U.S. patent application number 14/749768 was filed with the patent office on 2015-12-31 for alloy for tabstock and can end.
This patent application is currently assigned to Novelis Inc.. The applicant listed for this patent is Novelis Inc.. Invention is credited to McKay C. Brown, Johnson Go.
Application Number | 20150376739 14/749768 |
Document ID | / |
Family ID | 53761495 |
Filed Date | 2015-12-31 |
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United States Patent
Application |
20150376739 |
Kind Code |
A1 |
Brown; McKay C. ; et
al. |
December 31, 2015 |
ALLOY FOR TABSTOCK AND CAN END
Abstract
This application discloses 3XXX aluminum alloys useful in
fabricating can ends and tabs used for opening cans, particularly
AA3104 and AA3204 aluminum alloys. This application discloses 3XXX
aluminum alloys useful in fabricating cans comprising a body, end
and tab, particularly AA3104 and AA3204 aluminum alloys.
Inventors: |
Brown; McKay C.; (Kennesaw,
GA) ; Go; Johnson; (Marietta, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Novelis Inc. |
Atlanta |
GA |
US |
|
|
Assignee: |
Novelis Inc.
Atlanta
GA
|
Family ID: |
53761495 |
Appl. No.: |
14/749768 |
Filed: |
June 25, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62017995 |
Jun 27, 2014 |
|
|
|
Current U.S.
Class: |
420/532 |
Current CPC
Class: |
C22C 21/06 20130101;
C22C 21/00 20130101; C22C 21/08 20130101; B65D 17/4012 20180101;
B65D 1/12 20130101 |
International
Class: |
C22C 21/00 20060101
C22C021/00; B65D 1/12 20060101 B65D001/12; B65D 17/00 20060101
B65D017/00; C22C 21/08 20060101 C22C021/08 |
Claims
1. A can tab comprising a 3XXX aluminum alloy.
2. The can tab of claim 1, wherein the 3XXX aluminum alloy
comprises about 0.15-0.40 wt % Si, about 0.30-0.55 wt % Fe, up to
0.10 wt % Cu, about 0.70-0.90 wt % Mn, about 0.50-3.10 wt % Mg, up
to 0.05 wt % Cr, up to 0.15 wt % Zn, up to 0.05 wt % Ti, and up to
0.15 wt % impurities, with remainder Al.
3. The can tab of claim 1, wherein the 3XXX aluminum alloy
comprises about 2% Mg or about 3% Mg.
4. The can tab of claim 1, wherein the 3XXX aluminum alloy is a
AA3104 aluminum alloy or a AA3204 aluminum alloy.
5. A can end comprising a 3XXX aluminum alloy.
6. The can end of claim 5, wherein the 3XXX aluminum alloy
comprises about 0.15-0.40 wt % Si, about 0.30-0.55 wt % Fe, up to
0.10 wt % Cu, about 0.70-0.90 wt % Mn, about 0.50-3.10 wt % Mg, up
to 0.05 wt % Cr, up to 0.15 wt % Zn, up to 0.05 wt % Ti, and up to
0.15 wt % impurities, with remainder Al.
7. The can end of claim 5, wherein the 3XXX aluminum alloy
comprises about 2% Mg or about 3% Mg.
8. The can end of claim 5, wherein the 3XXX aluminum alloy is a
AA3104 aluminum alloy or a AA3204 aluminum alloy.
9. The can end of claim 5, wherein the can end is a 2 inch diameter
can end or a 2 inch 1/8'' diameter can end.
10. An aluminum can comprising a tab comprising a 3XXX aluminum
alloy, an end comprising a 3XXX aluminum alloy, or both the tab and
the end comprise a 3XXX aluminum alloy.
11. The aluminum can of claim 10, wherein the can comprises the tab
comprising a 3XXX aluminum alloy and the end comprising a 3XXX
aluminum alloy.
12. The aluminum can of claim 11, wherein the can further comprises
a body comprising a 3XXX aluminum alloy.
13. The aluminum can of claim 10, wherein the tab comprises a 3XXX
aluminum alloy comprising about 0.15-0.40 wt % Si, about 0.30-0.55
wt % Fe, up to 0.10 wt % Cu, about 0.70-0.90 wt % Mn, about
0.50-3.10 wt % Mg, up to 0.05 wt % Cr, up to 0.15 wt % Zn, up to
0.05 wt % Ti, and up to 0.15 wt % impurities, with remainder
Al.
14. The aluminum can of claim 10, wherein the tab comprises a 3XXX
aluminum alloy comprising about 2% Mg or about 3% Mg.
15. The aluminum can of claim 10, wherein the tab comprises a
AA3104 aluminum alloy or a AA3204 aluminum alloy.
16. The aluminum can of claim 10, wherein the end comprises a 3XXX
aluminum alloy comprising about 0.15-0.40 wt % Si, about 0.30-0.55
wt % Fe, up to 0.10 wt % Cu, about 0.70-0.90 wt % Mn, about
0.50-3.10 wt % Mg, up to 0.05 wt % Cr, up to 0.15 wt % Zn, up to
0.05 wt % Ti, and up to 0.15 wt % impurities, with remainder
Al.
17. The aluminum can of claim 10, wherein the end comprises a 3XXX
aluminum alloy comprising about 2% Mg or about 3% Mg.
18. The aluminum can of claim 10, wherein the end comprises a
AA3104 aluminum alloy or a AA3204 aluminum alloy.
19. The aluminum can of claim 10, wherein the end is a 2 inch
diameter end or a 2 inch 1/8'' diameter end.
20. The aluminum can of claim 10, wherein the can is a beverage can
or a food can.
Description
PRIOR RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S.
Provisional Patent Application Ser. No. 62/017,995, filed Jun. 27,
2014, the content of which is incorporated herein by reference in
its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the fields of metallurgy,
aluminum alloys, aluminum fabrication, and related fields. In
particular, the present invention provides 3XXX alloys useful in
fabricating can ends and tabs used for opening cans.
BACKGROUND
[0003] Can ends and tabs used to open cans are usually made from an
AA5182 aluminum alloy because it possesses good strength and
formability. The requirements for can ends and tabs are quite
different than those for can bodies. In general, greater strength
is required for can ends and tabs, and that requirement has
dictated that such can ends and tabs be fabricated from an aluminum
alloy, such as AA5182. AA5182 typically contains Mg in an amount of
about 4.4% by weight (wt %), thus adding to the cost of the alloy
used for can ends and tabs. Thus, there is a need to replace the
AA5182 with a more cost-effective alloy with required strength.
[0004] In the can-making industry, it is widely considered that can
ends and tabs made from an AA3104 alloy are not viable, because
they have diminished strength compared to the current industry
standard AA5182 alloys, and thus, there is a need to increase
thickness, which, in turn, increases costs.
SUMMARY
[0005] The terms "invention," "the invention," "this invention" and
"the present invention" used herein are intended to refer broadly
to all of the subject matter of this patent application and the
claims below. Statements containing these terms should be
understood not to limit the subject matter described herein or to
limit the meaning or scope of the patent claims below. Covered
embodiments of the invention are defined by the claims, not this
summary. This summary is a high-level overview of various aspects
of the invention and introduces some of the concepts that are
further described in the Detailed Description section below. This
summary is not intended to identify key or essential features of
the claimed subject matter, nor is it intended to be used in
isolation to determine the scope of the claimed subject matter. The
subject matter should be understood by reference to appropriate
portions of the entire specification, any or all drawings and each
claim.
[0006] The present invention solves the problems in the prior art
and provides a more cost-effective material alternative to the use
of AA5182 alloy for can ends and tabs. Cans include, but are not
limited to, cans that contain food or beverages.
[0007] It has unexpectedly been found that a stay-on tab made from
a 3XXX aluminum alloy, such as an AA3104 alloy or an AA3204 alloy,
provides suitable strength and forms properly without undesirable
cracking Further, this stay-on tab allows for up to 100% recyclable
content, thereby enhancing aluminum recycling.
[0008] It has unexpectedly been found that a can end made from a
3XXX aluminum alloy, such as an AA3104 alloy or an AA3204 alloy,
provides suitable strength and forms properly without undesirable
cracking Further, this can end allows for up to 100% recyclable
content, thereby enhancing aluminum recycling.
[0009] In one embodiment, the present invention provides a stay-on
tab made from either an AA3104 alloy or an AA3204 alloy for use on
"200" (2 inch diameter) or "202" (2 inch 1/8'' diameter) can ends
for beverage cans. In a specific embodiment, the beverage can is
the EVERCAN.TM. (Novelis, Atlanta, Ga.).
[0010] In another embodiment, the present invention provides a
stay-on tab made from a 3XXX series alloy comprising: about
0.15-0.40 wt % Si, about 0.30-0.55 wt % Fe, up to 0.10 wt % Cu, for
example, 0.001-0.10 wt % Cu, about 0.70-0.90 wt % Mn, about
0.50-3.10 wt % Mg, for example, about 2 wt % or about 3 wt % Mg, up
to 0.05 wt % Cr, for example, 0.001-0.15 wt % Cr, up to 0.15 wt %
Zn, for example, 0.001-0.15 wt % Zn, up to 0.05 wt % Ti, for
example, 0.001-0.05 wt % Ti, and up to 0.15 wt % impurities, for
example, 0.001-0.15 wt % impurities, with the remainder as Al, for
use as "200" or "202" can ends for beverage cans.
[0011] In another embodiment, the present invention provides a can
end made from either an AA3104 alloy or an AA3204 alloy for use as
"200" (2 inch diameter) or "202" can ends for beverage cans. In a
specific embodiment, the beverage can is the EVERCAN.TM. (Novelis,
Atlanta, Ga.).
[0012] In another embodiment, the present invention provides a can
end made from a 3XXX series alloy comprising: about 0.15-0.40 wt %
Si, about 0.30-0.55 wt % Fe, up to 0.10 wt % Cu, for example,
0.001-0.10 wt % Cu, about 0.70-0.90 wt % Mn, about 0.50-3.10 wt %
Mg, for example, about 2 wt % or about 3 wt % Mg, up to 0.05 wt %
Cr, for example, 0.001-0.15 wt % Cr, up to 0.15 wt % Zn, for
example, 0.001-0.15 wt % Zn, up to 0.05 wt % Ti, for example,
0.001-0.05 wt % Ti, and up to 0.15 wt % impurities, for example,
0.001-0.15 wt % impurities, with the remainder as Al, for use as
"200" or "202" can ends for beverage cans.
[0013] In one embodiment, the present invention provides a can
comprising a body, can end, and tab made from a 3XXX alloy.
[0014] In still another embodiment, the present invention provides
a can comprising a body, can end, and tab made from an AA3104
alloy.
[0015] In yet another embodiment, the present invention provides a
can comprising a body, can end, and tab made from an AA3204
alloy.
[0016] In yet another embodiment, the present invention provides a
can comprising a body, can end, and tab made from a 3XXX series
alloy comprising: about 0.15-0.40 wt % Si, about 0.30-0.55 wt % Fe,
up to 0.10 wt % Cu, for example, 0.001-0.10 wt % Cu, about
0.70-0.90 wt % Mn, about 0.50-3.10 wt % Mg, for example, about 2 wt
% or about 3 wt % Mg, up to 0.05 wt % Cr, for example, 0.001-0.15
wt % Cr, up to 0.15 wt % Zn, for example, 0.001-0.15 wt % Zn, up to
0.05 wt % Ti, for example, 0.001-0.05 wt % Ti, and up to 0.15 wt %
impurities, for example, 0.001-0.15 wt % impurities, with the
remainder as Al.
[0017] The present invention permits higher use of recycled metal.
For example, the present invention permits use of at least 75%,
80%, 85%, 90%, 95%, or 100% recycled metal.
BRIEF DESCRIPTION OF THE FIGURES
[0018] FIG. 1A shows several completed 100% 200 EVERCAN.TM.
(Novelis, Atlanta, Ga.) samples with 3XXX alloys. AA3204 &
AA3104 STOLLE Xl beverage tabs (Stolle Machinery Company, LLC
Centennial, Colo.) were attached to 200 EVERCAN.TM. (Novelis,
Atlanta, Ga.) ends that were produced. These tabs performed well
and presented no opening issues.
[0019] FIG. 1B shows shells produced from 3xxx alloys with 3%
Mg.
[0020] FIG. 2 shows an AA3204 STOLLE X1 beverage tabs, which
produced no formability problems.
[0021] FIG. 3 is a schematic representation of the opening
characteristics of a can end. When a can end is pulled at a certain
angle, it pops. The pop (opening) is shown at around 26 degrees and
3 lbs, which is represented by the solid line. The dotted lines
represent a normal specification limitation being used in the
industry. The top dotted line represents the maximum of the
specification and the bottom dotted line represents the minimum of
the specification. The solid line at the bottom represents the
standard deviation of the opening data. After the pop, the end
continues to open until fully opened at around 63 degrees and 3.5
lbs (tear).
[0022] FIG. 4 is a tabular representation of 7 groups of alloy
samples. The grey rows represent the tabulator tab strength in
pounds for the 7 groups of alloy samples.
[0023] FIG. 5 is a schematic representation of average cold opening
pop values for the 7 groups of alloy samples in FIG. 4. The solid
lines represent specification limitations used in the industry.
[0024] FIG. 6 is a schematic representation of average cold opening
tear values for the 7 groups of alloy samples in FIG. 4. The solid
lines represent specification limitations used in the industry.
[0025] FIG. 7 is a schematic representation of a tab failure. The
tab is turned 90 degrees so it can't open and then pulled until it
bends (fails). As shown in the figure, with 5 lbs of pressure
pulled at approximately 56 degrees, failure occurs.
DETAILED DESCRIPTION
[0026] In this description, reference is made to alloys identified
by AA numbers and other related designations, such as "series." For
an understanding of the number designation system most commonly
used in naming and identifying aluminum and its alloys, see
"International Alloy Designations and Chemical Composition Limits
for Wrought Aluminum and Wrought Aluminum Alloys" or "Registration
Record of Aluminum Association Alloy Designations and Chemical
Compositions Limits for Aluminum Alloys in the Form of Castings and
Ingot," both published by The Aluminum Association.
[0027] The present invention solves the problems in the prior art
and provides a cost-effective alternative to the use of AA5182
aluminum alloy for can ends and tabs. Cans include, but are not
limited to, cans that contain food or beverages.
[0028] It has also unexpectedly been found that a can end made from
a 3XXX aluminum alloy, such as an EVERCAN.TM. AA3104 alloy or an
EVERCAN.TM. AA3204 alloy, provides good strength, resists
deformation, such as cracking, reduces the weight of the can, and
reduces the cost of producing such a can. Further, a stay-on tab
produced from a 3XXX EVERCAN.TM. alloy allows for up to and
including 100% recyclable content, thereby decreasing cost and
enhancing aluminum recycling.
[0029] In one embodiment, the present invention provides a stay-on
tab made from either an EVERCAN.TM. AA3104 alloy or an AA3204 alloy
for use on "200" or "202" can ends for beverage cans. In a specific
embodiment the beverage can is the EVERCAN.TM. (Novelis, Atlanta,
Ga.).
[0030] In another embodiment, the present invention provides a
stay-on tab made from a 3XXX series alloy comprising: about
0.15-0.40 wt % Si, about 0.30-0.55 wt % Fe, up to 0.10 wt % Cu, for
example, 0.001-0.10 wt % Cu, about 0.70-0.90 wt % Mn, about
0.50-3.10 wt % Mg, for example, about 2 wt % or about 3 wt % Mg, up
to 0.05 wt % Cr, for example, 0.001-0.15 wt % Cr, up to 0.15 wt %
Zn, for example, 0.001-0.15 wt % Zn, up to 0.05 wt % Ti, for
example, 0.001-0.05 wt % Ti, and up to 0.15 wt % impurities, for
example, 0.001-0.15 wt % impurities, with the remainder as Al, for
use as "200" or "202" can ends for beverage cans.
[0031] In another embodiment, the present invention provides a can
end made from either an AA3104 alloy or an AA3204 alloy for use as
"200" or "202" can ends for beverage cans. In a specific embodiment
the beverage can is the EVERCAN.TM. (Novelis, Atlanta, Ga.).
[0032] In addition, the stay-on tab and can ends may be used on 200
or 202 diameter can ends made from either an AA3104 alloy or an
AA3204 alloy. This in turn, allows for lower costs and higher use
of recycled metal, up to and including 100% recyclable content.
[0033] In another embodiment, the present invention provides a can
end made from a 3XXX series alloy comprising: about 0.15-0.40 wt %
Si, about 0.30-0.55 wt % Fe, up to 0.10 wt % Cu, for example,
0.001-0.10 wt % Cu, about 0.70-0.90 wt % Mn, about 0.50-3.10 wt %
Mg, for example, about 2 wt % or about 3 wt % Mg, up to 0.05 wt %
Cr, for example, 0.001-0.15 wt % Cr, up to 0.15 wt % Zn, for
example, 0.001-0.15 wt % Zn, up to 0.05 wt % Ti, for example,
0.001-0.05 wt % Ti, and up to 0.15 wt % impurities, for example,
0.001-0.15 wt % impurities, with the remainder as Al, for use as
"200" or "202" can ends for beverage cans.
[0034] In one embodiment, the present invention provides a can
comprising a body, can end and tab made from a 3XXX alloy.
[0035] In still another embodiment, the present invention provides
a can comprising a body, can end and tab made from an AA3104
alloy.
[0036] In yet another embodiment, the present invention provides a
can comprising a body, can end and tab made from an AA3204
alloy.
[0037] In yet another embodiment, the present invention provides a
can comprising a body, can end and tab made from a 3XXX series
alloy comprising: about 0.15-0.40 wt % Si, about 0.30-0.55 wt % Fe,
up to 0.10 wt % Cu, for example, 0.001-0.10 wt % Cu, about
0.70-0.90 wt % Mn, about 0.50-3.10 wt % Mg, for example, about 2 wt
% or about 3 wt % Mg, up to 0.05 wt % Cr, for example, 0.001-0.15
wt % Cr, up to 0.15 wt % Zn, for example, 0.001-0.15 wt % Zn, up to
0.05 wt % Ti, for example, 0.001-0.05 wt % Ti, and up to 0.15 wt %
impurities, for example, 0.001-0.15 wt % impurities, with the
remainder as Al.
[0038] The present invention permits higher use of recycled metal,
further decreasing costs. For example, the present invention
permits use of at least 75%, 80%, 85%, 90%, 95%, or 100% recycled
metal.
[0039] Chemical compositions of AA3104 and AA3204 aluminum alloys
are known to one of ordinary skill in the art and are available in
the Teal sheets of the Aluminum Association.
[0040] In different embodiments, the stay-on tab may be coated with
a BPA-Free or BPA-NI (Bisphenol-A Free or Bisphenol-A Non-Intent)
coating, a laminate, or with standard roll coatings. Further, the
stay-on tab may be of various designs and colors for marketing or
promotional purposes.
[0041] In different embodiments, the can end may be coated with a
BPA-Free or BPA-NI coating, laminate, or standard roll coating.
Further, the can end may be of various designs and colors.
[0042] In different embodiments, the can body may be coated with a
BPA-Free or BPA-NI coating, laminate, or standard roll coating.
Further, the can body may be of various designs and colors.
[0043] This stay-on tab and can end may be used for any application
that requires a tab to open a can, such as beverage and/or food
can.
[0044] The aluminum alloy of the present invention was rolled using
the single stand cold mill route. This single stand process route
also increases the material strength due to the nature of the heat
buildup and dissipation in the coil. The material may also be
produced using a tandem or multi-stand cold mill practice.
[0045] The typical ultimate tensile strength range for alloys of
the present invention in an unleveled condition is 46-51 kilopounds
per square inch (ksi). The typical yield strength range for alloys
of the present invention in an unleveled condition is 43.5-48.5
ksi, with an elongation >3.
[0046] The AA3104 and AA3204 tab samples were produced with
Novelis' new state of the art STOLLE X1/X2 beverage tab die system
(die designed and produced by STOLLE SIDNEY a division of Stolle
Machinery Company, 2900 Campbell Road, Sidney, Ohio 45365). The
tabs were attached to a 200 EVERCAN.TM. (Novelis, Atlanta, Ga.) can
end.
[0047] The following examples will serve to further illustrate the
present invention without, at the same time, however, constituting
any limitation thereof On the contrary, it is to be clearly
understood that resort may be had to various embodiments,
modifications and equivalents thereof which, after reading the
description herein, may suggest themselves to those skilled in the
art without departing from the spirit of the invention. During the
studies described in the following examples, conventional
procedures were followed, unless otherwise stated. Some of the
procedures are described below for illustrative purposes.
Example 1
[0048] Formability performance tests were performed by producing
tabs with STOLLE commercial X1 beverage tab tooling in a Minster
100 ton conversion press utilizing CDL commercial tooling. The tabs
were initially optically evaluated for cracking on a Zeiss AxioCam
MRc5 Microscope System @ 50X. The tabs were then finally evaluated
and photographed on a NIKON IMAGE ANALYSIS system using standard
evaluation techniques and procedures. Opening tests on two types of
industry standard commercial testers, an ALTEK "POP & PULL"
tester and a TRAC tab testing machine, indicates the Tab
Formability to be adequate for the 200 EVERCAN end design. STOLLE
X1 beverage tabs produced with the AA3104 or AA3204 aluminum alloys
displayed no formability or cracking issues.
[0049] All patents, publications and abstracts cited above are
incorporated herein by reference in their entirety. Various
embodiments of the invention have been described in fulfillment of
the various objectives of the invention. It should be recognized
that these embodiments are merely illustrative of the principles of
the present invention. Numerous modifications and adaptations
thereof will be readily apparent to those skilled in the art
without departing from the spirit and scope of the present
invention as defined in the following claims.
* * * * *