodiment shown in FIG. 8, a drawn and ironed process is
used to manufacture metal container 1. Raw material may come from a
source in a variety of forms. For example, raw material may come
from a metal supplier in a large coil. This coil may be upended or
otherwise moved into a position to be unreeled by an unreeler. The
unreeled metal from the unreeler may be fed into a lubricator.
Lubricant may be applied to the unreeled metal by a series of
rollers or otherwise. Lubricant improves the workability of the raw
material later in the process.
[0037] A blank may be formed from the lubricated raw material or
otherwise provided (step 802). The blank may be sized such that the
blank may be fanned to create the container body. Blanks may be
formed using a variety of processes including cutting processes.
For example, the blanks may be fanned using a press cut-activity. A
cupping press machine may cut a blank that is shaped like a disk.
Once a blank has been formed or otherwise provided, the blank is
formed into a cup (step 804). This cup forming activity may take
place within the same machine and close-in-time to the blank
cutting step. For example, a single machine may act in a double
action; a first action may cut the blank and a second action may
form the cup. A cup may then be ejected and advanced to the can
handling system.
[0038] The cup fanned from the blank may be a relatively short or
squat cup. The bottom of the cup will be approximately the same
metal thickness as the original blank. The sides of the cup may be
worked slightly and may be thinner than the original metal of the
blank. Depending on the target height of the metal container, the
cup will be subjected to a drawn and ironed process that forms the
container body shape from the cup (step 806). The container body
shape may be fanned using a machine generally referred to in the
art as a "bodymaker." This machine works or forms the cup with a
punch and ironing rings in a progression to form the shape and size
of the container's body walls. While this drawn and ironed process
allows the container to be formed to a height taller than the cup,
the ironing reduces the wall thickness and often results in the
walls being too thin and/or brittle to reliably form fine and
precise structures such as threads. The base of the formed
container, however, is still approximately the same metal thickness
as the original blank (i.e., the original cup base is still the
base of the fanned container as of this step, and is relatively
unworked and un-thinned). This relatively unworked or un-thinned
container base may be reliably formed into the thread. So, the base
of the formed container shape, or the cup bottom, becomes the top
of the final container body and the container neck is fanned using
the base of the formed container (step 808). During this step or
another step, the container neck may be cut to create the primary
container opening that the closure will cover. According to various
exemplary embodiments, the primary container opening may be cut
prior to forming the neck from the base of the formed
container.
[0039] After the neck has been formed and the primary container
opening has been cut, threading may be formed from the container
neck (step 810). The threading may be formed using an interior
press, an exterior press, and/or any other suitable thread forming
process. The threads may be formed to fit a press-on, twist-off
closure. According to an exemplary embodiment, the thread or
threads may also be formed such that a threaded neck and thread
metal thickness of about at least 0.007 inches is maintained. In
addition to maintaining a certain thickness of the metal, it may be
important to maintain a certain low percentage of thinning. For
example, while the sides of the container may be thinned during the
drawing process down to about 40 percent of the original thickness
of the blank, the metal used to form the threaded neck and the
threads should not be thinned by more than 10 percent of the
original blank thickness. According to an exemplary embodiment, no
portion of the threaded neck and/or threads are thinned more than
12 percent and maintain a thickness of about at least 0.007 inches.
According to various alternative embodiments, greater thinning
percentages (e.g., thread thinning of greater than 12 percent,
thinning of up to 30 percent, etc.) may be used to create the
threaded neck and/or threads. According to yet other various
embodiments, container wall and/or thread thickness may be less
than 0.007 inches.
[0040] According to various exemplary embodiments, the threading
will be thick enough and resilient enough to withstand various
typical thread forming and container handling processes. The
threading should be prominent enough so that when human applied
rotation of the closure relative to the container body occurs, the
threads provide enough leverage in the plastisol to break the
vacuum seal (e.g., around 20 in Hg) holding the closure onto the
container body. The threading may thereby be configured to allow
the consumer easy initial access to the container contents and
thereafter allow the consumer to reclose the container with
sufficient thread-provided leverage and threading accuracy to
create a liquid-type seal (i.e., substantially watertight) upon
reclosure.
[0041] The container end opposite the neck (i.e., the can bottom
end) may be fixably enclosed (step 812) after a variety of steps in
the process. According to an exemplary embodiment, a container
bottom end part is attached to the container end opposite the neck
(i.e., the can bottom end shown in FIGS. 1 and 2) such that a
bottom most portion of the container body side walls and the edge
of a bottom end are interfolded together to create a fixed and
hermetic seal.
[0042] After both the top end and bottom end of the container are
formed, the container may be filled (step 814). While the open
container may be filled with any variety of materials or contents,
the container is filled with food according to an exemplary
embodiment. The food may be pre-cooked, partially pre-cooked,
warmed or cool. According to an exemplary embodiment, the container
is hot-filled.
[0043] Once the container has been filled, the closure may be
pressed onto the threaded neck (step 816). Step 816 may include
heating the closure prior to and/or during the activity of pressing
the closure onto the threaded neck. According to an exemplary
embodiment, the closure is a press-on, twist-off closure lined with
a plastisol material. The plastisol may be partially fluid,
softened and/or heated prior to pushing the closure onto the
threads such that the friction between the plastisol material and
the threaded structures is low enough to allow the closure to be
fully applied (i.e., installed, slidably installed, rotatably
installed) and/or formed around the threads (e.g., pressed onto the
threads). According to an exemplary embodiment, steam or hot air
may be applied to the closure to adequately soften the plastisol
material prior to pressing the closure onto the threads. According
to various exemplary embodiments, the steam temperature applied to
the closure is around 190 degrees Fahrenheit to 210 degrees
Fahrenheit.
[0044] The container may be subjected to a thermal retort process
(step 818). A thermal retort process may generally be characterized
as a process of subjecting the filled and closed container to a
cooking or sterilization process having different heat, time and
pressure variables sufficient to substantially sterilize the
interior and contents of the food container. Some thermal retort
processes may be overpressure thermal retort processes where
pressure outside the container is substantially matched or slightly
exceeded relative to the pressure that builds on the inside of the
container due to heating a sealed container. Overpressure thermal
retort processes may generally include inserting a filled and
closed container (or group of containers) into a retort vessel that
heats the container via steam, water or a combination of steam and
water and provides overpressure to prevent container deformation or
breakage due to pressure build-up inside the container.
[0045] During a thermal retort process, the container and the food
inside the container will be brought to a temperature of about at
least 200 degrees Fahrenheit. According to various exemplary
embodiments, a thermal retort process may include bringing the
container to a temperature of between 220 degrees Fahrenheit and
260 degrees Fahrenheit. According to yet other embodiments, a
thermal retort process includes bringing the container to a
temperature of at least 240 degrees Fahrenheit. According to a
preferred embodiment, the container and closure should be able to
withstand a thermal retort process of about 250 degrees Fahrenheit
with about 32 pounds per square inch of overriding pressure for a
period of about 45 minutes and 3 pounds per square inch
differential between overriding pressure and internal pressure.
Processing step 818 may also include steps of controllably ramping
up temperature, cooking and then controllably bringing temperature
down or dropping temperature so that a strong vacuum (e.g., 20 inHg
to 25 inHg) is formed between the closure and container body that
substantially holds the closure onto the neck and maintains the
hermetic seal. According to various other exemplary embodiments, a
weaker or stronger vacuum may be created and maintained.
[0046] The specifications of the thermal retort process will vary
depending on the food being cooked, the machinery (e.g., retort
vessel) being used, the amount of agitation used with the heat and
any number of other variables. It maybe desirable to cook different
types of food to certain different minimum temperatures for certain
different minimum amounts of time to ensure sterilization. A
container and closure of the present application should be able to
withstand a variety of typical temperature, time and pressure
levels such that the container may be considered suitable for use
with a thermal retort process for a wide variety of foodstuffs,
including, for example, adult nutritional drinks, to those skilled
in the art of food sterilization using a retort process.
[0047] During the manufacturing process, the metal container may
also be washed and coated as required for workability, cleanliness
of the container and longevity of the container surfaces when
subjected to container contents, liquids and/or air.
[0048] Referring to FIG. 9, a profile view of a container body
prior to forming the threading is shown, according to an exemplary
embodiment. As discussed above with reference to the process of
FIG. 8, a container neck 90 will be formed using the base of the
formed cup or container shape. Container neck 90 may be formed
prior to or after cutting a primary container opening into the
container. Unformed container neck 90 may be taller than a formed
threaded neck as the forming process will generally shorten the
neck as it bends or otherwise uses the material of the neck in
shaping the thread or threads. Furthermore, excess material may be
cut or otherwise removed from the top of container neck 90 and/or
the edges may be rolled or folded over to create the outward or
inward rolls of FIGS. 5 and 6. Referring still to FIG. 9, bottom
end flanges 92 maybe formed or created by machinery of the
container's manufacturing process to provide a beginning interface
or structure that a bottom end part may be interfolded with to
create a fixably attached and hermetically sealed (e.g.,
dry-sealed) bottom end.
[0049] Referring to FIGS. 10-13 generally, a container is shown
which includes a top container end, a bottom container end and a
can body. Cans of this type may include a shaped can body (as shown
by examples), separately formed bottom container end and a
separately formed top container end. The container ends may be
fabricated all, or in part, from a metal (e.g., steel) and are
joined to the can body with a rolled joint double-seam or soldered
joint creating a hermetic seal. The container body can be formed
from a rolled piece of metal with a seam or welded joint extending
from the top end of the can body to the bottom end of the can
body.
[0050] The relative dimensions, including angles, in FIGS. 10-13
are to scale. Actual measurements of FIGS. 10-13 will disclose the
relative dimensions and angles of the preferred embodiments.
Accordingly, actual dimensions not expressly set out in this
description, can be determined by using the ratios of dimensions
measured in FIGS. 10-13 in combination with the express dimensions
set out in this description.
[0051] Referring to FIGS. 10-13, the container body includes a neck
portion and a body portion. The neck portion is located at the top
end of the body portion and includes a curled portion of sheet
metal and a threaded portion. The threaded portion includes one or
more threads formed from the metal adjacent to the curled portion.
The curled portion may be formed by taking the end portion of the
sheet metal and curling it inwardly in order to form a hollow
toroid that surrounds the opening of the top can end. The hollow
toroid that is formed is referred to as a torus. The hollow toroid,
or torus, that is formed may have a generally circular
cross-section. In alternative embodiments, the threaded portion may
include at least one thread that wraps around the neck portion at
least 11/2 times. Alternative embodiments may further include a
curled portion formed by taking the end portion of the sheet metal
and curling it outwardly to form the hollow toroid surrounding the
opening in order to form a torus. Additionally, the hollow toroid
portion may have a generally elongated cross-section in various
other embodiments.
[0052] Referring to FIGS. 10-13, the body portion has a length that
includes a side wall that extends from the neck portion to the
bottom end of the container. The side wall includes a first lobe
portion, a second lobe portion and a transition portion located
between the first and second lobes. Each portion of the side wall
has a diameter. The first diameter is the diameter at the widest
portion of the first lobe located between the transition portion
and the bottom of the neck portion. The second diameter is the
diameter at the widest point of the second lobe located between the
transition portion and the bottom container end of the container
body. The third diameter is located at the transition portion and
is the diameter at the narrowest point of the container body.
[0053] Referring to FIG. 10, container 100 includes body portion
102, first lobe portion 104, second lobe portion 106, transition
portion 108, bottom container end 110, length 112, first diameter
D114, second diameter D116, third diameter D118 and end diameter
D120.
[0054] The dimensions of container 100 are suitable with various
diameters and lengths for various applications. Exemplary
dimensions are illustrated in centimeters (cm). Exemplary
dimensions with the diameters and length are between 6.0 cm and 12
cm in diameter and 10 cm and 20 cm in length. In one embodiment
diameter D114 is 102% of diameter D120, diameter D114 is about 7.2
cm and diameter D120 is about 7.0 cm. In this same embodiment
diameter D116 is 102% of diameter D120, diameter D116 is about 7.2
cm and diameter D120 is about 7.0 cm. Also, in this same
embodiment, diameter D118 is 87% of diameter D120, diameter D118 is
about 6.1 cm and diameter D120 is about 7.0 cm. This embodiment
also includes length 112 that is 165% of diameter D120, length 112
is about 11.6 cm and D120 is about 7.0 cm. In additional
embodiments diameter D114 can be substantially similar to or
greater in length than diameter D120. Diameter D116 can be
substantially similar, greater or lesser in length than diameter
D120, diameter D118 can be substantially similar or less than the
length of diameter D120 and length 112 is greater in length than
diameter D120.
[0055] Referring to FIG. 11, container 200 includes body portion
202, first lobe portion 204, second lobe portion 206, transition
portion 208, bottom container end 210, length 212, first diameter
D214, second diameter D216, third diameter D218 and end diameter
D220.
[0056] The dimensions of container 200 are suitable with various
diameters and lengths for various applications. Exemplary
dimensions are illustrated in centimeters (cm). Exemplary
dimensions with the diameters and length are between 6.0 cm and 12
cm in diameter and 10 cm and 20 cm in length. In one embodiment
diameter D214 is 101% of diameter D220, diameter D214 is about 7.5
cm and diameter D220 is about 7.4 cm. In this same embodiment
diameter D216 is 99% of diameter D220, diameter D216 is about 7.3
cm and diameter D220 is about 7.4 cm. Also, in this same
embodiment, diameter D218 is 86% of diameter D220, diameter D218 is
about 6.4 cm and diameter D220 is about 7.4 cm. This embodiment
also includes length 212 that is 218% of diameter D220, length 212
is about 16.1 cm and D220 is about 7.4 cm. In additional
embodiments diameter D214 can be substantially similar to or
greater in length than diameter D220. Diameter D216 can be
substantially similar, greater or lesser in length than diameter
D220, diameter D218 can be substantially similar or less than the
length of diameter D220 and length 212 is greater in length than
diameter D220.
[0057] Referring to FIG. 12, container 300 includes body portion
302, first lobe portion 304, second lobe portion 306, transition
portion 308, bottom container end 310, length 312, first diameter
D314, second diameter D316, third diameter D318 and end diameter
D320.
[0058] The dimensions of container 300 are suitable with various
diameters and lengths for various applications. Exemplary
dimensions are illustrated in centimeters (cm). Exemplary
dimensions with the diameters and length are between 6.0 cm and 12
cm in diameter and 10 cm and 20 cm in length. In one embodiment
diameter D314 is 107% of diameter D320, diameter D314 is about 7.8
cm and diameter D320 is about 7.3 cm. In this same embodiment
diameter D316 is 107% of diameter D320, diameter D316 is about 7.8
cm and diameter D320 is about 7.3 cm. Also, in this same
embodiment, diameter D318 is 90% of diameter D320, diameter D318 is
about 6.6 cm and diameter D320 is about 7.3 cm. This embodiment
also includes length 312 that is 179% of diameter D320, length 312
is about 13.1 cm and D320 is about 7.3 cm. In additional
embodiments diameter D314 can be substantially similar to or
greater in length than diameter D320. Diameter D316 can be
substantially similar, greater or lesser in length than diameter
D320, diameter D318 can be substantially similar or less than the
length of diameter D320 and length 312 is greater in length than
diameter D320.
[0059] Referring to FIG. 13, container 400 includes body portion
402, first lobe portion 404, second lobe portion 406, transition
portion 408, bottom container end 410, length 412, first diameter
D414, second diameter D416, third diameter D418 and end diameter
D420.
[0060] The dimensions of container 400 are suitable with various
diameters and lengths for various applications. Exemplary
dimensions are illustrated in centimeters (cm). Exemplary
dimensions with the diameters and length are between 6.0 cm and 12
cm in diameter and 10 cm and 20 cm in length. In one embodiment
diameter D414 is 116% of diameter D420, diameter D414 is about 8.0
cm and diameter D420 is about 6.9 cm. In this same embodiment
diameter D416 is 106% of diameter D420, diameter D416 is about 7.3
cm and diameter D420 is about 6.9 cm. Also, in this same
embodiment, diameter D418 is 94% of diameter D420, diameter D418 is
about 6.5 cm and diameter D420 is about 6.9 cm. This embodiment
also includes length 412 that is 174% of diameter D420, length 412
is about 12.0 cm and D420 is about 6.9 cm. In additional
embodiments diameter D414 can be substantially similar to or
greater in length than diameter D420. Diameter D416 can be
substantially similar, greater or lesser in length than diameter
D420, diameter D418 can be substantially similar or less than the
length of diameter D420 and length 412 is greater in length than
diameter D420.
[0061] According to one alternative embodiment, it may be desirable
to pre-coat the interior of a metal food container to ensure that a
thorough and even application of protective coating is applied to
the interior of the container. Using pre-coated blanks of material,
however, it may be desirable to form the container using a process
other than a drawn and ironed process described above. In this
process, a container may be formed using one or more steps to form
the basic shape of the container. More particularly, a metal
container using pre-coated material may be made by the process of
forming a container body from a blank of pre-coated metal, forming
a threaded neck from a top end of the container body to create an
integrally formed thread configured to receive a closure, and
filling the container body with foodstuffs. Once filled, the
process may further include pushing a closure onto the threaded
neck, the closure and the threaded neck creating a hermetic seal
when subjected to a heating and cooling process such that a
plastisol material lining the interior of the closure resiliently
engages the threads and a vacuum provides a physical force to hold
the closure onto the container top end.
[0062] According to various other exemplary embodiments, the
interior and/or exterior of the container are coated with a
preservative coating after the container is formed or substantially
formed. According to yet other exemplary embodiments, the container
is precoated and then coated with one or more post-forming coats.
Coating may be applied via spraying or any other suitable method.
Different coatings may be provided for different food applications.
The coating material may be a vinyl, polyester, epoxy and/or other
suitable preservative spray. The coating, for example, may be a
spray epoxy such as PPG Z12215L, sold by PPG Industries, Inc.
According to other embodiments, the coating may be a coating such
as sold by Valspar Coatings (e.g., coating number 6256-069,
etc.).
[0063] According to various exemplary embodiments, a user of
various embodiments of a metal container described throughout this
application may open the container by applying an opening torque to
the closure, container body and/or other structures of the
container to rotatably remove the closure. Using the thread indents
or molds created in the plastisol, the thread surfaces should be
able to slide along the interfacing plastisol such that the closure
is directed upward by the spiral or helix nature of the threads.
With enough twisting, the closure will be directed upward until the
hermetic seal between the closure and the container will be broken
and the vacuum inside the container will be released. If the
closure has a safety-button type incorporated, a safety-button
formerly depressed when the vacuum was maintained will pop-up to
indicate to the user that the seal has been broken.
[0064] According to any preferred embodiment, although the
container includes a closure at the top end, and a bottom end part
at the bottom end, the container embodies a 2-piece can in that one
continuous blank of material forms the container body, neck, and
threads and a vertical seam or weld line does not run down the side
wall of the container. According to various alternative
embodiments, the container may be a three-piece can wherein a flat
blank or sheet of material is shaped or bent until a first side and
a second side of the shaped sheet may be welded together.
[0065] As the container and the food inside the container are
heated, the inside of the container is sterilized so that the food
does not spoil. When the container begins cooling, the closure is
fixed to the threads by the plastisol cooling and a negative
pressure relationship or a vacuum that develops on the container
interior. As the plastisol cools, it hardens and forms around the
threads of the container and resembles a resilient foam. As the
container interior cools, a vacuum creates a physical force that
provides a seal between the closure and the rest of the container
interior.
[0066] It should be understood that the phrase "food" used to
describe various embodiments of this disclosure may refer to dry
food, moist food, liquid, or any other drinkable or edible
material, regardless of nutritional value.
[0067] According to various other embodiments, a container kit may
be provided utilizing various containers and closures described
herein.
[0068] While the exemplary embodiments illustrated in the figures
and described herein are presently preferred, it should be
understood that these embodiments are offered by way of example
only. Accordingly, the present application is not limited to a
particular embodiment, but extends to various modifications that
nevertheless fall within the scope of the appended claims. The
order or sequence of any processes or method steps may be varied or
re-sequenced according to alternative embodiments.
[0069] The construction and arrangement of the container as shown
in the various exemplary embodiments is illustrative only. Although
only a few embodiments have been described in detail in this
disclosure, those skilled in the art who review this disclosure
will readily appreciate that many modifications are possible (e.g.,
variations in sizes, dimensions, structures, shapes and proportions
of the various elements, values of parameters, mounting
arrangements, use of materials, colors, orientations, etc.) without
materially departing from the novel teachings and advantages of the
subject matter recited in the claims. For example, elements shown
as integrally formed may be constructed of multiple parts or
elements, the position of elements may be reversed or otherwise
varied, and the nature or number of discrete elements or positions
may be altered or varied. Accordingly, all such modifications are
intended to be included within the scope of the present
application. The order or sequence of any process or method steps
may be varied or re-sequenced according to alternative embodiments.
In the claims, any means-plus-function clause is intended to cover
the structures described herein as performing the recited function
and not only structural equivalents but also equivalent structures.
Other substitutions, modifications, changes and omissions may be
made in the design, operating conditions and arrangement of the
exemplary embodiments without departing from the scope of the
present application.
[0070] It should be noted that although the figures herein may show
a specific order of method steps, it is understood that the order
of these steps may differ from what is depicted. Also, two or more
steps may be performed concurrently or with partial concurrence. It
is understood that all such variations are within the scope of the
application.
* * * * *