U.S. patent application number 15/846558 was filed with the patent office on 2018-06-21 for method and apparatus of forming a deboss in a closed end of a metallic cup.
This patent application is currently assigned to BALL CORPORATION. The applicant listed for this patent is BALL CORPORATION. Invention is credited to Greg Robinson.
Application Number | 20180169734 15/846558 |
Document ID | / |
Family ID | 62557112 |
Filed Date | 2018-06-21 |
United States Patent
Application |
20180169734 |
Kind Code |
A1 |
Robinson; Greg |
June 21, 2018 |
METHOD AND APPARATUS OF FORMING A DEBOSS IN A CLOSED END OF A
METALLIC CUP
Abstract
An apparatus and method for forming a deboss in a closed
end-wall of a metallic cup is provided. The deboss apparatus
generally includes a rotatable turret with tooling assemblies. The
tooling assemblies are configured to receive a metallic cup formed
by upstream equipment. The metallic cup formed by the upstream
equipment has a closed end-wall that is generally planar. As the
turret rotates, the tooling assemblies are configured to form a
deboss in the closed end-wall of the metallic cup. In one
embodiment, the deboss projects inwardly into an interior of the
metallic cup. The metallic cup with a deboss is subsequently
stripped from the tooling assembly for further processing.
Inventors: |
Robinson; Greg; (Boulder,
CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BALL CORPORATION |
Broomfield |
CO |
US |
|
|
Assignee: |
BALL CORPORATION
Broomfield
CO
|
Family ID: |
62557112 |
Appl. No.: |
15/846558 |
Filed: |
December 19, 2017 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62436177 |
Dec 19, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B21D 51/2607 20130101;
B21D 51/26 20130101 |
International
Class: |
B21D 51/26 20060101
B21D051/26 |
Claims
1. A forming apparatus for shaping a closed end-wall portion of a
metallic cup, comprising: a turret operable to rotate at a
predetermined rate; and a plurality of tooling assemblies
associated with the turret, each of the tooling assemblies
comprising: a pressure pad to receive the metallic cup, the
pressure pad operably engaged to the turret; a forming tool
associated with the pressure pad and having a geometric profile
selected to form a deboss with a predetermined shape in the closed
end-wall portion of the metallic cup; a ram with a stroke oriented
substantially perpendicular to the turret; and an interior sleeve
interconnected to the ram, the interior sleeve having an exterior
diameter no greater than an interior diameter of the metallic cup,
wherein, when the turret rotates, the ram moves in a forward stroke
such that the interior sleeve applies a force to the metallic cup
and the forming tool forms the deboss with the predetermined shape
in the closed end-wall portion of the metallic cup.
2. The apparatus of claim 1, further comprising a biasing means to
bias the pressure pad in relation to the turret.
3. The apparatus of claim 2, wherein the biasing means biases the
pressure pad away from the turret.
4. The apparatus of claim 2, wherein the biasing means comprises at
least one spring.
5. The apparatus of claim 1, wherein the ram is operably engaged to
an upper portion of the turret of the forming apparatus, the upper
turret portion spaced from the pressure pad.
6. The apparatus of claim 1, wherein the ram includes a cam
follower which engages a cam of the forming apparatus.
7. The apparatus of claim 6, wherein the cam is formed on a shaft
of the forming apparatus.
8. The apparatus of claim 1, wherein the forming tool includes an
end that is generally planar, and wherein the end of the forming
tool does not extend beyond a plane defined by an upper surface of
the turret.
9. The apparatus of claim 1, wherein the pressure pad includes an
annular end to support a portion of the closed end-wall of the
metallic cup, the annular end being generally planar.
10. The apparatus of claim 9, wherein the annular end of the
pressure pad does not extend beyond a plane defined by an upper
surface of the turret.
11. The apparatus of claim 10, wherein, when the metallic cup is
positioned in the tooling assembly, the annular end of the pressure
pad is positioned approximately even with the plane define by the
turret upper surface.
12. The apparatus of claim 1, wherein the forming tool is
interconnected to the turret such that the forming tool is
substantially stationary during the stroke of the ram.
13. The apparatus of claim 1, wherein the interior sleeve includes
a chamber with an interior diameter that is greater than an
interior diameter of a cavity of the pressure pad.
14. The apparatus of claim 1, further comprising: an infeed
mechanism that positions the metallic cup in the pressure pad of
one of the tooling assemblies; and an outfeed mechanism that
receives the metallic cup from the pressure pad after the forming
apparatus forms the deboss in the metallic cup.
15. A method of forming a deboss in a closed end-wall portion of a
metallic cup, comprising: receiving the metallic cup in an infeed
mechanism associated with a forming apparatus; feeding the metallic
cup to a turret of the forming apparatus, the turret rotatable
around a central axis and including a plurality of tooling
stations, each of the tooling stations comprising: a pressure pad
operably associated with the turret and including an annular
surface to support the metallic cup; a ram operably engaged by an
upper turret spaced from the turret, the ram having a stroke
oriented substantially parallel to the central axis an interior
sleeve interconnected to the ram, the interior sleeve having an
exterior diameter no greater than an interior diameter of the
metallic cup; and a forming tool associated with the pressure pad,
the forming tool having a geometric profile selected to form the
deboss with a predetermined shape in the closed end-wall portion of
the metallic cup; and rotating the turret at a predetermined rate,
wherein, when the ram moves in a forward stroke, the interior
sleeve applies a force to the metallic cup and presses the closed
end-wall against the forming tool to form the deboss with the
predetermined shape in the closed end-wall portion of the metallic
cup.
16. The method of claim 15, wherein the pressure pad is biased to
the turret by a spring.
17. The method of claim 15, wherein the forming apparatus includes
a cam which is engaged by a cam follower of the ram.
18. The method of claim 15, further comprising biasing the annular
surface of the pressure pad to a position substantially level with
a surface of the turret before the metallic cup is fed to the
turret.
19. The method of claim 15, wherein the forming tool extends into a
chamber of the interior sleeve, the chamber having an interior
diameter that is greater than an interior diameter of a cavity of
the pressure pad.
20. The method of claim 15, wherein the deboss includes a closed
end with an interior surface that is not supported when the
metallic cup presses against the protrusion of the forming tool.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. .sctn.
119(e) to U.S. Provisional Patent Application Ser. No. 62/436,177
filed Dec. 19, 2016, which is incorporated herein in its entirety
by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the manufacturing
of metallic containers. More specifically, the present invention
relates to a method and apparatus for forming a deboss in a closed
end-wall of a metallic cup to enhance performance during subsequent
operations in which the metallic cup is formed into a metallic
container.
BACKGROUND
[0003] Metallic containers offer distributors and consumers many
benefits. The body of a metallic container provides optimal
protection properties for products. For example, the metallic body
prevents CO.sub.2 migration and transmission of UV radiation which
may damage the contents, such as beverages or other consumable
products, negatively influencing the flavor, appearance, or color
of the product. Metallic containers also offer an impermeable
barrier to light, water vapor, oils and fats, oxygen, and
micro-organisms and keep the contents of the container fresh and
protected from external influences, thereby guaranteeing a long
shelf-life. The surfaces of metallic containers are also ideal for
decorating with brand names, logos, designs, product information,
and/or other preferred indicia for identifying, marketing, and
distinguishing the metallic container and its contents from other
products and competitors. Thus, metallic containers offer bottlers,
distributors, and retailers an ability to stand out at the point of
sale.
[0004] Metallic containers are also produced in a large variety of
sizes. Common sizes range from approximately 6 ounces to
approximately 32 ounces or larger. Exemplary diameter sizes for
metallic beverage containers are 2 2/16 inches, 2 4/16 inches, and
2 11/16 inches, which are commonly known as 202, 204, and 211
containers, respectively. Numerous other diameter sizes exist and
are well known in the art. Metallic containers may also be produced
in various shapes but are frequently cylindrical.
[0005] Because of these and other benefits, sales of metallic
containers were valued at approximately $53 billion globally in
2014. A sizable percentage of the metallic container market is
driven by beverage containers. According to one report,
approximately 290 billion metallic beverage containers were shipped
globally in 2012. One U.S. trade group reported that 126 billion
metallic containers were shipped in the U.S. alone in 2014.
[0006] To meet this demand, metallic container manufacturing
facilities operate some of the fastest, if not the fastest,
production lines in the container industry. Because of the high
speeds of metallic container production lines, techniques or
processes that may work in other industries or with containers
formed of other materials do not necessarily work at the high
speeds required for metallic container production lines.
Accordingly, specialized equipment is required for many of the
operations performed to form the metallic containers. The
production equipment must also be durable and easy to service to
avoid down-time on the high-speed production lines used to form
metallic containers.
[0007] An important consideration in designing and fabricating
metallic containers involves providing a desirable balance between
minimizing material requirements (such as providing relatively
thin-gauge metal) while achieving a metallic container that will
maintain its integrity and/or form, despite shipping and handling
impacts or forces and impacts arising from dropped beverage
containers and shipping mishaps. Moreover, it is critical to
provide metallic containers which maintain integrity and/or form
even when the contents are under pressure due to carbonated or
otherwise gas-pressured contents and/or arising from high internal
temperatures, including, in some cases, pasteurization
temperatures.
[0008] Metallic containers are generally formed of two separate
pieces: a container body and a container end closure. The container
body is formed from a single piece of metal and generally includes
a bottom dome portion, a sidewall portion, and a neck portion with
a decreased diameter extending upwardly from the sidewall portion.
The neck portion is adapted to receive an end closure after the
container body is filled with a beverage or other product. An
example of a known process of forming a container body for a
metallic beverage container is generally illustrated and described
in "Inside a Ball Beverage Can Plant," available at:
http://www.ball.com/Ball/media/Ball/Global/Downloads/How_a_Ball_Metal_Bev-
erage_Can_Is_Made.pdf?ext=.pdf (last visited Oct. 26, 2016) which
is incorporated herein by reference in its entirety.
[0009] Typical processes of forming the body of a metallic
container include subjecting a thin sheet of metal alloy to a
series of operations including blanking out a substantially round
disk, drawing the disk into a cup, and subsequently redrawing,
ironing, and/or forming the cup. One of the first steps performed
on such a metal sheet is a cupping process in which the sheet is
blanked into a substantially round blank. The blank is drawn into a
seamless metallic cup to establish an initial shape and inside
diameter of the metallic cup. A second draw operation is frequently
performed on the cup to reduce the cup diameter further and bring
the diameter of the cylindrical body to the final body diameter.
Subsequently, the metallic cup is pushed through a series of
ironing rings to thin the wall of the cylindrical body to a
selected thickness. During these ironing processes, performed with
equipment commonly referred to as a bodymaker, the diameter of the
cylindrical body is essentially maintained while the outer wall
length is substantially increased to establish the capacity of the
final metallic container. A variety of different bodymakers are
known to those of skill in the art and are generally described in
PCT Publication WO 2014/047115, PCT Publication WO 2014/110387,
U.S. Pat. App. Pub. 2013/0239644, U.S. Pat. No. 9,079,237, and U.S.
Pat. No. 9,387,530 which are each incorporated herein in their
entirety. Because typical metallic container manufacturing
facilities often produce hundreds of millions or billions of
metallic containers per year, the wear of components of bodymakers
is inherent based of the tremendous speed and output of
product.
[0010] The bodymaker can also form a dome on a closed end-wall of
the metallic container. The configuration of the closed end-wall of
the metallic container is important for a variety of reasons. The
outside dome profile is often configured for purposes of stacking
metallic containers. The outside and inside dome profiles are also
important in facilitating material usage reductions, since various
geometric configurations can be utilized to enhance strength
characteristics. The recessed or concave dome is configured to
resist deformation due to internal fluid pressures. More
specifically, the geometry of the closed end-wall and the concave
dome can be configured to increase the pressure at which concave
dome is deformed or reversed. The geometry of the concave dome is
also important to improve the drop resistance of the metallic
container and reduce the risk of damage caused when the closed
end-wall of a filled metallic container is dropped onto a hard
surface during shipping, storage, and use. This drop resistance can
be described as the cumulative drop height at which the closed
end-wall is damaged sufficiently to preclude the metallic container
from standing upright on a flat surface.
[0011] One problem experienced during the formation of metallic
containers is that the closed end-wall of the metallic cup is prone
to thinning and wrinkling during the drawing, ironing, and dome
forming operations performed by the bodymaker to transform the
metallic cup into a container body. More specifically, continual
efforts to decrease the weight of metallic containers, known as
light-weighting of the containers, by using thinner sheets of stock
metal has resulted in undesirable wrinkling of the sheet during
formation of the container body. The closed end-wall is
particularly susceptible to thinning of the metal and to the
formation of fractures in the metal.
[0012] One prior art method of overcoming these problems is to form
a deboss in a closed end-wall of the metallic cup before the
redraw, ironing, and dome forming operations are performed. The
deboss of the end-wall improves performance in the final container
body as well as during subsequent forming operations performed on
the metallic cup by breaking the forming operation of the bottom
portion of the container body into two stages. The deboss makes
subsequent container manufacturing operations easier to execute
with reduced wrinkling, reduction in thinning of the metal, and
improved container performance. This enables the manufacture of
lighter containers with improved appearance and performance
characteristics and reduces the thinning and wrinkling experienced
during conversion of metallic cups without a deboss.
[0013] Prior art methods and apparatus used to form a deboss in a
metallic cup typically include modifying a press, such as a cupping
press or a bodymaker, to form the deboss in one machine at the end
of a blank and draw process used to form the metallic cup. This has
required a conversion of the press action to increase the stroke
length of a crank of the press as well as the phase timing angle of
the press. Alternatively, existing cupping presses can be converted
to produce a metallic cup with a deboss. However, converting a
cupping press to form a deboss in a metallic cup typically involves
a large expense and may compromise the speed and reliability of the
cupping press.
[0014] Presses modified to form a deboss during metallic cup
formation may operate at reduced production rates compared to
similar presses that do not form a deboss. The modification of
existing presses also causes operational and maintenance problems
because the deboss tooling is located at the bottom of the press
and is difficult to access and service. For example, in a
traditional cupping press, cups formed by the press drop out of the
bottom of the cupping press. However, if the cupping press is
modified to form a deboss, the tooling to form the deboss is
positioned below the cup forming tooling of the cupping press.
Accordingly, a jammed cup or scrap generated during operation of
the modified cupping press are challenging to clear and correct.
This results in increased down-time of the container production
line associated with the press and associated losses. One example
of an apparatus for forming a deboss in a metallic cup is disclosed
in U.S. Pat. No. 5,394,727 which is incorporated herein in its
entirety.
[0015] Other methods of forming the deboss use a vertical double
acting stamping press to form the deboss at the end of the blank
and draw operation. Alternatively, it is also possible to modify
short-stroke body makers used for redrawing metallic cups to form a
deboss. However, these options require a large capital expense for
additional equipment and the use of substantial amounts of floor
space in the manufacturing facility. Further, many existing
metallic container production lines do not have sufficient
production floor space available for additional cupping presses or
body makers which typically are quite large. Because of these and
other problems associated with prior art equipment and methods of
forming a deboss in a metallic cup, there has been limited
commercial use of these systems.
[0016] Accordingly, it would be beneficial to have an apparatus
that receives a pre-formed metallic cup without a deboss and forms
a deboss in a closed end-wall portion of the metallic cup as well
as a method of forming a deboss in a pre-formed metallic cup.
SUMMARY OF THE INVENTION
[0017] The present invention provides systems and methods for
forming a deboss in a closed end-wall of a metallic cup in a
cost-effective, fast, and reliable manner. One aspect of the
present invention is a method of forming a deboss in a metallic cup
at low cost and high speed. Another aspect is a system and method
of forming a deboss in a metallic cup that requires less production
space than prior art bodymakers and cupping presses. Still another
aspect of the present invention is a deboss apparatus that is cost
effective to purchase and operate and which operates in a fast and
reliable manner. Yet another aspect of the present invention is a
method and apparatus of forming a deboss in a metallic cup that
does not require modification of existing cupping presses or
bodymakers. Another aspect of the present invention is an apparatus
for forming a deboss which has fewer moving parts and which has
tooling that is easier to service and replace compared to prior art
bodymakers and cupping presses operable to form a deboss in a
metallic cup. It is another aspect of the present invention to
provide a deboss apparatus that is smaller, and takes up less
production floor space, than conventional cupping presses and known
horizontal body-makers.
[0018] One aspect of the present invention is a deboss apparatus
that receives a metallic cup and forms a deboss in a closed
end-wall of the metallic cup. The deboss apparatus includes a
rotatable turret or table with a plurality of tooling stations. The
turret is operable to rotate around a central shaft or axis of the
deboss apparatus. Metallic cups without debosses are received by an
infeed mechanism of the deboss apparatus and loaded into the
tooling stations. In one embodiment, the metallic cups generally
include a closed end-wall, a sidewall extending from the end-wall,
and an open end opposite the close end-wall. Optionally, the closed
end-walls are generally planar when the metallic cups are received
by the infeed mechanism.
[0019] In one embodiment, the sidewall height of the metallic cups
to be debossed is between approximately 0.7 inch and approximately
3.0 inches. In another embodiment, the initial sidewall height is
between approximately 1.0 and approximately 2.0 inches.
[0020] In one embodiment, the turret includes between 12 and 20
tooling stations. Each of the tooling stations of the deboss
apparatus includes tooling to form a deboss in the closed end-wall
portion of a metallic cup. More specifically, in one embodiment,
each tooling station includes a ram, an interior sleeve, a pressure
pad, and a forming tool. In one embodiment, the pressure pad is
moveably associated with the turret. Optionally, the pressure pad
can travel between approximately 0.10 inches and approximately 0.60
inches along an axis substantially parallel to the shaft or axis of
the deboss apparatus.
[0021] The interior sleeve is slightly smaller in diameter than the
interior diameter of the metallic cup. The interior sleeve enters
the open end of the metallic cup and applies pressure to the flat
bottom (or closed end-wall) of the metallic cup. The interior
sleeve and metallic cup push against the forming tool. The interior
sleeve must clear the metallic cup and have enough stroke to form
the deboss. Thus, in one embodiment, the interior sleeve has a
stroke length at least equal to the sidewall height of the metallic
cup plus the maximum travel distance of the pressure pad. In
another embodiment, the stroke of the interior sleeve is between
approximately 1.0 and approximately 3.0 inches. In one embodiment,
the pressure pad and the forming tool do not project above a
surface of the turret.
[0022] In one embodiment, the interior sleeve is interconnected to
the ram. Optionally, the ram can have a stroke of between
approximately 1.0 inches and approximately 3.0 inches, and in
another embodiment, between approximately 1.2 inches and 2.0
inches. In still another embodiment, the ram applies a forming load
of between approximately 500 pounds and approximately 3,200 pounds
of force which is transmitted to the metallic cup.
[0023] The turret is configured to rotate at a predetermined rate.
In one embodiment, the turret rotates at up to approximately 175 to
300 rotations per minute (rpm) such that the deboss apparatus may
form a deboss in up to approximately 3,500 metallic cups per
minute. In another embodiment, the turret is operable to rotate at
150 to 250 rpm to produce 3,000 deboss metallic cups per minute. In
another embodiment, the turret rotates at between approximately 70
and 150 rpm to produce between approximately 1,400 and
approximately 1,800 deboss metallic cups per minute. In this
manner, the deboss apparatus can be configured to operate in
metallic container production lines that operate at a variety of
rates.
[0024] Another aspect of the present invention is a forming
apparatus for shaping a closed end-wall portion of a metallic cup.
The forming apparatus includes, but is not limited to: (1) a turret
operable to rotate at a predetermined rate; and (2) a plurality of
tooling assemblies associated with the turret, each of the tooling
assemblies comprising: (i) a pressure pad to receive the metallic
cup, the pressure pad operably engaged to the turret; (ii) a
forming tool associated with the pressure pad; (iii) a ram with a
stroke oriented substantially perpendicular to the turret; and (iv)
an interior sleeve interconnected to the ram, the interior sleeve
having an exterior diameter no greater than an interior diameter of
the metallic cup, wherein, when the turret rotates, the ram moves
in a forward stroke such that the interior sleeve applies a force
to the metallic cup and the forming tool forms the deboss with the
predetermined shape in the closed end-wall portion of the metallic
cup.
[0025] The forming tool has a geometric profile selected to form
the deboss with the predetermined shape. In one embodiment, the
forming tool optionally includes a protrusion. Optionally, the
forming tool is interconnected to the turret. More specifically,
the forming tool may be interconnected to the turret such that the
forming tool is substantially stationary during the stroke of the
ram. In one embodiment, the form tool does not project above a
plane defined by an exterior surface of the turret.
[0026] Optionally, the forming tool is generally concentrically
aligned within a cavity of the pressure pad. In one embodiment, an
interior diameter of the cavity of the pressure pad is less than an
interior diameter of a chamber of the interior sleeve.
[0027] In one embodiment, the forming tool includes a body portion
which is generally cylindrical. In another embodiment, the body
portion includes an end with a planar portion. The optional
protrusion may include a sidewall that extends from the end of the
body portion. In this manner, the end of the body portion defines a
shoulder between a body of the forming tool and the protrusion. In
another embodiment, the body of the forming tool has an exterior
diameter that is greater than the maximum exterior diameter of the
protrusion. Optionally, the protrusion includes an end-wall
defining a plane that is approximately parallel to a plane defined
by the end of the body portion.
[0028] In one embodiment, the forming apparatus includes from 12 to
20 tooling assemblies. Optionally, the tooling assemblies can be
positioned proximate to a periphery of the turret. In another
embodiment, the tooling assemblies are substantially evenly spaced
around the turret at a predetermined distance from a center of the
turret.
[0029] In one embodiment, the forming apparatus further includes a
biasing means to bias the pressure pad with respect to the turret.
In one embodiment, the biasing means comprises at least one coil
spring. In another embodiment, the biasing means biases the
pressure pad away from the turret. Optionally, the pressure pad
does not project beyond the plane defined by an upper surface of
the turret. The pressure pad, in one embodiment, includes a lip
which defines a recess to retain a metallic cup. Alternatively, in
another embodiment, a free end of the forming apparatus can be
generally planar. In one embodiment, the free end of the pressure
pad is configured to support a portion of a closed end-wall of a
metallic cup. Optionally, the free end has a shape that is annular.
In another embodiment, when the metallic cup is positioned in the
tooling assembly, the annular end of the pressure pad is positioned
approximately even with the plane define by the turret upper
surface.
[0030] Optionally, in another embodiment, the forming apparatus
includes an infeed mechanism that positions the metallic cup in a
tooling assembly of the deboss apparatus. In one embodiment, the
infeed mechanism positions the metallic cup in the pressure pad of
one of the tooling assemblies. Alternatively, the infeed mechanism
can position the metallic cup on an interior sleeve of a tooling
assembly.
[0031] The forming apparatus can also include an outfeed mechanism
that receives the metallic cup after the forming apparatus forms
the deboss in the metallic cup. In one embodiment, one or more of
the infeed mechanism and the outfeed mechanism is a starwheel. The
infeed mechanism can also include an infeed track. Similarly, the
outfeed mechanism can optionally include an outfeed track.
[0032] In one embodiment, the ram is operably engaged to an upper
portion of the turret of the forming apparatus, the upper turret
portion being spaced from the pressure pad. In one embodiment the
interior sleeve and ram are driven by a cam. More specifically, the
ram can include a cam follower configured to engage a cam of the
forming apparatus. Optionally, the cam is formed on a shaft of the
forming apparatus. The cam is operable to translate the rotational
force of the turret into a linear force substantially perpendicular
to the turret for performing the deboss operation. As the turret
and the associated cam complete a revolution, the cam follower
forces the ram to move in at least one cycle including one forward
and one backward stroke.
[0033] Another aspect of the present invention is a method of
forming a deboss in a closed end-wall portion of a metallic cup.
The method comprises: (1) receiving the metallic cup in an infeed
mechanism associated with a forming apparatus, the closed end-wall
of the metallic cup being generally planar; (2) feeding the
metallic cup to a turret of the forming apparatus, the turret
rotatable around a central axis and including a plurality of
tooling stations, each of the tooling stations comprising: (i) a
pressure pad operably associated with the turret; (ii) a ram
operably engaged by an upper turret spaced from the turret, the ram
having a stroke oriented substantially parallel to the central
axis; (iii) an interior sleeve interconnected to the ram, the
interior sleeve having an exterior diameter no greater than an
interior diameter of the metallic cup; and (iv) a forming tool
associated with the pressure pad, the forming tool having a
geometric profile selected to form the deboss with a predetermined
shape in the closed end-wall portion of the metallic cup; and (3)
rotating the turret at a predetermined rate, wherein, when the ram
moves in a forward stroke, the interior sleeve applies a force to
the metallic cup and presses the closed end-wall against the
forming tool to form the deboss with the predetermined shape in the
closed end-wall portion of the metallic cup. Optionally, the method
may further include inspecting the metallic cup for irregularities
or damage. In one embodiment, the tooling stations are positioned a
predetermined distance from a perimeter of the turret.
[0034] The turret can rotate at a predetermined rate. In one
embodiment, the turret is operable to rotate at from approximately
70 rpm to approximately 300 rpm. In another embodiment, the turret
is operable to rotate at between approximately 70 rpm and
approximately 150 rpm.
[0035] The rate of rotation of the turret and the number of tooling
stations can be selected to produce a predetermined number of cups
per minute. In one embodiment, the turret includes tooling stations
and rotates at a rate sufficient to produce from about 500 cups per
minute to about 4,000 cups per minute. In one embodiment, the
turret includes tooling stations and rotates at a rate to produce
from approximately 1,400 to approximately 1,800 debossed cups per
minute. In another embodiment, the turret produces up to
approximately 3,500 debossed cups per minute. Optionally, the
turret includes from 6 to 30 tooling stations. In one embodiment,
the turret includes from 12 to 20 tooling stations.
[0036] Optionally, the ram driving the interior sleeve has a stroke
of between approximately 1.5 inches and approximately 3.0 inches.
In one embodiment, the deboss apparatus includes a cam which is
engaged by a cam follower of the ram. In another embodiment, the
cam follower and ram apply a forming load of between approximately
500 pounds and approximately 3,200 pounds of force.
[0037] In one embodiment, the pressure pad is moveably biased with
respect to the turret, for example, by a spring. In another
embodiment, the pressure pad includes a lip to retain a metallic
cup in a predetermined alignment. Optionally, the pressure pad may
have a free end to support a closed end-wall of a metallic cup, the
free end being generally planar with a central cavity. In one
embodiment, the free end of the pressure pad has a shape that is
generally annular. In one embodiment, the annular surface of the
pressure pad is biased to a position substantially level with a
surface of the turret before the metallic cup is fed to the
turret.
[0038] The forming tool has a generally cylindrical body and an
end-wall. In one embodiment, the end-wall is generally planar.
Additionally, or alternatively, the forming tool can include a
protrusion. Optionally, the protrusion extends from the end-wall of
the forming tool, the end-wall defining a shoulder between the body
of the forming tool and the protrusion. In another embodiment, the
body of the forming tool has an exterior diameter that is greater
than the maximum exterior diameter of the protrusion. In yet
another embodiment, the protrusion extends into a chamber of the
interior sleeve during formation of the deboss. In one embodiment,
the interior sleeve chamber has an interior diameter that is
greater than an interior diameter of a cavity of the pressure pad.
In one embodiment, the forming tool is positioned within the cavity
of the pressure pad.
[0039] In one embodiment, the deboss includes a closed end with an
interior surface that is not supported when the metallic cup
presses against the forming tool. More specifically, when the ram
moves in the forward stroke, an interior surface of a portion of
the closed end-wall that is formed into the deboss does not contact
the forming apparatus.
[0040] It is yet another aspect of the present invention to provide
a metallic cup with a deboss formed by a deboss apparatus. The
metallic cup comprises: (1) a sidewall portion; (2) a closed
end-wall portion; and (3) a deboss formed in the closed end-wall
portion. The deboss generally includes a neck extending from the
closed end-wall and a closed end. In one embodiment, the neck has a
reduced diameter at a position distal to the closed end-wall.
[0041] In one embodiment, the deboss has a depth of between
approximately 11% and approximately 15% of the height of the
sidewall portion. Alternatively, in another embodiment, the deboss
depth is between approximately 26% and approximately 30% of the
sidewall height. In still another embodiment, the deboss depth is
between approximately 0.1 inches and approximately 0.60 inches.
Optionally, the deboss depth is approximately 0.15 inches.
Alternatively, the deboss depth is approximately 0.30 inches. In
another embodiment, the deboss depth is about 0.375 inches. In one
embodiment, the deboss is substantially centered in the closed
end-wall portion.
[0042] In one embodiment, the deboss of the metallic cup is formed
by a deboss apparatus of the present invention. The deboss
apparatus includes a turret operable to rotate at a predetermined
rate. A plurality of tooling assemblies are associated with the
turret. The tooling assemblies generally include a pressure pad to
hold the metallic cup. As the turret rotates, a ram presses an
interior sleeve into an open end of the metallic cup. The interior
sleeve presses the closed end-wall of the metallic cup against
forming tool. The forming tool has a geometric profile configured
to form the deboss in the closed end-wall portion of the metallic
cup.
[0043] As will be appreciated by one of skill in the art, the
method and apparatus of the current invention may be used to form a
deboss in metallic cups of any material used to form metallic
containers, including without limitation aluminum, tin plate steel,
steel, and combinations thereof. Further, the method and apparatus
of the current invention may be used to form debosses in cups that
are subsequently formed into container bodies or vessels of any
size and shape and for storing any type of product for any
industry. Accordingly, cups formed by the method and apparatus of
the present invention may be formed into containers or vessels used
to store or contain liquids and gases of all types, including
consumer products and beverages as well as industrial chemicals and
products. Additionally, it is contemplated that various features
and devices shown and/or described with respect to one embodiment
may be combined with or substituted for features or devices of
other embodiments regardless of whether or not such a combination
or substitution is specifically shown or described herein.
[0044] Although generally referred to herein as "metallic
container," "beverage container," "can," and "container," it should
be appreciated that the current invention may be used with metallic
cups that are subsequently formed into containers of any size or
shape including, without limitation, beverage cans and beverage
bottles. Accordingly, the term "container" is intended to cover
containers of any type. Further, as will be appreciated by one of
skill in the art, the methods and apparatus of the present
invention may be used for any type of metallic container and are
not specifically limited to a beverage container such as a soft
drink or beer can.
[0045] Although metallic cups are described as being formed by a
draw and wall ironing (DWI) process, alternatively, the metallic
cups may be formed by a draw, redraw processes. Further, the terms
"metal" or "metallic" as used hereinto refer to any metallic
material that may be used to form a container, including without
limitation aluminum, steel, tin coated steel, and any combination
thereof.
[0046] The phrases "at least one," "one or more," and "and/or," as
used herein, are open-ended expressions that are both conjunctive
and disjunctive in operation. For example, each of the expressions
"at least one of A, B and C," "at least one of A, B, or C," "one or
more of A, B, and C," "one or more of A, B, or C," and "A, B,
and/or C" means A alone, B alone, C alone, A and B together, A and
C together, B and C together, or A, B and C together.
[0047] Unless otherwise indicated, all numbers expressing
quantities, dimensions, conditions, and so forth used in the
specification and claims are to be understood as being modified in
all instances by the term "about" or "approximately." The term "a"
or "an" entity, as used herein, refers to one or more of that
entity. As such, the terms "a" (or "an"), "one or more" and "at
least one" can be used interchangeably herein.
[0048] The use of "including," "comprising," or "having" and
variations thereof herein is meant to encompass the items listed
thereafter and equivalents thereof as well as additional items.
Accordingly, the terms "including," "comprising," or "having" and
variations thereof can be used interchangeably herein.
[0049] It shall be understood that the term "means" as used herein
shall be given its broadest possible interpretation in accordance
with 35 U.S.C., Section 112(f). Accordingly, a claim incorporating
the term "means" shall cover all structures, materials, or acts set
forth herein, and all of the equivalents thereof. Further, the
structures, materials, or acts and the equivalents thereof shall
include all those described in the Summary of the Invention, Brief
Description of the Drawings, Detailed Description, Abstract, and
Claims themselves.
[0050] The Summary of the Invention is neither intended, nor should
it be construed, as being representative of the full extent and
scope of the present invention. Moreover, references made herein to
"the present invention" or aspects thereof should be understood to
mean certain embodiments of the present invention and should not
necessarily be construed as limiting all embodiments to a
particular description or embodiment. The present invention is set
forth in various levels of detail in the Summary of the Invention
as well as in the attached drawings and the Detailed Description
and no limitation as to the scope of the present invention is
intended by either the inclusion or non-inclusion of elements or
components. Additional aspects of the present invention will become
more readily apparent from the Detailed Description, particularly
when taken together with the drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0051] The accompanying drawings, which are incorporated herein and
constitute a part of the specification, illustrate embodiments of
the invention and together with the Summary of the Invention given
above and the Detailed Description of the drawings given below
serve to explain the principles of these embodiments. In certain
instances, details that are not necessary for an understanding of
the disclosure or that render other details difficult to perceive
may have been omitted. It should be understood, of course, that the
present invention is not necessarily limited to the particular
embodiments illustrated herein. Additionally, it should be
understood that the drawings are not necessarily to scale.
[0052] FIG. 1 is a schematic flow diagram which depicts the
progression of a metallic cup formed by upstream equipment to a
deboss apparatus of one embodiment of the present invention, the
deboss apparatus being configured to form a deboss in a closed
end-wall of the metallic cup, and the flow of the metallic cup to
downstream equipment that performs subsequent operations on the
metallic cup;
[0053] FIG. 2A is a top plan view of one embodiment of a deboss
apparatus of the present invention with an upper turret portion
removed for clarity and illustrating a rotary turret with tooling
assemblies that receive metallic cups from an infeed mechanism and
the tooling assemblies subsequently releasing the metallic cups to
an outfeed mechanism;
[0054] FIG. 2B is a front elevation view of the deboss apparatus of
FIG. 2A;
[0055] FIG. 3 is a partial cross-sectional front elevation view
taken along line 3-3 of FIG. 2A illustrating a tooling assembly of
the deboss apparatus before receiving a metallic cup according to
one embodiment of the present invention;
[0056] FIG. 3A is a partial cross-sectional front elevation view
similar to FIG. 3 and illustrating a tooling assembly of another
embodiment of the present invention;
[0057] FIG. 4 is a cross-sectional front elevation view of a
pressure pad of one embodiment of the present invention;
[0058] FIG. 4A is cross-sectional front elevation view of another
embodiment of a pressure pad;
[0059] FIG. 5 is a cross-sectional front elevation view of a form
tool according to one embodiment of the present invention;
[0060] FIG. 5A is another cross-sectional front elevation view
illustrating a form tool of another embodiment of the present
disclosure;
[0061] FIG. 6 is another partial cross-sectional front elevation
view taken along line 6-6 of FIG. 2A and illustrating a metallic
cup positioned in a tooling assembly of the deboss apparatus before
a forming stroke of the tooling assembly is completed according to
another embodiment of the present invention; and
[0062] FIG. 7 is still another partial cross-sectional front
elevation view similar to FIG. 6 and taken along line 7-7 of FIG.
2A illustrating another tooling assembly of the deboss apparatus
according to one embodiment of the present invention, the tooling
assembly shown after a forming stroke has been completed to form a
deboss in a metallic cup.
[0063] Similar components and/or features may have the same
reference number. Components of the same type may be distinguished
by a letter following the reference number. If only the reference
number is used, the description is applicable to any one of the
similar components having the same reference number. To assist in
the understanding of one embodiment of the present invention the
following list of components and associated numbering found in the
drawings is provided herein:
TABLE-US-00001 Number Component 2 Upstream equipment 4 Metallic cup
devoid of a deboss 6 Sidewall 7 Height of sidewall 8 Closed
end-wall 10 Deboss apparatus 12 Turret 13 Turret upper portion 14
Shaft of turret 15 Shaft axis 16 Recess 18 Tooling assembly 19
Surface of turret 20 Longitudinal axis of tooling assembly 22 Ram
23 Cam follower 24 Interior sleeve 25 Cam or groove 26 Outer nose
of the interior sleeve 28 Chamber of interior sleeve 29 Interior
diameter of the sleeve chamber 30 Pressure pad 31 Lip of pressure
pad 32 Recess of pressure pad 33 Cavity of pressure pad 34 Upper
surface portion of pressure pad 35 Interior surface portion of the
pressure pad 36 Biasing means or coil spring 37A Diameter of
pressure pad 37B Interior diameter of pressure pad cavity 38 Height
of pressure pad 39 Wear plug 40 Form tool 41 Body of form tool 42
Protrusion of the form tool 43 Sidewall 44 End-wall of form tool 45
Surface of form tool body 46 Infeed mechanism or starwheel 47
Infeed conveyor 48 Devices for positioning metallic cups 49
Exterior diameter of the form tool 50 Outfeed mechanism or
starwheel 51 Height of form tool 52 Devices for positioning
metallic cups 54 Outfeed conveyor 60 Metallic cup with deboss 61
Diameter 62 Sidewall 63 Height of sidewall 64 Closed end-wall 66
Deboss 67 Neck 68 Deboss depth 69 Closed end 70 Maximum diameter of
deboss 72 Minimum diameter of deboss 74 Downstream equipment R1
Radius of interior sleeve nose R2 Radius of protrusion R3 Radius
between closed end-wall and deboss R4 Radius of deboss R5 Radius of
pressure pad R6 Radius of pressure pad R7 Outer radius of form
tool
DETAILED DESCRIPTION
[0064] The present invention has significant benefits across a
broad spectrum of endeavors. It is the Applicant's intent that this
specification and the claims appended hereto be accorded a breadth
in keeping with the scope and spirit of the invention being
disclosed despite what might appear to be limiting language imposed
by the requirements of referring to the specific examples
disclosed. To acquaint persons skilled in the pertinent arts most
closely related to the present invention, a preferred embodiment
that illustrates the best mode now contemplated for putting the
invention into practice is described herein by, and with reference
to, the annexed drawings that form a part of the specification. The
exemplary embodiment is described in detail without attempting to
describe all of the various forms and modifications in which the
invention might be embodied. As such, the embodiments described
herein are illustrative, and as will become apparent to those
skilled in the arts, may be modified in numerous ways within the
scope and spirit of the invention.
[0065] Although the following text sets forth a detailed
description of numerous different embodiments, it should be
understood that the detailed description is to be construed as
exemplary only and does not describe every possible embodiment
since describing every possible embodiment would be impractical, if
not impossible. Numerous alternative embodiments could be
implemented, using either current technology or technology
developed after the filing date of this patent, which would still
fall within the scope of the claims. To the extent that any term
recited in the claims at the end of this patent is referred to in
this patent in a manner consistent with a single meaning, that is
done for sake of clarity only so as to not confuse the reader, and
it is not intended that such claim term by limited, by implication
or otherwise, to that single meaning.
[0066] Referring now to FIG. 1, a schematic flow diagram of the
progressive formation of a metallic cup 60 with a closed end-wall
64 having a deboss 66 according to one embodiment of the present
invention is illustrated. Upstream equipment 2 forms a metallic cup
4. The upstream equipment 2 can be a cup drawing process or a draw
and redraw process to make the metallic cup 4. Accordingly, the
metallic cup 4 may be formed by either a draw machine or a draw and
redraw process. In one embodiment, the upstream equipment is a
cupper known to those of skill in the art.
[0067] The metallic cup 4 generally includes a sidewall 6 and a
closed end-wall 8. The sidewall 6 has a shape that is generally
cylindrical. In one embodiment, the closed end-wall 8 is generally
planar. The sidewall 6 has a predetermined height. In one
embodiment, the sidewall height is between approximately 0.750
inches and approximately 2.5 inches. In another embodiment, the
sidewall height is between approximately 1.0 and 2.0 inches. In one
embodiment, the metallic cup 4 has a diameter of between
approximately 3.00 inches and approximately 4.00 inches. In one
optional embodiment, the diameter is approximately 35/8 inches, or
approximately 3.63 inches. As one of skill in the art will
appreciate, the deboss apparatus 10 of the present invention may be
configured to form a deboss on metallic cups 4 of any height and
diameter.
[0068] A deboss apparatus 10 of one embodiment of the present
invention receives the metallic cup 4 from the upstream equipment
2. Referring now to FIGS. 2A-7, the deboss apparatus 10 generally
includes a table or turret 12 with a plurality of tooling
assemblies 18. Each tooling assembly 18 generally includes a ram
22, an interior sleeve 24, a pressure pad 30, and a form tool 40.
The deboss apparatus 10 is similar to a container necker known to
those of skill in the art. Examples of necking apparatus are
described in U.S. Pat. No. 8,807,325, and U.S. Pat. No. 9,308,570
which are each incorporated herein by reference in their entirety.
In one embodiment, the deboss apparatus 10 operates in a manner
similar to the rotary drawing presses described in U.S. Patent
Application No. 2016/0107219 ("the '210 publication"), which is
incorporated herein by reference in its entirety. However, the
deboss apparatus 10 includes tooling assemblies 18 with different
tooling and which perform different operations compared to the
tooling of known necking apparatus or of the rotary drawing presses
described in the '210 publication.
[0069] In one embodiment, the deboss apparatus 10 includes from 10
to 24 tooling assemblies 18. In another embodiment, the deboss
apparatus 10 has sixteen tooling assemblies 18; however, one of
skill in the art will appreciate that the deboss apparatus 10 can
include any number of tooling assemblies 18. Accordingly, in still
another embodiment, the apparatus 10 includes 12 tooling
assemblies.
[0070] In operation, the turret 12 rotates around a shaft 14 (or
axis 15) at a predetermined rate. Optionally, the turret 12 can
rotate at speeds of between approximately 75 and 300 rpm. In
another embodiment, the turret 12 rotates at between approximately
70 and 90 rpm to produce approximately 1,800 metallic cups 60 with
a deboss 66 per minute. In one embodiment, deboss apparatus 10
includes twelve tooling assemblies 18 and the turret 12 is operable
to rotate at more than approximately 300 rpm. In this manner, the
deboss apparatus 10 can produce 3,000 or more deboss metallic cups
60 per minute.
[0071] Referring now to FIG. 2B, the deboss apparatus 10 optionally
includes an upper turret portion 13. The rams 22 are operably
interconnected to, and substantially evenly spaced around, the
upper turret portion 13. Each ram 22 is aligned substantially
parallel to an axis 15 of the shaft 14.
[0072] The rams 22 are configured to move with respect to an
associated pressure pad 30 of a tooling assembly 18. In one
embodiment, the rams 22 include a cam follower 23 that engages a
cam 25 of the deboss apparatus 10. The cam 25 is shaped to move the
cam follower 23 and the ram 22 toward and away from the turret 12.
Accordingly, with each full rotation of the turret 12, each ram 22
and the interconnected interior sleeve 24 moves through a motion
path of a forward and a return stroke. In one embodiment, the cam
25 comprises a groove formed in the shaft 14. In one embodiment,
the groove 25 has a generally arcuate shape formed radially around
shaft 14.
[0073] Optionally, the ram 22 is mounted to the upper turret 13 in
a guide bushing. In one embodiment, each ram 22 is capable of a
stroke of between approximately 0.75 inches and approximately 3
inches. In another embodiment, the stroke of the ram 22 is between
approximately 1.0 inches and approximately 2.0 inches. In an
optional embodiment, the stroke of the ram 22 is approximately 1.5
inches.
[0074] Referring now to FIG. 2A, a metallic cup 4 without a deboss
is positioned in a tooling assembly 18 by an infeed mechanism 46.
In one embodiment, the infeed mechanism 46 positions the metallic
cup 4 in the tooling assembly 18 such that a closed end-wall
portion 8 of the metallic cup 4 is proximate to the turret 12. The
infeed mechanism 46 can include a conveyor 47 interconnected to the
upstream equipment 2. In one embodiment, the infeed mechanism 46
comprises a starwheel with devices 48 for positioning metallic cups
4. Suitable infeed mechanisms 46 are known to those of skill in the
art and include, but are not limited to, those described in U.S.
Pat. No. 8,807,325, PCT Publication WO 2011/113710, and PCT
Publication WO 2014/108489 which are each incorporated herein by
reference in their entirety.
[0075] Referring now to FIG. 3, a tooling assembly 18A is
illustrated before the tooling assembly 18A has received a metallic
cup 4. More specifically, the tooling assembly 18A is illustrated
when the tooling assembly 18A has rotated to a position between the
outfeed mechanism 50 and the infeed mechanism 46.
[0076] The tooling assembly 18A generally includes a ram 22, an
interior sleeve 24 (also referred to as a hold-down sleeve or a
draw/pressure sleeve), a pressure pad 30, biasing means 36, and a
forming tool 40. Optionally, the forming tool 40 includes a
protrusion 42. In one embodiment, the interior sleeve 24, pressure
pad 30, and forming tool 40 are each substantially concentrically
aligned with the ram 22 along a longitudinal axis 20 of the tooling
assembly 18A. In one embodiment, the longitudinal axis 20 is
substantially parallel to the shaft axis 15 of the deboss apparatus
10.
[0077] The biasing means 36 bias the pressure pad 30 to a
predetermined position with respect to the turret 12. In one
embodiment, before a metallic cup 4 is received in the tooling
assembly 18A, an annual surface 34 of the pressure pad 30 projects
above a surface 19 of the turret 12 and towards the ram 22. The
forming tool 40 is positioned within a cavity 33 of the pressure
pad 30.
[0078] As the turret 12 rotates, the ram 22 applies a force
generally parallel to the tooling axis 20 to the interior sleeve
24. In one embodiment, the ram 22 applies a forming load of between
approximately 500 pounds and approximately 4,000 pounds. In another
embodiment, the ram 22 applies between approximately 500 pounds and
approximately 3,200 pounds of force. In still another embodiment,
the ram 22 applies between approximately 500 pounds and
approximately 1,000 pounds of force to the interior sleeve 24.
[0079] The interior sleeve 24 is interconnected to the ram 22 and
is sized to fit at least partially within an interior of a metallic
cup 4, 60. Accordingly, the interior sleeve 24 has an exterior
diameter approximately equal to (but slightly less than) the
interior diameter of a metallic cup 4, 60. In one embodiment, an
outer nose portion 26 of the interior sleeve 24 has a radius R1 of
less than approximately 0.10 inches.
[0080] The interior sleeve 24 also includes a recess or chamber 28.
In one embodiment, the chamber 28 has a depth at least equal to a
height of the protrusion 42 of the form tool 40. In one embodiment,
the chamber 28 has a depth of at least approximately 0.5 inches and
up to approximately 1.1 inches. Optionally, the depth of the sleeve
chamber 28 may be greater than the height of the form tool
protrusion 42. In this manner, the weight of the interior sleeve 24
may be reduced. More specifically, a deep chamber 28 will lighten
the interior sleeve 24 which beneficially reduces the rotating mass
of the tooling of the deboss apparatus 10.
[0081] The interior sleeve 24 can move, or has a stroke,
substantially parallel to the tooling axis 20. The stroke of the
interior sleeve 24 has a length sufficient to clear the cup
sidewall 6, 62 during loading of the metallic cup 4 into the
tooling assembly 18 and to move the pressure pad 30 axially by a
predetermined distance. In one embodiment, the interior sleeve
stroke is between approximately 1 inch and approximately 4 inches.
In another embodiment, the interior sleeve 24 can travel between
approximately 1.0 inches and approximately 3.0 inches along the
tooling axis 20 relative to the turret 12. In yet another
embodiment, the interior sleeve 24 can travel between approximately
0.75 inches and approximately 2.0 inches with respect to the turret
12. In another embodiment, the interior sleeve stroke is between
approximately 1.5 inches and approximately 2.5 inches. As one of
skill in the art will appreciate, the stroke of the interior sleeve
24 is determined by the design of the cam follower 23 and the cam
25 and is selected based on the size of the metallic cup 60 and the
deboss 66 to be formed.
[0082] Referring now to FIG. 3A, an optional embodiment of a
tooling assembly 18A of the present invention is generally
illustrated. The tooling assembly 18A includes a pressure pad 30A
that is similar pressure pad 30 of FIG. 3. However, pressure pad
30A does not include a lip 31. Accordingly, a free end 34 of the
pressure pad 30A oriented opposite to the biasing means 36 is
generally planar. Additionally, or alternatively, the pressure pad
30A can be oriented with the turret 12A such that the free end 34
does not extend beyond an upper surface 19 of the turret 12A.
Similarly, in one embodiment, the form tool 40 can be fixed to the
turret 12A such that an end-wall 44 of the form tool does not
project above a plane defined by the upper surface 19 of the turret
12A. In this manner, a closed end-wall 8, 64 of a metallic cup can
move with respect to the turret surface 19 without obstruction from
the pressure pad 30A and/or the form tool 40 during loading and
unloading into a tooling assembly 18.
[0083] Referring now to FIG. 4, a pressure pad 30 of one embodiment
of the present invention is illustrated. The pressure pad 30 has a
generally cylindrical shape. The pressure pad 30 may have any
predetermined diameter 37A and height 38. Optionally, the diameter
37A is between approximately 3.0 inches and approximately 4.5
inches. In another embodiment, the diameter 37A is between
approximately 3.65 inches and approximately 3.75 inches. In one
embodiment, the height 38 is between approximately 1.1 inches and
approximately 2.1 inches.
[0084] A cavity 33 is formed in the pressure pad. In one
embodiment, the cavity extends through the pressure pad 30. The
cavity 33 has an interior surface portion 35 that establishes a
clearance between an outside diameter of the form tool 40 and the
interior diameter 37B of the pressure pad 30. The pressure pad 30
can thus move freely relative to the form tool 40 and generally
parallel to the tool axis 20. In one embodiment, the cavity
diameter 37B is between approximately 2.0 inches and approximately
2.4 inches. In another embodiment, the cavity diameter 37B is
between approximately 2.2 inches and approximately 2.3 inches.
Optionally, the cavity diameter 37B is less than an interior
diameter 29 of the chamber 28 of the interior sleeve 24.
[0085] The upper surface portion 34 of the pressure pad 30 is
adapted to hold and retain a metallic cup 4, 60 in a predetermined
alignment with respect to the interior sleeve 24 and the form tool
40. In one embodiment, the upper surface portion 34 is
substantially planar. In another embodiment, the upper surface
portion 34 has a shape that is annular. Optionally, in another
embodiment, the pressure pad 30 can include a lip 31 that extends
from the upper surface portion 34. The lip 31 defines a pocket or
recess 32 adapted to hold and retain the metallic cup 4, 60 in the
predetermined alignment. The recess 32 has an interior diameter no
less than the exterior diameter of the metallic cup 4, 60.
Optionally, at least a portion of the pressure pad 30 proximate to
and including the upper surface portion 34 is formed of carbide. In
one embodiment, a portion of the pressure pad 30 is formed of
steel.
[0086] Referring now to FIG. 4A, another embodiment of a pressure
pad 30A is illustrated. Pressure pad 30A may be used with the
deboss apparatus 10 interchangeably with the pressure pad 30A in
all embodiments of the present invention. The pressure pad 30A is
generally similar to pressure pad 30 and includes many of the same
features and dimensions. However, pressure pad 30A does not include
a lip 31. Additionally, a radius R5 is formed between the upper
surface 34 and the cylindrical body of the pressure pad 30A. In one
embodiment, the radius R5 can range from approximately 0.03 inches
to approximately 0.1 inches. In one embodiment, pressure pad 30A
includes a radius R6 between the upper surface 34 and the cavity
interior surface 35. Optionally, radius R6 can be between
approximately 0.02 inches and approximately 0.06 inches.
[0087] Additionally, FIG. 4A illustrates an optional wear plug 39
associated with the pressure pad 30A. The wear plug 39 extends at
least partially beyond the circumference of the cylindrical body of
the pressure pad 30A. In one embodiment, a plurality of wear plugs
39 are spaced substantially evenly around a circumference of the
cylindrical body of the pressure pads 30, 30A. Optionally, the
pressure pads 30, 30A can include from eight to sixteen wear plugs
39. In one embodiment, the pressure pad 30A includes at least one
flange to retain the wear plug 39.
[0088] Referring again to FIGS. 3, 3A, in one embodiment, the
pressure pads 30, 30A are movable with respect to the turret.
Accordingly, the pressure pads 30, 30A can move generally parallel
to the longitudinal axis 20 toward the turret 12 in response to
receiving a force transmitted by the ram 22 and the interior sleeve
24. In one embodiment, the pressure pads 30, 30A have a stroke of
between approximately 0.1 inches and 0.6 inches. In another
embodiment, the stroke of the pressure pads 30, 30A is between
approximately 0.1 inches and approximately 0.5 inches. Optionally,
the pressure pad stroke is between approximately 0.20 inches and
approximately 0.40 inches.
[0089] Optionally, the pressure pads 30, 30A are operably retained
to the turret 12 by biasing means 36. The biasing means 36 is
generally arranged between the pressure pad 30 and the turret 12.
Biasing means 36 is selected to provide a predetermined support
force to the pressure pads 30, 30A. In one embodiment, the biasing
means 36 comprises one or more coil springs. The coil springs may
be arranged in a spring pack. However, in another embodiment, the
biasing means 36 comprises a compressible material. In one
embodiment, the biasing means 36 is capable of supporting between
approximately 500 pounds and at least approximately 3,000 pounds of
force. In another embodiment, biasing means 36 can provide a
support force of between approximately 500 pounds and approximately
4,000 pounds. In yet another embodiment, the biasing means 36
provides a support force of between approximately 500 pounds and
approximately 1,500 pounds. In one embodiment, biasing means 36 is
positioned at least partially within a groove or recess 16 formed
in the turret 12. Optionally, the biasing means 36 is configured to
bias the pressure pads 30, 30A away from the turret 12.
[0090] The pressure pads 30, 30A and biasing means 36 are
releasably interconnected to the turret 12. In one embodiment, the
pressure pads 30, 30A and biasing means 36 are configured to be
quickly changed to deliver different forming loads to metallic cups
4, 60 formed by the deboss apparatus 10.
[0091] The forming tool 40 is operably associated with the turret
12. In one embodiment, the forming tool 40 is positioned at least
partially within the cavity 33 of the pressure pads 30, 30A. In
another embodiment, the form tool 40 is generally arranged below
the pressure pads 30, 30A when the pressure pad 30 is biased away
from the turret 12. Optionally, the form tool 40 is fixedly
interconnected to the turret 12. Thus, in one embodiment, the form
tool 40 does not move, or is substantially immobile, during
formation of a deboss 66 in a metallic cup 60. Additionally, or
alternatively, at least a portion of the form tool 40 may be
recessed below a plane defined by an upper surface 19 of the turret
12.
[0092] Referring now to FIG. 5, a form tool 40 of one embodiment of
the present invention is illustrated separate from the pressure pad
30. The form tool 40 generally includes a body 41. In one
embodiment, the body 41 has a shape that is generally cylindrical.
An exterior diameter 49 of the body 41 is selected to be about
equal to, but no greater than, an interior diameter 37B of the
pressure pad cavity 33. Accordingly, the pressure pads 30, 30A can
move with respect to the form tool 40 in response to a force
received from a ram 22 of the deboss apparatus 10. Optionally, the
exterior diameter 49 is between approximately 2.0 inches and
approximately 2.4 inches. In another embodiment, the exterior
diameter 49 is between approximately 2.2 inches and approximately
2.3 inches. In one embodiment, the exterior diameter 49 is less
than an interior diameter 29 of the chamber 28 of the interior
sleeve 24.
[0093] In one embodiment, the form tool body 41 has a surface 45
that is substantially planar. When the form tool 40 is associated
with the turret 12, the surface 45 is positioned distal to the
turret 12. More specifically, the tool surface 45 faces an interior
sleeve 24 of a tooling station 18. In one embodiment, at least a
portion of the form tool 40 comprises carbide.
[0094] Optionally, a protrusion 42 projects from the surface 45 of
the body 41. The body surface 45 defines a shoulder between the
protrusion 42 and the body 41. In one embodiment, the protrusion 42
includes a sidewall 43 interconnected to the body 41. An end-wall
44 is interconnected to the sidewall 43. Optionally, the end-wall
44 is generally planar. Alternatively, the end-wall 44 may have a
surface that is not planar.
[0095] The protrusion 42 has a shape selected to form a deboss 66
with a predetermined profile in a metallic cup 60. In one
embodiment, the protrusion 42 has a frustum shape of a truncated
cone. However, the protrusion 42 can have any cross-sectional
profile selected to form a deboss 66 of a predetermined size and
shape.
[0096] In one embodiment, the protrusion sidewall 43 has a
cross-section that is generally planar. Alternatively, in another
embodiment, the cross-section of the sidewall 43 is not planar.
More specifically, the sidewall 43 can optionally have a
cross-section that is arcuate. Other shapes of the sidewall 43 are
contemplated.
[0097] In one embodiment, the protrusion sidewall 43 extends from
the surface 45 of the body 41 at an oblique angle. More
specifically, in one embodiment, a first diameter of the protrusion
42 proximately to the body surface 45 is greater than a second
diameter of the protrusion 42 proximate to the end-wall 44. In
another embodiment, the sidewall 43 of the protrusion 42 is
approximately orthogonal to the body surface 45. More specifically,
the sidewall 43 can optionally be approximately parallel to the
exterior surface of the form tool body 41. Accordingly, in one
embodiment, the protrusion is generally cylindrical with a diameter
which is different than the body diameter 49.
[0098] Optionally, a second radius R2 is formed between the surface
45 and the sidewall 43. The second radius R2 is selected to form an
interior radius R3 (illustrated in FIG. 1) between the closed
end-wall 64 and the deboss 66 formed in the metallic cup 60.
[0099] A radius R7 may optionally be formed between the end-wall 44
and the sidewall 43. In one embodiment, radius R7 is between
approximately 0.05 inches and approximately 0.15 inches.
[0100] Referring now to FIG. 5A, another embodiment of a form tool
40A is illustrated. Form tool 40A may be used with the deboss
apparatus 10 interchangeably with form tool 40 in all embodiments
of the present invention.
[0101] Form tool 40A includes a body 41 with a sidewall 43 and an
end-wall 44. The body 41 is generally cylindrical. Optionally, a
radius R7 is formed between the sidewall 43 and the end-wall 44. In
one embodiment, the end-wall 44 is generally planar. The form tool
40A has a diameter 49 and a height 51. In one embodiment, the
height 51 is between approximately 2.0 inches and approximately 3.2
inches.
[0102] Referring now to FIG. 6, a tooling assembly 18B is
illustrated when rotated proximate to the infeed mechanism 46. More
specifically, the infeed mechanism 46 has conveyed a metallic cup 4
into the tooling assembly 18B. The metallic cup 4 sits in or on the
upper surface portion 34 of the pressure pad 30. In one embodiment,
the metallic cup 4 is received at least partially within the
pressure pad recess 32. The metallic cup 4 is positioned with a
closed end-wall 8 proximate to the pressure pad 30. In this manner
the closed end-wall 8 extends across the pressure pad cavity 33. An
open end of the metallic cup faces the interior sleeve 24.
[0103] When the biasing means 36 is not compressed, such as when
the tooling assembly 18B is proximate to the infeed mechanism 46,
the pressure pad 30 supports the metallic cup 4 with the closed
end-wall 8 a predetermined distance from the forming tool 40. In
one embodiment, the end-wall 44 of the form tool 40 does not
contact the closed end-wall 8. Subsequently, as the turret 12
rotates, the ram 22 moves the interior sleeve 24 toward the
metallic cup 4 and the turret 12. The interior sleeve 24 moves into
an interior of the metallic cup 4 and contacts an interior surface
of the closed end-wall 8. The metallic cup 4 is pressed downwardly
by the ram 22 and interior sleeve 24 and the end-wall 44 of the
form tool 40 applies a force to the closed end-wall 8 of the
metallic cup. In this manner, the form tool 40 is configured to
create a metallic cup 60 with a deboss 66 in a closed end-wall
64.
[0104] Referring now to FIG. 7, another tooling assembly 18C and a
metallic cup 60 are illustrated during a forming stroke. As the
turret 12 rotates, the interior sleeve 24 is driven down by the cam
25 and the ram 22 and the interior sleeve 24 enters the interior of
the metallic cup 60. As the turret rotation and corresponding
forward stroke continue, the interior sleeve 24 presses on the
closed end-wall 64 of the metallic cup 60, driving the metallic cup
and the pressure pad 30 toward the turret 12 as the biasing means
36 compresses. The metallic cup 60 is clamped between the interior
sleeve 24 and the pressure pad 30. In one embodiment, a center
portion of the closed end-wall 64 of the metallic cup 60 is not
supported as the deboss 66 is formed. More specifically, in one
embodiment, an interior surface of the closed end-wall 64 that is
formed into the deboss 66 does not contact a tool of the deboss
apparatus 10 during the forming stroke of the ram 22.
[0105] The forward stroke of the ram 22 causes the closed end-wall
64 of the metallic cup 60 to contact the form tool 40, clamping the
metallic cup between the interior sleeve 24 and the pressure pad
30. As the deboss 66 is formed, the metal of the metallic cup 60 is
prone to wrinkling; however, the clamping force on the closed
end-wall 64 between interior sleeve 24 and the pressure pad 30
provide resistance to wrinkling. The interior sleeve 24 continues
the forward stroke until the deboss is fully formed, as generally
illustrated in FIG. 7. The closed end-wall 64 is then formed and/or
drawn between the interior sleeve 24 and the form tool 40 as the
ram 22 completes the forward stroke.
[0106] The form tool 40 may extend at least partially into the
chamber 28 of the interior sleeve 24 during the stroke of the ram
22. Accordingly, as described above, the interior sleeve chamber 28
has a depth at least equal to the height of the optional protrusion
42. In one embodiment, the depth of the interior sleeve chamber 28
is greater than the height of the protrusion 42. Optionally, in one
embodiment, the chamber 28 has a depth of at least approximately
0.6 inches.
[0107] As material of the metallic cup 60 in drawn inwardly to form
the deboss 66, the height of the sidewall 62 of the metallic cup
decreases. The cup bottom, or closed end-wall 64, is clamped, but
the clamp surfaces are large and the clamping forces are relatively
low. Accordingly, in one embodiment, the metal of the metallic cup
64 does not thin or stretch appreciably. More specifically, in one
embodiment, the material of the closed end-wall 64 can slide
between the interior sleeve 24 and the pressure pad 30 during
formation of the deboss 66. Forming a deboss 66 in a metallic cup
60 with the deboss apparatus 10 improves the appearance and
performance of a metallic container subsequently formed from the
metallic cup 60 by downstream equipment 74.
[0108] As the turret 12 continues rotating, the ram 22 completes
the forward stroke and begins the return stroke. During the return
stroke, the ram 22 and interior sleeve 24 move along the
longitudinal axis 20 away from the turret 12 and the interior
sleeve 24 retracts from the interior of the metallic cup 60 back to
a position similar to that illustrated in FIG. 6. The metallic cup
60 with the deboss 66 is then conveyed out of the tooling assembly
18C by a support device 52 of an outfeed mechanism 50. The outfeed
mechanism 50 may be the same as, or similar to, the infeed
mechanism 46. In one embodiment, the outfeed mechanism 50 comprises
a starwheel.
[0109] In one embodiment, each tooling assembly 18 includes an
aperture for compressed air to strip the metallic cup 60 from the
interior sleeve 24. Alternatively, stripper fingers may be included
with the tooling assembly 18 to remove the metallic cup 60 from the
interior sleeve 24. One example of a stripper finger is generally
described in U.S. Pat. No. 6,032,505 which is incorporated herein
by reference in its entirety. Optionally, a stripper can be
positioned at least partially within the chamber 28 of the interior
sleeve 24.
[0110] Referring again to FIG. 1, the deboss 66 formed by the
tooling 18 of the deboss apparatus 10 may have a geometry with any
predetermined size and profile. The deboss 66 generally includes a
neck portion 67 extending from the closed end-wall 64 of the
metallic cup 60. A radius R3 is formed between the closed end-wall
64 and the neck 67. Optionally, the interior radius R3 is between
approximately 0.06 inches and approximately 0.2 inches. A closed
end 69 is interconnected to the neck portion 67. Optionally, the
neck portion 67 has a cross-section that is generally planar.
Additionally, or alternatively, the closed end 69 can be generally
planar. A radius R4 is formed between the neck 67 and the closed
end 69. In one embodiment, the radius R4 is approximately equal to
the radius R3. In another embodiment, the radius R4 is between
approximately 0.06 inches and approximately 0.2 inches. Optionally,
one or more of the radii R3, R4 can be altered by varying the
diameter 49 of the form tool 40, 40A and an interior diameter 29 of
the chamber 28 of the interior sleeve 24.
[0111] In one embodiment, in which the metallic cup 60 has a
diameter 61 of between approximately 3.53 inches and approximately
3.73 inches, the deboss 66 has a maximum diameter 70 of between
approximately 2.44 inches and approximately 2.64 inches. In another
embodiment, the maximum diameter 70 of the deboss 66 is between
approximately 68% and approximately 72% of the diameter 61 of the
metallic cup 60.
[0112] The deboss 66 has a minimum diameter 72 which, in one
embodiment, is between approximately 1.9 inches and approximately
2.1 inches. In another embodiment, the minimum diameter 72 is
between approximately 2.01 inches and approximately 2.03 inches. In
another embodiment, the deboss minimum diameter 72 is between
approximately 54% and approximately 58% of the cup diameter 61.
Optionally, in another embodiment, the minimum diameter 72 is
between approximately 78% and approximately 81% of the maximum
deboss diameter 70.
[0113] The deboss 66 may be of any predetermined depth 68. In one
embodiment, the deboss 66 has a depth 68 of between approximately
0.05 inches and approximately 0.50 inch or, in another embodiment,
between approximately 0.10 inches and approximately 0.40 inches. In
another embodiment, the deboss depth 68 is between approximately
0.25 inches and approximately 0.35 inches.
[0114] As previously described, forming the deboss 66 does not
significantly thin the material of the closed end-wall 64 of the
metallic cup 60. Accordingly, in one embodiment, when a metallic
cup 4 formed of 0.0100 gauge metal is fed into the deboss apparatus
10, the deboss closed end 69 has a thickness that is not less than
0.01 inches. In another embodiment, the closed end-wall 64 has a
thickness which is not less than 0.01 inches. In another
embodiment, when the metallic cup 4 is formed of 0.0100 gauge
metal, the neck 67 of the deboss 66 has a thickness of not less
than approximately 0.008 inches. In still another embodiment, when
the metallic cup 4 is formed of 0.0100 gauge metal, no portion of
the closed end-wall 64 or deboss 66 have a thickness of less than
approximately 0.008 inches.
[0115] In one embodiment, the deboss 66A of the metallic cup 60A
has a depth 68A of between approximately 0.14 inches and
approximately 0.16 inches. In one embodiment, the sidewall 62A has
a height 63A of between approximately 0.90 inches and approximately
1.3 inches after the deboss 66A is formed. In contrast, in one
embodiment the sidewall 6 of the metallic cup 4 has an initial
height 7 of between approximately 1.0 inches and approximately 1.5
inches before the deboss 66 is formed. In another embodiment,
forming the deboss 66A reduces the sidewall height 7 by between
approximately 0.010 inches and approximately 0.15 inches. In
another embodiment, the deboss depth 68A is between approximately
11% and approximately 15% of the sidewall height 63A of the
metallic cup 60A.
[0116] In another embodiment, the deboss 66B has a depth 68B of
between approximately 0.2 inches and approximately 0.4 inches. For
this embodiment, when the initial sidewall height 7 is between
approximately 1.0 inches and approximately 2.0 inches, the sidewall
62B has a height 63B which decreases to between approximately 0.98
inches and approximately 1.18 inches when the deboss 66B is formed.
In another embodiment, the deboss depth 68B is between
approximately 26% and approximately 30% of the height 63B of the
sidewall 62B.
[0117] In one embodiment, a single form tool 40, 40A can be used to
form metallic cups 60A, 60B having debosses 66A, 66B of different
depths 68. More specifically, the depth 68 of a deboss 66 formed by
the deboss apparatus 10 can be adjusted by one or more of altering
the stroke length of the rams 22, adjusting the biasing force of
the biasing means 36, and altering the stroke length of the
pressure pad 30. Accordingly, the form tool 40, 40A does not need
to be replaced to adjust the depth 68 of a deboss 66 and can be
used to form debosses 66 with a variety of different depths 68.
[0118] After the metallic cup 60 is removed from the deboss
apparatus 10 by the outfeed mechanism 50, the metallic cup 60 can
be transported to downstream equipment 74. The downstream equipment
74 can include a conveyor 54 to transport the metallic cups 60 to
downstream equipment 74. In one embodiment, the downstream
equipment 74 includes a bodymaker.
[0119] Optionally, the metallic cups 60 may be inspected for
irregularities and damage, such as dents or protrusions. In one
embodiment, a sensor is configured to visually inspect the metallic
cup. The sensor may be the same as, or similar, sensors described
in U.S. Pat. No. 7,905,174 which is incorporated herein in its
entirety by reference. Alternatively, the metallic cups 60 can be
inspected using an electrode that identifies voltage changes
associated with surface irregularities. One example of a device
including an electrode for detecting surface irregularities in
metallic objects is described in U.S. Patent Application
Publication No. 2012/0119725 which is incorporated herein by
reference in its entirety.
[0120] The description of the present invention has been presented
for purposes of illustration and description, but is not intended
to be exhaustive or limiting of the invention to the form
disclosed. Many modifications and variations will be apparent to
those of ordinary skill in the art. The embodiments described and
shown in the figures were chosen and described in order to best
explain the principles of the invention, the practical application,
and to enable those of ordinary skill in the art to understand the
invention.
[0121] While various embodiments of the present invention have been
described in detail, it is apparent that modifications and
alterations of those embodiments will occur to those skilled in the
art. Moreover, references made herein to "the present invention" or
aspects thereof should be understood to mean certain embodiments of
the present invention and should not necessarily be construed as
limiting all embodiments to a particular description. It is to be
expressly understood that such modifications and alterations are
within the scope and spirit of the present invention, as set forth
in the following claims.
* * * * *
References