U.S. patent application number 17/196362 was filed with the patent office on 2021-09-09 for die guide for a container necker.
The applicant listed for this patent is BALL CORPORATION. Invention is credited to Mark A. Jacober, Kevin Reed Jentzsch, Dean L. Johnson.
Application Number | 20210276069 17/196362 |
Document ID | / |
Family ID | 1000005477025 |
Filed Date | 2021-09-09 |
United States Patent
Application |
20210276069 |
Kind Code |
A1 |
Johnson; Dean L. ; et
al. |
September 9, 2021 |
DIE GUIDE FOR A CONTAINER NECKER
Abstract
The present disclosure provides methods and a necking apparatus
to reduce a first diameter of an open end of a container body to a
second diameter. The necking apparatus includes a necking die and a
die guide. The die guide is selectively moveable relative to the
necking die to guide the open end of the container body into
engagement with the necking die. The die guide includes a flange
that extends into a cylindrical bore of the die guide. The flange
is configured to engage a shoulder of the container body when the
die guide is in a first clamping position relative to the necking
die. After engaging the container shoulder with the flange, the die
guide moves toward the necking die into a second necking position
such that the open end contacts the necking die and the first
diameter of the open end is reduced to the second diameter.
Inventors: |
Johnson; Dean L.;
(Littleton, CO) ; Jacober; Mark A.; (Arvada,
CO) ; Jentzsch; Kevin Reed; (Woodland Hills,
UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BALL CORPORATION |
Westminster |
CO |
US |
|
|
Family ID: |
1000005477025 |
Appl. No.: |
17/196362 |
Filed: |
March 9, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62987201 |
Mar 9, 2020 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B21D 37/12 20130101;
B21D 51/2638 20130101 |
International
Class: |
B21D 37/12 20060101
B21D037/12; B21D 51/26 20060101 B21D051/26 |
Claims
1. A necking apparatus for reducing a diameter of an open end of a
container body, comprising: a housing having a body with an
interior cavity and having a center axis; a necking die positioned
in the interior cavity about the center axis, the necking die
configured to reduce the diameter of the open end of the container
body in a necking operation; a knockout positioned in the interior
cavity and concentrically aligned with the necking die; an outer
guide with a first end operably interconnected to a free end of the
housing, a central bore that extends through the first end and a
second end, and a ring that extends into the central bore proximate
to the first end; a die guide operably engaged to the housing and
selectively moveable relative to the housing and into the central
bore of the outer guide from a first clamping position to a second
necking position, the die guide including a first end facing the
free end of the housing, a cylindrical bore, and a flange extending
inwardly into the cylindrical bore, the flange configured to engage
a shoulder of the container body; a biasing element operably
engaged to the housing with a first end contacting the outer guide
and a second end contacting the die guide; and a keeper
interconnected to the second end of the outer guide, the keeper
configured to limit a stroke of the die guide to a predetermined
length.
2. The necking apparatus of claim 1, wherein the cylindrical bore
of the die guide has an interior wall with an interior diameter
that is greater than an exterior diameter of the container
body.
3. The necking apparatus of claim 1, wherein the flange has an
inner diameter that is less than an exterior diameter of the
container body.
4. The necking apparatus of claim 1, wherein during the necking
operation, the die guide engages the shoulder of the container body
to align the open end of the container body with the necking die
before a forming surface of the necking die contacts the open end
of the container body.
5. The necking apparatus of claim 1, wherein the biasing element is
a spring with the first end extending into a hole formed in the
ring and the second end positioned in a first passage extending
into the first end of the die guide.
6. The necking apparatus of claim 5, wherein the die guide further
comprises a second passage with a second depth that is different
than a first depth of the first passage such that a force applied
to the die guide by the spring is altered by positioning the second
end of the spring in the second passage.
7. The necking apparatus of claim 1, wherein the die guide includes
a protrusion extending from the first end facing the necking die,
and wherein the flange extends inwardly from an interior surface of
the protrusion.
8. The necking apparatus of claim 7, wherein the protrusion has an
exterior diameter that is less than an interior diameter of the
ring of the outer guide.
9. The necking apparatus of claim 1, wherein the die guide includes
a first flute that extends from a second end of the die guide
toward the first end of the die guide that is proximate to the
necking die, and wherein the keeper has a projection positionable
in the first flute to limit movement of the die guide to the stroke
of the predetermined length.
10. The necking apparatus of claim 9, wherein the die guide further
comprises a second flute with a second height that is different
than a first height of the first flute such that the length of the
stroke is altered by positioning the projection of the keeper in
the second flute.
11. The necking apparatus of claim 1, wherein a body of the die
guide is spaced a first distance from the necking die in the first
clamping position and the body is spaced a second distance from the
necking die in the second necking position, the second distance
being less than the first distance.
12. A method of reducing a diameter of an open end of a container
body, comprising: positioning the container body in a necking
apparatus comprising: a housing with a body, an interior cavity,
and a center axis; a necking die retained in the interior cavity; a
knockout retained in the interior cavity, the knockout
concentrically aligned with the necking die and the center axis; an
outer guide operably interconnected to the housing and which has a
first end facing a free end of the housing, a second end, and a
central bore that extends through the first and second ends; a die
guide operably engaged to the housing and selectively moveable into
the central bore from a first clamping position to a second necking
position, the die guide including a first end facing the housing
and a flange which extends inwardly into a cylindrical bore formed
through the die guide; a biasing element secured to the housing to
apply a force to the die guide; and a keeper interconnected to the
second end of the outer guide; engaging a shoulder of the container
body with the flange of the die guide in the first clamping
position; moving the die guide from the first clamping position to
the second necking position relative to the housing such that the
open end of the container body engages the necking die to perform a
necking operation to reduce the diameter of the open end; and
discharging the container body from the necking apparatus.
13. The method of claim 12, wherein an interior wall of the
cylindrical bore of the die guide has an interior diameter that is
greater than an exterior diameter of the container body such that
the interior wall does not contact the container body during
operation of the necking apparatus.
14. The method of claim 13, wherein the flange has an inner
diameter that is less than the exterior diameter of the container
body, wherein the container body is clamped by the flange to impede
unintended movement of the container body relative to the necking
die.
15. The method of claim 12, further comprising altering the force
applied by the biasing element to the die guide by: removing the
keeper from the outer guide to separate the die guide from the
central bore of the outer guide; removing the biasing element from
a first passage extending into the first end of the die guide, the
first passage having a first depth; positioning the biasing element
in a second passage extending into the first end of the die guide,
the second passage having a second depth that is different than
first depth; returning the die guide to the central bore of the
outer guide; and interconnecting the keeper to the outer guide to
interconnect the die guide to the housing.
16. The method of claim 12, further comprising adjusting a length
of a stroke of the die guide by: removing the keeper from the outer
guide to withdraw a projection of the keeper from a first flute of
the die guide, the first flute having a first height to limit the
stroke of the die guide to a first length; positioning the
projection in a second flute of the die guide that has a second
height that is different than the first height; and interconnecting
the keeper to the outer guide with the projection in the second
flute such that the stroke of the die guide is limited to a second
length that is different than the first length.
17. A die guide to align an open end of a container body with a
necking die of a necking apparatus, comprising: a body with a first
end and a second end; a cylindrical bore extending through the
first and second ends which is sized to receive the container body;
a flange extending from the body of the die guide into the
cylindrical bore, the flange configured to engage a shoulder of the
container body; a passage extending into the first end that is
adapted to receive a biasing element; and a flute extending from
the second end toward the first end, the flute having a first
height to limit a stroke of the die guide to a first length when a
projection of a keeper interconnected to the necking apparatus is
positioned in the flute.
18. The die guide of claim 17, further comprising a second passage
that extends into the first end to a second depth that is different
than a first depth of the passage such that a force applied to the
die guide by the biasing element is altered by moving the biasing
element from the passage to the second passage.
19. The die guide of claim 17, further comprising a second flute
with a second height that is different than the first height to
limit the stroke to a second length that is different than the
first length when the projection of the keeper is in the second
flute.
20. The die guide of claim 17, wherein the cylindrical bore is
concentrically aligned with a central axis of the die guide, and
wherein the cylindrical bore is defined by an interior wall that
has an interior diameter that is greater than an inner diameter of
the flange.
21. The die guide of claim 17, further comprising a protrusion
extending from the first end, wherein the flange is formed on the
protrusion.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35
U.S.C. .sctn. 119(e) to U.S. Provisional Patent Application Ser.
No. 62/987,201, filed Mar. 9, 2020, entitled "DIE GUIDE FOR A
CONTAINER NECKER," the entire disclosure of which is hereby
expressly incorporated by reference in its entirety.
FIELD
[0002] The present disclosure relates generally to the manufacture
of metallic containers. More specifically, the present disclosure
provides a method and apparatus for necking the open end of a
metallic container.
BACKGROUND
[0003] Metallic beverage containers offer distributors and
consumers many benefits. The metallic body of a beverage container
provides enhanced protection properties for beverages and
foodstuffs. 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] Additionally, many consumers prefer metallic containers
compared to containers made of glass or plastic. Metallic
containers are particularly attractive to consumers because they
are recyclable, lightweight, and efficient. Metallic containers are
particularly suitable for use in public places and outdoors because
they are more durable than glass containers. Further, some
consumers avoid plastic containers due to concerns that the plastic
may leach chemicals into consumable products.
[0005] As a result of these and other benefits, sales of metallic
containers were valued at approximately $53 billion globally in
2014. A large 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. To meet this demand,
metallic container manufacturing facilities operate some of the
fastest and most efficient production lines in the container
industry. Accordingly, specialized equipment is required for many
of the high-speed operations performed to form the metallic
containers. For example, container neckers often operate at speeds
of 2,000 to 3,000 or more metallic containers per minute.
[0006] Metallic containers come in a variety of shapes and sizes.
Many metallic containers are cylindrical, although other shapes are
known. Common sizes range from about 6 ounces to about 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.
[0007] Two popular types of metallic beverage containers are
metallic bottles and two-piece cans. A metallic bottle generally
has a closed bottom end which can have a dome for improved strength
characteristics, a cylindrical body extending upwardly from the
closed end, a neck with a reduced diameter extending up from the
body, and an open end. An upper end of the neck is typically
threaded so that the open end of the metallic bottle can be closed
with a Roll-On Pilfer Proof (ROPP) closure or another closure known
in the art.
[0008] A two-piece can generally includes a cylindrical body with a
closed end and an inwardly oriented dome, a neck that has a reduced
diameter and which extends up from the body, and an open end
opposite to the closed end. A flange is frequently formed at the
open end of the container body so that an end closure can be double
seamed to the body after filling the container with a product.
[0009] For pressurized contents such as carbonated beverages or
beer, the end closure must be made of a metal with a thickness that
is on the order of at least twice the thickness of body. To
minimize the overall container weight and inherent costs, the end
closure should be diametrically as small as possible and yet
maintain the structural integrity of the container and the
functionality of the end. By forming a neck on a container body,
the diameter of the end closure used to seal the open end is
significantly decreased which ultimately saves material and
costs.
[0010] Bodies of two-piece cans used for beverages frequently have
an outside diameter of 2 11/16 inches ("a 211 container") which is
necked down to have an open end with a diameter of 2 9/16 inches
("a 209 neck"), 2 6/16 inches ("a 206 neck") or even less. Some
two-piece cans have necks with an even smaller diameter, such as
204, 202, 200 or less.
[0011] The machine that forms a neck in a container body is known
as a "necker" and is typically located downstream from container
decorators in the metallic container production lines. After the
container body is formed into its cylindrical shape and decorated,
dies of the necker apply pressure to the upper end of the container
body to reshape the open end and form the neck. To form the neck,
the container body typically passes progressively through several
neckers arranged in series. For example, bodies of two-piece cans
typically pass through six or more neckers. In some production
lines, 14 neckers are used to successively decrease the diameter of
the open end to form the neck. Metallic bottles typically require
more necking operations and production lines for metallic bottles
may include more than 30 necking operations. The dies of the
neckers gradually reduce the diameter of the open end of the
container body to a final diameter.
[0012] Prior art neckers for two-piece cans and metallic bottles
have several deficiencies which decrease the operating efficiency
of metallic container production lines. For example, prior art
neckers include a necking die with a cylindrical guide which slides
along the body of a container as the cylindrical guide aligns the
open end of the container with a necking surface of the necking
die. The cylindrical guide can scratch the container body as the
cylindrical guide slides toward the closed end of the container.
This contact between the cylindrical guide and the container body
produces friction and the accumulation of metal particles on the
cylindrical guide. Further, the accumulation of metal particles on
the cylindrical guide reduces production and increases costs.
[0013] These problems are illustrated in FIG. 1 in which a prior
art necker 20 is shown prior to performing a first necking
operation on a container body 4. The necker 20 generally includes a
necking die 24 and a pilot or knockout 34 which fits within the
container body 4.
[0014] The necking die 24 has a free end 26, a cylindrical guide
28, a necking surface 30, and a second cylindrical wall 32. The
necking surface 30 is adapted to reduce the diameter of the open
end 18 of the container body 6 by a predetermined amount.
[0015] The cylindrical guide 28 is fixed to the second cylindrical
wall 32 and the necking surface 30. The free end 26 of the necking
die is spaced from the necking surface 30 by the cylindrical guide.
More specifically, the cylindrical guide 28 is positioned between
the free end 26 and the necking surface 30. The prior art necking
die 24 can be formed as a unitary piece.
[0016] The cylindrical guide 28 has a first interior diameter
approximately equal to the exterior diameter of the container body
4. In some prior art neckers 20, the clearance between the
cylindrical guide 28 and the container body 4 is only about 0.006
inch or less. The second cylindrical wall 32 has a second interior
diameter that is less than the first interior diameter. The second
interior diameter is equal to the external diameter of the neck
that will be formed by the first necking operation.
[0017] Referring now to FIG. 2, the container body 4 is shown
engaged with the necker 20 during the first forming operation. As
the container body 4 is engaged with the necking die 24, the
cylindrical guide 28 of the prior art necker 20 slides along an
exterior surface 6 of the container body 4. The open end 18 of the
container body contacts the necking surface 30 which directs the
open end 18 inwardly toward a central axis 22 of the necker to form
a shoulder 12. The container open end 18 is then directed
substantially parallel to the container body and the central axis
22 to form a neck 14 with a reduced diameter.
[0018] The cylindrical guide 28 and the knockout 34 work together
to help maintain concentricity of the container body relative to
the prior art necker 20 and to the central axis 22. Some prior art
neckers 20 have cylindrical guides 28 with a greater length
parallel to the central axis 22 to increase the amount of time the
cylindrical guides 28 contact the container body 4 in an attempt to
improve the alignment of the container body with the necker.
However, the increased stroke length required to operate longer
cylindrical guides 28 decreases the cycle rate of the necker
20.
[0019] In addition, some prior art cylindrical guides 28 have an
interior diameter which provide less than 0.006 inch clearance with
the container body. Unfortunately, this minimal clearance leads to
contact between the cylindrical guide and the container body which
can cause several problems and decrease efficiency of the container
production line. The contact of the cylindrical guide with the
container body generates friction. The friction may decrease the
accuracy of alignment of the necking die 24. Moreover, the contact
and friction cause metal particles from the container body to build
up on the cylindrical guide 28. The buildup of particles on the
cylindrical guide can damage container bodies by forming scratches.
The sliding contact of the cylindrical guide may also damage
decorations printed on the container body 4. Container production
lines have experienced decreased efficiency due to stoppages causes
by damaged containers and the need to clean or replace the prior
art necking dies 24. Moreover, these problems may become worse in
neckers that have longer cylindrical guides 28 because of the
increased amount of time the cylindrical guides contact the
container body.
[0020] Another problem is that in some prior art neckers, there is
predetermined space or clearance between the exterior diameter of
the container neck 14 and the interior diameter of the cylindrical
guide 26. The clearance can cause the container neck 14 to be
improperly aligned with the necking surface 30 of the necking die
24. More specifically, the container neck 14 may not be co-axially
aligned with the necking surface due to the clearance between the
exterior surface 6 of the container neck and the interior surface
of the cylindrical guide 26. This improper alignment will cause the
neck to be formed offset from a central axis of the metallic
container. As the metallic container moves to subsequent neckers,
the neck will be progressively formed offset from the central axis.
As will be appreciated by one of skill in the art, a metallic
container with an offset neck is weaker compared to a metallic
container with a cylindrical neck that is aligned with the central
axis.
[0021] Accordingly, there is a need for a new and improved necker
which is reliable and which includes a guide that does not slide
along the exterior surface of the container body to improve the
efficiency of metallic container production lines.
SUMMARY
[0022] One aspect of the present disclosure is an improved die
guide for a necking apparatus to form a neck on a container body in
a manner which is more efficient, has less wear than conventional
necking tools, and ultimately reduces operating costs by improving
efficiency in a high speed metallic container production plant. The
die guide generally includes a body with a first end which is
positioned opposite to a second end. The body of the die guide is
configured to be fixed to a housing of the necking apparatus and is
selectively moveable relative to the housing between a first
clamping position and a second necking position.
[0023] Another aspect of the present disclosure is a novel die
guide to align an open end of a container body with a necking die
of a necking apparatus. The die guide generally includes a
cylindrical bore formed through a body of the die guide. The
cylindrical bore has an interior wall with an interior diameter
that is greater than an exterior diameter of the container body.
Accordingly, during operation of the necking apparatus, the
interior wall of the die guide is spaced from an exterior surface
of the container body.
[0024] A flange of the die guide extends from the body into the
cylindrical bore. In one embodiment, the flange is integrally
formed with the body of the die guide. Alternatively, the flange is
formed separately from the body of the die guide. Accordingly, in
one embodiment, the flange is formed of a different material than
the die guide body.
[0025] The flange has an inner diameter that is less than the
exterior diameter of the container body. However, the inner
diameter of the flange is greater than an exterior diameter of a
neck of the container body. Accordingly, during a necking operation
of the necking apparatus, the container neck and the open end of
the container body will pass through the cylindrical bore past a
first end of the die guide until the flange engages a shoulder of
the container body. The die guide will then move from the first
clamping position to the second necking position while guiding the
open end of the container body into engagement with the necking die
positioned in a housing of the necking apparatus.
[0026] A first aspect of the present disclosure is a necking
apparatus for reducing a diameter of an open end of a container
body, comprising: (1) a housing having a body with an interior
cavity and having a center axis; (2) a necking die positioned in
the interior cavity about the center axis, the necking die
configured to reduce the diameter of the open end of the container
body in a necking operation; (3) a knockout positioned in the
interior cavity and concentrically aligned with the necking die;
(4) an outer guide with a first end operably interconnected to a
free end of the housing, a central bore that extends through the
first end and a second end, and a ring that extends into the
central bore proximate to the first end; (5) a die guide operably
engaged to the housing and selectively moveable relative to the
housing and into the central bore of the outer guide from a first
clamping position to a second necking position, the die guide
including a first end facing the free end of the housing, a
cylindrical bore, and a flange extending inwardly into the
cylindrical bore, the flange configured to engage a shoulder of the
container body; (6) a biasing element operably engaged to the
housing with a first end contacting the outer guide and a second
end contacting the die guide; and (7) a keeper interconnected to
the second end of the outer guide, the keeper configured to limit a
stroke of the die guide to a predetermined length.
[0027] In one embodiment of the necking apparatus of the first
aspect, the cylindrical bore of the die guide has an interior wall
with an interior diameter that is greater than an exterior diameter
of the container body.
[0028] Additionally, or alternatively, the flange has an inner
diameter that is less than an exterior diameter of the container
body.
[0029] Additionally, or alternatively, in another embodiment of the
necking apparatus of the first aspect, during the necking
operation, the die guide engages the shoulder of the container body
to align the open end of the container body with the necking die
before a forming surface of the necking die contacts the open end
of the container body.
[0030] In one embodiment of the necking apparatus of the first
aspect, the die guide includes a protrusion extending from the
first end facing the necking die. When present, the protrusion has
an exterior diameter that is less than an interior diameter of the
ring of the outer guide. The flange extends inwardly from an
interior surface of the protrusion.
[0031] In another embodiment of the necking apparatus of the first
aspect, the biasing element is a spring. The first end of the
spring extends into a hole formed in the ring and the second end is
positioned in a first passage extending into the first end of the
die guide.
[0032] Additionally, or alternatively, the die guide may further
comprise a second passage with a second depth that is different
than a first depth of the first passage. In this manner, a force
applied to the die guide by the spring is adjusted by positioning
the second end of the spring in the second passage.
[0033] In another embodiment of the necking apparatus of the first
aspect, the die guide includes a first flute that extends from a
second end of the die guide toward the first end of the die guide
that is proximate to the necking die. The keeper has a projection
positionable in the first flute to limit movement of the die guide
to the stroke of the predetermined length.
[0034] Additionally, or alternatively, the die guide may further
comprise a second flute with a second height that is different than
a first height of the first flute. In this manner, the length of
the stroke is altered by positioning the projection of the keeper
in the second flute.
[0035] In one embodiment, the outer guide includes an aperture for
a fastener, the aperture extending from through the first and
second ends. The aperture is oriented approximately parallel to the
center axis. Optionally, the aperture is offset from the central
bore of the outer guide.
[0036] In one embodiment, the keeper includes an aperture alignable
with the fastener aperture of the outer guide. Accordingly, to
interconnect the outer guide and the keeper to the housing, a
fastener is positioned through the aperture of the keeper, through
the aperture of the outer guide, and into a hole formed in the
housing.
[0037] In one embodiment, the necking apparatus according to the
first aspect includes one or more of the previous embodiments and
the body of the die guide is spaced a first distance from the
necking die in the first clamping position and the body is spaced a
second distance from the necking die in the second necking
position, the second distance being less than the first
distance.
[0038] In one embodiment, the outer guide is formed of a first
material and the die guide is formed of the first material.
Alternatively, in another embodiment, the outer guide is formed of
the first material and the die guide is formed of a second material
that is different from the first material.
[0039] In one embodiment, the flange is integrally formed with the
die guide. Alternatively, in another embodiment, the flange is
formed separately from the die guide and is subsequently
interconnected to the die guide.
[0040] In one embodiment, the flange is formed of a first material
and the die guide is formed of the first material. Alternatively,
in another embodiment, the flange is formed of the first material
and the die guide is formed of a second material that is different
from the first material.
[0041] In one embodiment, the central bore of the outer guide has
an interior diameter that is substantially constant. Additionally,
or alternatively, the cylindrical bore of the die guide has an
interior diameter that is optionally substantially constant.
[0042] A second aspect of the present disclosure is a method of
reducing a diameter of an open end of a container body, comprising:
(1) positioning the container body in a necking apparatus
comprising: (a) a housing with a body, an interior cavity, and a
center axis; (b) a necking die retained in the interior cavity; (c)
a knockout retained in the interior cavity, the knockout
concentrically aligned with the necking die and the center axis;
(d) an outer guide operably interconnected to the housing and which
has a first end facing a free end of the housing, a second end, and
a central bore that extends through the first and second ends; (e)
a die guide operably engaged to the housing and selectively
moveable into the central bore from a first clamping position to a
second necking position, the die guide including a first end facing
the housing and a flange which extends inwardly into a cylindrical
bore formed through the die guide; (f) a biasing element secured to
the housing to apply a force to the die guide; and (g) a keeper
interconnected to the second end of the outer guide; (2) engaging a
shoulder of the container body with the flange of the die guide in
the first clamping position; (3) moving the die guide from the
first clamping position to the second necking position relative to
the housing such that the open end of the container body engages
the necking die to perform a necking operation to reduce the
diameter of the open end; and (4) discharging the container body
from the necking apparatus.
[0043] In one embodiment of the method of the second aspect, an
interior wall of the cylindrical bore of the die guide has an
interior diameter that is greater than an exterior diameter of the
container body such that the interior wall does not contact the
container body during operation of the necking apparatus.
[0044] Additionally, or alternatively, the flange has an inner
diameter that is less than the exterior diameter of the container
body. In this manner, the container body is clamped by the flange
to impede unintended movement of the container body relative to the
necking die.
[0045] In one embodiment, the method of the second aspect
optionally includes altering the force applied by the biasing
element to the die guide.
[0046] Altering the force applied by the biasing element may
further comprise one or more of: (i) removing the keeper from the
outer guide to separate the die guide from the central bore of the
outer guide; (ii) removing the biasing element from a first passage
extending into the first end of the die guide, the first passage
having a first depth; (iii) positioning the biasing element in a
second passage extending into the first end of the die guide, the
second passage having a second depth that is different than first
depth; (iv) returning the die guide to the central bore of the
outer guide; and (v) interconnecting the keeper to the outer guide
to interconnect the die guide to the housing.
[0047] The method of the second aspect may include any of the
previous embodiments and, additionally or alternatively, further
comprises adjusting a length of a stroke of the die guide.
[0048] In one embodiment, the length of the stroke is adjusted by
one or more of: (i) removing the keeper from the outer guide to
withdraw a projection of the keeper from a first flute of the die
guide, the first flute having a first height to limit the stroke of
the die guide to a first length; (ii) positioning the projection in
a second flute of the die guide that has a second height that is
different than the first height; and (iii) interconnecting the
keeper to the outer guide with the projection in the second flute
such that the stroke of the die guide is limited to a second length
that is different than the first length.
[0049] Optionally, the method of the second aspect further
comprises injecting a gas into the container body at a
predetermined pressure to enhance rigidity of the container body
during a necking operation.
[0050] In one embodiment, the first end of the die guide is spaced
a first distance from the necking die in the first clamping
position. In the second necking position, the first end is spaced a
second distance from the necking die, the second distance being
less than the first distance.
[0051] A third aspect of the present disclosure is a die guide to
align an open end of a container body with a necking die of a
necking apparatus, comprising: (1) a body with a first end and a
second end; (2) a cylindrical bore extending through the first and
second ends which is sized to receive the container body; (3) a
flange extending from the body of the die guide into the
cylindrical bore, the flange configured to engage a shoulder of the
container body; (4) a first passage extending into the first end
that is adapted to receive a biasing element; and (5) a first flute
extending from the second end toward the first end, the flute
having a first height to limit a stroke of the die guide to a first
length when a projection of a keeper interconnected to the necking
apparatus is positioned in the flute.
[0052] The first passage is optionally oriented approximately
parallel to a central axis of the die guide. In one embodiment, the
first passage is offset from the cylindrical bore. Additionally, or
alternatively, the first passage may extend between an exterior
surface of the body and an interior wall of the cylindrical bore.
In one embodiment, the first passage is offset from the first
flute.
[0053] Additionally, or alternatively, the first flute may be
oriented approximately parallel to a central axis of the die guide.
In one embodiment, the first flute is offset from the cylindrical
bore. Optionally, the first flute is recessed into the exterior
surface of the body.
[0054] In one embodiment, the die guide of the third aspect further
comprises a second passage that extends into the first end to a
second depth. The second depth is different than a first depth of
the first passage. In this manner, a force applied to the die guide
by the biasing element is altered by moving the biasing element
from the first passage to the second passage.
[0055] In one embodiment, the second passage is oriented
approximately parallel to the first passage.
[0056] In another embodiment, the die guide further comprises a
third passage that extends into the first end to a third depth. The
third depth is different than the first depth and the second
depth.
[0057] In one embodiment, the third passage is oriented
approximately parallel to the first passage.
[0058] The body has a body height. In one embodiment, the first,
second and third depths are less than the body height such that the
first, second, and third passages do not extend through the second
end of the body.
[0059] The die guide of the third aspect optionally includes four
of the first passages, four of the second passages, and four of the
third passages.
[0060] In one embodiment, the first flute extends between a first
flute opening and a first flute end. In one embodiment, the first
flute opening is at the second end of the body. The first flute end
defines a stop that is engaged by the projection to limit the
stroke to the first length.
[0061] In one embodiment, the first flute end is spaced from the
first end of the body. Optionally, the first flute end is closer to
the first end than to the second end of the die guide.
[0062] Additionally, or alternatively, the die guide of the third
aspect may further comprise a second flute with a second height.
The second height is different than the first height to limit the
stroke to a second length that is different than the first length
when the projection of the keeper is in the second flute.
[0063] In one embodiment, the second flute is oriented
approximately parallel to the first flute. Additionally, or
alternatively, the first passage extends between the first and
second flutes.
[0064] In one embodiment, the second flute has a second flute
opening and a second flute end. Optionally, the second flute end is
closer to the first end than to the second end of the die
guide.
[0065] In another embodiment, the die guide of the third aspect
optionally includes a third flute with a third height. The third
height is different than the first height and the second height to
limit the stroke to a third length that is different than the first
and second lengths when the projection of the keeper is in the
third flute.
[0066] In one embodiment, the third flute has a third flute opening
and a third flute end. Optionally, the third flute end is closer to
the second end than to the first end of the die guide.
[0067] In one embodiment, the first, second and third heights are
less than the body height such that the first, second, and third
flutes do not extend to the first end of the body.
[0068] The die guide of the third aspect optionally includes four
of the first flutes, four of the second flutes, and four of the
third flutes.
[0069] In one embodiment, the cylindrical bore is defined by an
interior wall. The interior wall has an interior diameter that is
greater than an inner diameter of the flange. In another
embodiment, the cylindrical bore is concentrically aligned with a
central axis of the die guide.
[0070] The die guide of the third aspect may include any of the
previous embodiments and optionally further comprises a protrusion
extending from the first end. In this embodiment, the flange is
formed on the protrusion.
[0071] In one embodiment, the flange is integrally formed with the
die guide. Alternatively, in another embodiment, the flange is
formed separately from the die guide and is subsequently
interconnected to the die guide. Optionally, the flange is
releasably fixed to the die guide.
[0072] In one embodiment, the flange is formed of a first material
and the die guide is formed of the first material. Alternatively,
in another embodiment, the flange is formed of the first material
and the die guide is formed of a second material that is different
from the first material.
[0073] One aspect of the present disclosure is a necking apparatus
including a die guide and a necking die. The die guide is spaced
from the necking die and configured to move from a first clamping
position to a second necking position. A flange of the die guide is
adapted to engage a shoulder of a container body. After the flange
engages the shoulder, the die guide moves from the first clamping
position to the second necking position such that the necking die
will engage an open end of the container body. The necking die is
configured to reduce a diameter of a neck of the container body by
a predetermined amount.
[0074] Yet another aspect of the present disclosure is a method of
forming a neck on an open end of a container body. The container
body is positioned in a necking apparatus of the present
disclosure. The necking apparatus includes a die guide and a
necking die. During a necking operation, a neck of the container
body is advanced through a cylindrical bore of the die guide until
a flange of the die guide engages a shoulder of the container body.
The die guide then moves from a first clamping position to a second
necking position relative to the necking die while guiding an open
end of the container body into contact with a transition surface of
the necking die. The transition surface is configured to reduce the
diameter of the open end of the container body.
[0075] One aspect is a necking apparatus for reducing a diameter of
an open end of a container body, comprising: (1) a housing defined
by a body with an interior cavity and having a center axis; (2) a
necking die positioned in the interior cavity of the housing about
the center axis, the necking die configured to reduce the diameter
of the open end of the container body in a necking operation; (3) a
knockout positioned in the interior cavity and concentrically
aligned with the necking die; (4) a biasing element operably
engaged to the housing with a first end and a second end, the
second end contacting a die guide; and (5) the die guide operably
interconnected to the housing and selectively moveable relative to
the housing from a first clamping position to a second necking
position, the die guide including a cylindrical bore and a flange
extending inwardly into the cylindrical bore, the flange configured
to engage a shoulder of the container body.
[0076] In one embodiment, the cylindrical bore of the die guide has
an interior wall with an interior diameter that is greater than an
exterior diameter of the container body.
[0077] In another embodiment, the flange has an inner diameter that
is less than the exterior diameter of the container body.
[0078] The inner diameter of the flange is greater than an exterior
diameter of the open end of the container body.
[0079] In some embodiments, the necking die is retained in the
interior cavity by a retention ring. In one embodiment, the
retention ring is positioned on a post extending from an open end
of the housing. Optionally, the retention ring includes an
aperture, and the post extends through the aperture.
[0080] In further embodiments, the biasing element is positioned
with the first end in contact with the retention ring.
[0081] The die guide may be formed of any suitable material. In one
embodiment, the die guide is formed of an engineered plastic, such
as a polyether ether ketone (PEEK). Optionally, the die guide is
formed of a polymer. For example, in some embodiments, the die
guide is formed of a polyethylene, a polypropylene, or a nylon
material. Alternatively, the die guide is formed of a metal or a
ceramic. Optionally, the die guide is formed of a bronze alloy. The
die guide may also be formed of a carbide, including but not
limited to a tungsten carbide.
[0082] In one embodiment, the flange is integrally formed with the
die guide. Alternatively, in another embodiment, the flange is
formed separately from the die guide and is interconnected to the
die guide.
[0083] Optionally, the flange is formed of a material that is
different than a material of the die guide. In one embodiment, the
flange is formed of the same material as the die guide.
[0084] Optionally, the flange is formed of a metal (such as a
bronze alloy or a carbide), a plastic (for example, a PEEK), or a
ceramic. The flange may also be formed of a polymer, including one
or more of a polyethylene, a polypropylene, or a nylon
material.
[0085] In one embodiment, during the necking operation, the die
guide engages the shoulder of the container body to align the open
end of the container body with the necking die before a transition
surface of the necking die contacts the open end of the container
body.
[0086] Optionally, the biasing element is a spring. Any suitable
spring known to one of skill in the art may be used with the
necking apparatus. For example, the biasing element may be a
compression spring, including a coil spring.
[0087] In another embodiment, the biasing element biases the die
guide to the first clamping position.
[0088] In one embodiment, in the first clamping position, the die
guide is a first distance from a free end of the knockout. In the
second necking position, the die guide is a second distance from
the free end of the knockout, the second distance being less than
the first distance.
[0089] In one embodiment, the necking apparatus includes a
transmission line to inject a gas into the container body at a
predetermined pressure before the necking die performs the necking
operation. Optionally, the shaft positioned within the housing
includes a bore to inject the gas into the container body. The gas
may be compressed air. Alternatively, the gas may be any suitable
gas known in the art.
[0090] It is another aspect of the present disclosure to provide a
method of reducing a diameter of an open end of a container body.
The method generally includes, but is not limited to, one or more
of: (1) positioning the container body in a necking apparatus
including (a) a housing with a body, an interior cavity, and a
center axis; (b) a necking die retained in the interior cavity; (c)
a knockout retained in the interior cavity, the knockout
concentrically aligned with the necking die and the center axis;
(d) a die guide operably interconnected to the housing and
selectively moveable from a first clamping position to a second
necking position, the die guide including a flange which extends
inwardly into a cylindrical bore formed through the die guide; and
(e) a biasing element secured to the housing to apply a force to
the die guide; (2) engaging a shoulder of the container body with
the flange of the die guide in the first clamping position; (3)
moving the die guide from the first clamping position to the second
necking position relative to the housing such that the open end of
the container body engages the necking die to perform the necking
operation to reduce the diameter of the open end of the container
body; and (4) discharging the container body from the necking
apparatus.
[0091] In one embodiment, an interior wall of the cylindrical bore
has an interior diameter that is greater than an exterior diameter
of the container body such that the interior wall does not contact
the container body during operation of the necking apparatus.
[0092] In another embodiment, the flange has an inner diameter that
is less than the exterior diameter of a shoulder of the container
body. In this manner, the shoulder is clamped by the flange to
impede unintended movement of the container body relative to the
necking die.
[0093] In one embodiment, the inner diameter of the flange is
greater than an exterior diameter of the open end of the container
body. In this manner, the open end does not contact the flange.
[0094] The necking apparatus optionally includes a post extending
from an open end of the housing. In one embodiment, the necking die
is retained in the interior cavity by a retention ring. The
retention ring may be positioned on the post. The retention ring is
adapted to be retained in a predetermined position with respect to
the housing. In one embodiment the retention ring includes an
aperture. The post may extend through the aperture to retain the
retention ring in the predetermined position. Optionally, the post
is oriented approximately parallel to the center axis.
[0095] The post can be interconnected to the housing in any
suitable manner. Optionally the post is threadably engaged to the
housing. In one embodiment, the housing includes a threaded
aperture to receive a threaded portion of the post.
[0096] The post may include a head opposite to the threaded
portion. In one embodiment, a distance between the head and the
housing may be adjusted by rotating the post. For example, rotating
the post in a first direction will move the head closer to the
housing. Alternatively, rotating the post in a second direction
will move the head further away from the housing.
[0097] In one embodiment, the method further comprises injecting a
gas into the container body at a predetermined pressure to enhance
rigidity of the container body during a necking operation.
[0098] Yet another aspect is a die guide to align an open end of a
container body with a necking die of a necking apparatus,
comprising: (1) a body with a first end and a second end; (2) a
cylindrical bore extending through the first and second ends which
is sized to receive the container body; and (3) a flange extending
from the body of the die guide into the cylindrical bore; and (4)
an aperture extending into the first end of the body to receive a
biasing element.
[0099] In one embodiment, the aperture does not extend through the
second end of the body.
[0100] The aperture of the body may be configured to receive a
guide post extending from an open end of a housing of the necking
apparatus to moveably interconnect the die guide to the necking
apparatus.
[0101] Optionally, the aperture includes a seat to engage the
biasing element to bias the die guide in a first clamping position
relative to the housing of the necking apparatus. For example, the
aperture may optionally include a first portion with a first
diameter. A second portion of the aperture may have a second
diameter that is less than the first diameter.
[0102] In one embodiment, the cylindrical bore is concentrically
aligned with a center axis of the die guide.
[0103] In another embodiment, the aperture extends in a direction
that is approximately parallel to the center axis.
[0104] In one embodiment, the aperture is offset from the
cylindrical bore.
[0105] In another embodiment, the cylindrical bore defines an
interior wall of the die guide, the interior wall having an
interior diameter that is greater than an inner diameter of the
flange.
[0106] The die guide may be formed of any suitable material. In one
embodiment, the die guide is formed of an engineered plastic, such
as a polyether ether ketone (PEEK). Optionally, the die guide is
formed of a polymer. For example, in some embodiments, the die
guide is formed of a polyethylene, a polypropylene, or a nylon
material. Alternatively, the die guide is formed of a metal or a
ceramic. Optionally, the die guide is formed of a bronze alloy. The
die guide may also be formed of a carbide, including but not
limited to a tungsten carbide.
[0107] In one embodiment, the flange is interconnected to the body
of the die guide. Alternatively, the flange can be integrally
formed with the die guide body.
[0108] In one embodiment, the flange is formed of a material that
is different than a material of the die guide body. In another
embodiment, the flange is formed of a material that is the same as
the material of the body of the die guide.
[0109] Optionally, the flange can be formed of a ceramic, a metal
(such as a bronze alloy), or a plastic (for example, a PEEK).
[0110] In another embodiment, the flange protrudes from one end of
the body of the die guide. For example, the flange may protrude
from the first end.
[0111] The Summary is neither intended nor should it be construed
as being representative of the full extent and scope of the present
disclosure. The present disclosure is set forth in various levels
of detail in the Summary as well as in the attached drawings and
the Detailed Description and no limitation as to the scope of the
present disclosure is intended by either the inclusion or
non-inclusion of elements, components, etc. in this Summary.
Additional aspects of the present disclosure will become more clear
from the Detailed Description, particularly when taken together
with the drawings.
[0112] 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, copper, and any
combination thereof.
[0113] Although generally referred to herein as a "container body"
or a "metallic container," it should be appreciated that the
methods and apparatus described herein may be used to form a neck
on a container of any size, shape, or type, including without
limitation a metallic beverage bottle, a metallic beverage
container or can, an aluminum bottle, a two-piece container, a
two-piece can, or a can.
[0114] As used herein, a "container body" can be formed into a
two-piece can or a metallic bottle.
[0115] 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.
[0116] 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.
[0117] Unless otherwise indicated, all numbers expressing
quantities, dimensions, conditions, ratios, ranges, 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".
Accordingly, unless otherwise indicated, all numbers expressing
quantities, dimensions, conditions, ratios, ranges, and so forth
used in the specification and claims may be increased or decreased
by approximately 5% to achieve satisfactory results. Additionally,
where the meaning of the terms "about" or "approximately" as used
herein would not otherwise be apparent to one of ordinary skill in
the art, the terms "about" and "approximately" should be
interpreted as meaning within plus or minus 5% of the stated
value.
[0118] All ranges described herein may be reduced to any sub-range
or portion of the range, or to any value within the range without
deviating from the invention. For example, the range "5 to 55"
includes, but is not limited to, the sub-ranges "5 to 20" as well
as "17 to 54."
[0119] 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.
[0120] 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, Brief Description of
the Drawings, Detailed Description, Abstract, and Claims
themselves.
BRIEF DESCRIPTION OF THE DRAWINGS
[0121] The accompanying drawings, which are incorporated in and
constitute a part of the specification, illustrate embodiments of
the disclosed system and together with the general description of
the disclosure given above and the detailed description of the
drawings given below, serve to explain the principles of the
disclosed system(s) and device(s).
[0122] FIG. 1 is a partial cross-sectional elevation view of a
prior art necking apparatus prior to performing a necking operation
on an upper end of a container body;
[0123] FIG. 2 is another partial cross-sectional elevation view of
the necking apparatus of FIG. 1 during the necking operation;
[0124] FIG. 3 is a cross-sectional elevation view of a tooling
assembly for a necker according to one embodiment of the present
disclosure and with a die guide in a first clamping position
relative to the tooling assembly;
[0125] FIG. 4 is an expanded cross-sectional elevation view of a
portion of the tooling assembly of FIG. 3;
[0126] FIG. 5 is another expanded cross-sectional elevation view of
another portion of the tooling assembly of FIG. 3 and showing an
upper flange of the die guide engaged to a shoulder of a container
body;
[0127] FIG. 6 is a top plan view of the die guide of FIG. 3;
[0128] FIG. 7 is another cross-sectional elevation view of the
tooling assembly of FIG. 3 showing the die guide in a second
necking position in which the die guide is in a retracted position
relative to the tooling assembly;
[0129] FIG. 8A is a front perspective view of a tooling assembly
according to another embodiment of the present disclosure and
illustrating a die guide in a first clamping position relative to
the tooling assembly;
[0130] FIG. 8B is a cross-sectional front perspective view of the
tooling assembly of FIG. 8A;
[0131] FIG. 8C is a cross-sectional front elevation view of the
tooling assembly of FIG. 8A;
[0132] FIG. 9A is an upper perspective view of an outer guide of
the tooling assembly of FIG. 8A;
[0133] FIG. 9B is a top plan view of the outer guide of FIG.
9A;
[0134] FIG. 9C is a cross-sectional side elevation view of the
outer guide taken along line C-C of FIG. 9B;
[0135] FIG. 9D is another cross-sectional side elevation view of
the outer guide taken along line D-D of FIG. 9B;
[0136] FIG. 10A is a top front perspective view of a die guide of
the tooling assembly of FIG. 8A;
[0137] FIG. 10B is a bottom perspective view of the die guide of
FIG. 10A;
[0138] FIG. 10C is a side elevation view of the die guide of FIG.
10A;
[0139] FIG. 10D is a top plan view of the die guide of FIG.
10A;
[0140] FIG. 10E is a cross-sectional side elevation view of the die
guide taken along line E-E of FIG. 10D;
[0141] FIG. 10F is another cross-sectional side elevation view of
the die guide taken along line F-F of FIG. 10D;
[0142] FIG. 10G is yet another cross-sectional side elevation view
of the die guide taken along line G-G of FIG. 10D;
[0143] FIG. 10H is an expanded cross-sectional view of a portion of
the die guide of FIG. 10G;
[0144] FIG. 10I is a bottom plan view of the die guide of FIG.
10A;
[0145] FIG. 10J is a cross-sectional side elevation view of the die
guide taken along line J-J of FIG. 10I;
[0146] FIG. 10K is another cross-sectional side elevation view of
the die guide taken along line K-K of FIG. 10I;
[0147] FIG. 10L is yet another cross-sectional side elevation view
of the die guide taken along line L-L of FIG. 10I;
[0148] FIG. 11A is a bottom perspective view of a keeper of the
tooling assembly of FIG. 8A;
[0149] FIG. 11B is a side elevation view of the keeper of FIG.
11A;
[0150] FIG. 11C is a bottom plan view of the keeper of FIG.
11A;
[0151] FIG. 12A is a cross-sectional front elevation view of the
tooling assembly of FIG. 8A and illustrating the die guide in a
second necking position and retracted relative to the tooling
assembly;
[0152] FIG. 12B is a cross-sectional front perspective view of the
tooling assembly with the die guide in the second necking position
of FIG. 12A;
[0153] FIG. 13 is a side elevation view of a container body of a
two-piece can with a neck formed by a necking apparatus of one
embodiment of the present disclosure; and
[0154] FIG. 14 is a cross-sectional elevation view of a metallic
bottle with a neck formed by a necking apparatus of another
embodiment of the present disclosure.
[0155] The drawings are not necessarily (but may be) to scale. 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 disclosure is not necessarily
limited to the embodiments illustrated herein. As will be
appreciated, other embodiments are possible using, alone or in
combination, one or more of the features set forth above or
described below. For example, 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.
[0156] The following is a listing of components according to
various embodiments of the present disclosure, and as shown in the
drawings:
TABLE-US-00001 Number Component 2 Metallic container 3 Longitudinal
axis of metallic container 4 Container body 5 Sidewall 6 Exterior
surface of container body 8 Exterior diameter of container body 10
Closed end (bottom) 11 Dome 12 Shoulder 14 Neck 16 Neck exterior
diameter 18 Open end (or free end) of the container body 20 Necker
(prior art) 22 Central axis 24 Necking die 26 Free end of necking
die 28 Cylindrical guide of necking die 30 Necking surface 32
Second cylindrical wall of necking die 34 Knockout 40 Necker 42
Tooling assembly 44 Center axis 46 Housing 47 Cylindrical body of
housing 48 Interior cavity of housing 49 Shoulder 50 Knockout shaft
51 Bore of knockout shaft 52 Locating diameter of knockout shaft 54
Head of knockout shaft 55 Port of housing 56 Open end of housing 57
Hole of housing 58 Post 59 Shoulder of post 60 Biasing element or
spring 61 Head of post 62 Retention ring (for necking die) 63
Aperture of retention ring 64 Spacer 65 Knockout spacer 66 Knockout
68 Cylindrical sidewall of knockout 70 Guide surface of knockout 72
Maximum exterior diameter of guide surface 74 Minimum exterior
diameter of guide surface 76 End wall of knockout 77 Interior wall
of retention ring 78 Necking die 80 Inner end of necking die 82
Free end of necking die 84 Transition surface or necking surface of
the necking die 86 Maximum interior diameter of transition surface
88 Minimum interior diameter of transition surface 89 Interior
diameter of interior wall of the retention ring 90 Cylindrical wall
of necking die 92 Clearance between necking die and knockout 93
Clearance between transition surface and interior wall of retention
ring 94 Die guide 96 Body of die guide 98 First end of die guide 99
Second end of die guide 100 Cylindrical bore of die guide 102
Interior wall of cylindrical bore 104 Interior diameter of interior
wall of the die guide 106 Flange of die guide 107 Inner wall of
flange 108 Inner diameter of the die guide flange 109 Protrusion of
die guide 110 Aperture of die guide 110A First portion of aperture
(large diameter) 110B Second portion of aperture (smaller diameter)
111 Exterior diameter of protrusion 112 Seat for biasing element
113 Height of flange inner wall 114 Distance of die guide body from
the retention ring in the first clamping position 116 Distance of
die guide body from the retention ring in the second necking
position 118 Recess between the die guide and the container body
exterior surface 120 First distance of die guide body from the
necking die in the first clamping position 122 Second distance of
die guide body from the necking die in the second necking position
124 Exterior diameter of body 126 Protrusion height 128 Passage 130
Passage depth 132 Flute or "channel" 134 Flute opening 136 Flute
end 138 Flute height 140 Outer guide 142 Cylindrical body 144 Upper
end 146 Dowel pin 148 Lower end 150 Outer diameter 152 Height 154
Central bore 156 Inner wall 158 Wall interior diameter 160 Ring 162
Hole 164 Ring interior diameter 166 Fastener aperture 170 Keeper
172 Cylindrical exterior 174 Central cutout 176 Interior diameter
of the cutout 178 Aperture 180 Projection 182 Interior diameter of
projection 184 Fastener
DETAILED DESCRIPTION
[0157] Referring now to FIGS. 3-6, a tooling assembly 42A of a
necker 40A according to one aspect of the present disclosure is
generally illustrated prior to performing a necking operation on a
container body 4. The necker 40A and the tooling assembly 42A can
be oriented either horizontally or vertically.
[0158] The tooling assembly 42A generally includes a housing 46
with a body 47 and an interior cavity 48 concentrically aligned
with a center axis 44. The interior cavity 48 has a shape which is
generally cylindrical.
[0159] A knockout shaft 50 is engaged to the housing and extends
within the cavity 48. The knockout shaft 50 may include an interior
bore 51. The interior bore 51 of the knockout shaft may be
configured to transmit a compressed gas to an interior of a
container body 4.
[0160] A locating diameter 52 of the knockout shaft 50 aligns the
knockout shaft with the housing 46. More specifically, the locating
diameter 52 is configured to accurately align the knockout shaft
substantially concentrically within the housing 46. In one
embodiment, the knockout shaft 50 and its locating diameter 52 are
substantially concentrically or coaxially aligned with the center
axis 44.
[0161] In one embodiment, a pressurized gas is directed through the
interior bore 51 of the knockout shaft 50 and into the container
body 4 during the necking operation to enhance the rigidity of the
metal sidewalls and temporarily strengthen the container body.
Additionally, or alternatively, a pressurized gas can optionally be
used to separate or strip the container body 4 from the tooling
assembly 42A after completion of the necking operation. For
example, the housing 46 optionally includes a port 55 to direct a
pressurized gas into the interior cavity 48 of the housing and into
a metallic container 2 engaged by the necker 40A. The port 55 may
be connected to a source of pressurized gas, such as a compressor
or a pressure vessel. The pressurized gas can be directed through
the port 55 during a necking operation to increase the rigidity of
the metallic container 2. Additionally, or alternatively,
pressurized gas can be directed through the port 55 after
completion of the necking operation to facilitate separation of the
metallic container 2 from the tooling assembly 42A. In one
embodiment, the pressurized gas is compressed air. In alternative
embodiments, the pressurized gas may be any suitable gas known in
the art.
[0162] A knockout 66 is fixed within the cavity 48 of the housing
46 to facilitate alignment of the container body 4 with a necking
die 78. More specifically, the knockout 66 helps guide the open end
18 of the container body 4 to engagement with the necking die
78.
[0163] In one embodiment, the knockout 66 is interconnected to the
knockout shaft 50, for example, by a head 54 of the knockout shaft
50. Optionally, a knockout spacer 65 engages the knockout 66. In
one embodiment, the knockout spacer 65 is positioned on the
knockout shaft 50. The knockout spacer 65 has a body that is
generally cylindrical and has a length selected to hold the
knockout 66 in a predetermined position within the interior cavity
48 of the housing 46.
[0164] The knockout 66 is optionally mounted in such a manner that
it is immobile relative to the housing 46. Accordingly, in some
embodiments, the knockout 66 does not move during operation of the
necker 40A. Alternatively, the knockout 66 may be moveably retained
within the housing 46 by the knockout shaft 50.
[0165] In some embodiments, the knockout 66 may be integrally
formed with the knockout shaft 50. In other embodiments, the
knockout 66 may be selectively connected to the knockout shaft
50.
[0166] The knockout 66 has a cylindrical sidewall 68 with an
exterior diameter 72 that is less than an interior diameter of a
neck 14 of the container body 4. In one embodiment, the cylindrical
sidewall 68 is approximately parallel to the center axis 44.
[0167] Optionally, the knockout 66 has a guide surface 70 (best
seen in FIG. 4) which extends between the cylindrical sidewall 68
and an end wall 76 of the knockout. In one embodiment, a
cross-section of the guide surface 70 has a curved or arcuate
shape. Specifically, in one embodiment an exterior of the guide
surface is convex. In other embodiments, the cross-section of the
guide surface 70 is generally linear. Alternatively, the
cylindrical sidewall 68 may extend to the end wall 76 at an
orthogonal intersection.
[0168] The exterior diameter of the guide surface 70 increases from
the end wall 76 to an intersection of the guide surface 70 with the
cylindrical sidewall 68. Accordingly, the guide surface 70 has a
maximum exterior diameter 72 defined by the cylindrical sidewall
68. The guide surface 70 has a minimum exterior diameter 74 at a
point proximate to the end wall 76. In one embodiment, the guide
surface 70 is generally convex in cross-section. However, the guide
surface 70 may have other shapes. In one embodiment, the guide
surface 70 has a cross-section that is approximately linear.
[0169] A necking die 78 according to one embodiment of the present
disclosure is retained within the housing cavity 48. The necking
die can be secured to the housing 46 in any suitable manner known
to those of skill in the art. In one embodiment, a retention ring
62 secures the necking die 78 within the housing cavity 48.
[0170] The retention ring 62 can be secured to the housing 46 in
any suitable manner known to those of skill in the art. In one
embodiment, a post 58 is used to secure the retention ring 62 to
the housing. The post 58 may extend through an aperture 63 formed
through the retention ring. Optionally, the post 58 has a shoulder
59 (shown in FIG. 4) with an increased diameter to retain the
retention ring 62.
[0171] The post 58 optionally extends from an open end 56 of the
housing 46. For example, the post 58 can extend from the housing
end 56 approximately parallel to the center axis 44. In one
embodiment, the post 58 is a bolt or a screw with threads that
engage threads of a hole 57 formed in the housing 46.
[0172] The post 58 optionally includes a head 61 spaced from the
housing. Optionally, a distance between the head 61 and the housing
46 may be adjusted by rotating the post. For example, rotating the
post in a first direction will move the head 61 closer to the
housing. Alternatively, rotating the post in a second direction
will move the head 61 further away from the housing 46. In this
manner, a stroke length of the die guide 94A can be adjusted. More
specifically, for a metallic container with a long neck 14, the
stroke length of the die guide 94A may be increased by rotating the
post in the second direction. Alternatively, for a metallic
container with a short neck, the stroke length of the die guide can
be decreased by rotating the post in the first direction.
[0173] Optionally, the retention ring 62 prevents movement of the
necking die 78 relative to the housing 46. More specifically, in
one embodiment, an inner end 80 of the necking die 78 engages a
portion of the housing 46. For example, the inner end 80 may engage
a projection or shoulder 49 of the housing 46 which projects
inwardly into the interior cavity 48. The retention ring 62 can
then engage a free end 82 of the necking die. Accordingly, in one
embodiment, the necking die 78 is substantially immobily secured or
interconnected to the housing 46 by the retention ring 62.
[0174] In some embodiments, the retention ring 62 is generally
circular. In alternative embodiments, the retention ring has an
asymmetrical shape.
[0175] The retention ring 62 may have a central hole with an
interior wall 77 (best seen in FIG. 4). The interior wall 77 may be
oriented approximately perpendicular to an end of the retention
ring 62. Alternatively, the interior wall 77 may be oriented at an
oblique angle with respect to the retention ring end. In one
embodiment, the interior wall has a curved or an arcuate
cross-section as generally shown in FIG. 4. In one embodiment, the
interior wall 77 is generally convex in cross-section.
[0176] The interior wall 77 has an interior diameter 89. In one
embodiment, when the interior wall 77 is approximately
perpendicular to the end of the retention ring, the interior
diameter is approximately constant.
[0177] Alternatively, the interior diameter 89 of the interior wall
77 varies. For example, in one embodiment the interior diameter 89
increases from a minimum interior diameter 89 at a first end of the
retention ring (illustrated in FIG. 4) to a maximum interior
diameter at a second end of the retention ring.
[0178] Optionally, the inner end 80 of the necking die 78 may
engage a spacer 64 within the housing cavity 48. In one embodiment,
one or more spacers 64A-64E are positioned within the interior
cavity 48 of the housing 46. The spacers 64 may be of different
sizes and shapes. For example, in some embodiments, a first spacer
64A has a first height that is less than a second height of a
second spacer 64B. Moreover, a fifth spacer 64E has a diameter that
is less than the diameters of spacers 64A-64D.
[0179] One or more of the spacers 64 can include a hollow interior.
Optionally, an interior diameter of the spacers 64 is greater than
the exterior diameter of the knockout 66. In one embodiment, the
interior diameter of a spacer 64 is greater than an interior
diameter 86 of a cylindrical wall 90 of the necking die 78.
[0180] Any number of spacers 64 can be positioned within the
housing to arrange the necking die 78 in a predetermined position
of the interior cavity 48. For example, the number and sizes of the
spacers 64 can be altered to move the necking die 78 closer to (or
away from) the retention ring 62. Optionally, a spacer 64 can be
positioned between the free end 82 of the necking die 78 and the
retention ring 62. It will be understood by one of skill in the art
that in some embodiments the spacer 64 is not used, for example
based on the size or shape of the metallic container 2.
[0181] The necking die 78 generally includes the free end 82
opposite to the inner end 80, a transition surface 84, and a hollow
interior that defines a cylindrical wall 90. The cylindrical wall
90 is approximately parallel to the center axis 44.
[0182] Notably, compared to the prior art necking die 24 described
in conjunction with FIGS. 1-2, the necking die 78 of the present
disclosure does not include a cylindrical guide 28. For example,
the free end 82 of the necking die 78 is proximate to the
transition surface 84. More specifically, in one embodiment, the
transition surface 84 of the necking die 78 begins at the free end
82. In one embodiment, the free end 82 is approximately planar.
Optionally, the free end 82 defines a plane that is oriented
approximately perpendicular to the center axis 44.
[0183] The transition surface 84 is adapted to reduce the diameter
of the open end 18 of the container body by a predetermined amount.
The transition surface 84 has an interior diameter that varies from
a maximum interior diameter 86 proximate to the free end 82 and
decreases to a minimum interior diameter 88 proximate to the
cylindrical wall 90. The minimum interior diameter 88 of the
transition surface 84 is equal to the diameter of the cylindrical
wall 90 of the necking die. Moreover, the minimum interior diameter
88 of the necking die transition surface 84 is greater than the
maximum exterior diameter 72 of the knockout guide surface 70 to
define a clearance 92 (best seen in FIG. 4) between the cylindrical
sidewall 68 of the knockout 66 and the necking die cylindrical wall
90. The clearance 92 is greater than or equal to a thickness of the
material of the metallic container 2. In one embodiment, the
clearance 92 is slightly greater than a thickness of the material
of the metallic container 2. Optionally, the clearance 92 has a
width of between approximately 0.003 inch and approximately 0.02
inch.
[0184] In one embodiment, the transition surface 84 has a
cross-sectional shape that is curved or arcuate. Optionally, the
cross-sectional shape of an exterior of the transition surface 84
is convex. Other shapes for the transition surface 84 are
contemplated.
[0185] The transition surface 84 is adapted to form a shoulder 12
in the container body 4 during a necking operation. More
specifically, the maximum interior diameter 86 of the transition
surface is greater than an exterior diameter 16 of a neck 14 of the
container body 4, and the minimum interior diameter 88 is less than
the neck exterior diameter 16. Accordingly, during the necking
operation, the open end 18 of the container neck 14 contacts the
transition surface 84. The transition surface 84 then directs the
open end 18 inwardly toward the center axis 44 to form (or reform)
the shoulder 12. The cylindrical wall 90 of the necking die 78 and
the cylindrical sidewall 68 of the knockout 66 then guide the open
end 18 back approximately parallel to the center axis 44 to reduce
the diameter of the neck 14.
[0186] The diameter of the cylindrical wall 90 of the necking die
78 is approximately equal to an external diameter of the neck 14
that will be formed during the necking operation. However, the
diameter of the cylindrical wall 90 can be increased or decreased
as necessary to account for springback of the metal material of the
container neck 14 which occurs after the necking operation as will
be appreciated by one of skill in the art.
[0187] A die guide 94A according to one embodiment of the present
disclosure is interconnected to an end 56 of the housing. The die
guide is retained in a spaced relationship to the housing end 56
and to the necking die 78. The die guide 94A is configured to
engage a shoulder 12 of the container body 4 and align the
container body 4 with the knockout 66 and the necking die 78 of the
necker 40A of the present disclosure. More specifically, the die
guide 94A aligns the open end 18 of the container body 4 with the
forming profile (for example, the transition surface 84) of the
necking die 78.
[0188] The die guide 94A is moveably interconnected to the housing
46. Specifically, the die guide 94A is moveable from a first
clamping position (shown in FIG. 3) to a second necking position
(which is generally illustrated in FIG. 7).
[0189] In one embodiment, in the first clamping position, a first
end 98 of the die guide 94A is separated from the retention ring 62
by a predetermined distance 114. The distance 114 may be up to
approximately 1 inch. Optionally, the distance 114 is between
approximately 0.05 inch and approximately 0.85 inch. In one
embodiment, the distance is less than about 0.82 inch.
Additionally, or alternatively, the die guide 94A can move between
approximately 0.5 inch and 0.9 inch, or about 0.76 inch, from the
first clamping position to the second necking position.
[0190] The first clamping position of the die guide 94A is
associated with initiation of the necking operation. In the first
clamping position, the die guide 94A contacts the container
shoulder 12 before the necking die 78 contacts the open end 18 of
the container body.
[0191] In both the first clamping position and the second necking
position the die guide 94A is spaced from the necking die 78 by the
retention ring 62. More specifically, in the first clamping
position, the first end 98 of the die guide 94A is spaced from the
free end 82 of the necking die 78 by a first distance 120. In one
embodiment, the first distance is equal to the distance 114 plus
the thickness of the retention ring 62. The first distance 120 is
greater than a second distance 122 between the die guide 94A and
the necking die 78 when in the second necking position (generally
illustrated in FIG. 7).
[0192] The die guide 94A can be interconnected to the housing 46 in
any suitable manner known to those of skill in the art. In one
embodiment, the die guide 94A is secured to the housing 46 by the
post 58. For example, the post 58 can include a head 61 that
engages a second end 99 of the die guide 94A.
[0193] A biasing element 60 can optionally be positioned between
the retention ring 62 and the die guide 94A. In this manner, the
die guide 94A remains spaced from the housing end 56 and the
necking die 78 by the retention ring.
[0194] In one embodiment, the biasing element 60 is a helical
spring, such as a compression spring, although any suitable biasing
element can be used with the necker 40A of the present disclosure.
Optionally, the biasing element 60 is positioned on the post 58. In
one embodiment, the biasing element 60 biases (or urges) the die
guide 94A into the first clamping position.
[0195] Referring now to FIGS. 5-6, the die guide 94A generally has
a body 96 with a cylindrical bore 100 and a flange 106. The
cylindrical bore 100 is coaxially aligned with the center axis 44
and has an interior wall 102 that is approximately parallel to the
center axis 44. In one embodiment, the interior wall 102 has an
interior diameter 104 that is substantially constant. The wall
interior diameter 104 is greater than an exterior diameter 8 of the
container body 4. Accordingly, the interior wall 102 is spaced from
the exterior surface 6 of the container body 4 by a recess 118
(generally illustrated in FIG. 5) with a predetermined width. In
one embodiment, the width of the recess is between approximately
0.004 inch and approximately 0.02 inch. In one embodiment, the
width of the recess is approximately 0.006 inch.
[0196] The flange 106 of the die guide 94A extends from the body 96
into the cylindrical bore 100. In one embodiment, the flange
extends from the first end 98 of the body 96. Optionally, the
flange 106 extends continuously around the cylindrical bore 100.
Alternatively, the flange 106 comprises a plurality of individual
flanges that project into the cylindrical bore 100.
[0197] In one embodiment, the first end 98 of the die guide has a
protrusion 109. The protrusion extends away from the first end 98
in a direction generally parallel to the center axis 44. In some
embodiments, the flange 106 extends inwardly from the protrusion
and into the cylindrical bore 100.
[0198] The protrusion 109 has an exterior diameter 111. In one
embodiment, the interior diameter 89 of the retention ring interior
wall 77 is greater than the protrusion exterior diameter 111. In
this manner, when the die guide 94A is in the second necking
position, the protrusion 109 can fit into the clearance 93
(illustrated in FIG. 4) between the transition surface 84 of the
necking die and the interior wall 77 of the retention ring.
[0199] An inner diameter 108 of the flange 106 is less than the
interior diameter 104 of the interior wall 102 and less than the
exterior diameter 8 of the container body 4. In this manner, the
flange 106 will engage a shoulder 12 of the container body 4 while
the interior wall 102 of the die guide 94A remains spaced from the
exterior surface 6 of the container body 4 by the recess 118. The
minimum interior diameter 88 of the transition surface 84 of the
necking die 78 is less than the inner diameter 108 of the flange
106.
[0200] The inner diameter 108 of the flange 106 is greater than the
exterior diameter 16 of the container neck 14. Accordingly, the
container neck 14 and the open end 18 of the container body 4 will
pass through the cylindrical bore 100 of the die guide 94A without
contacting the flange 106.
[0201] In one embodiment, the flange 106 is integrally formed with
the die guide 94A. Accordingly, in one embodiment, the flange 106
is formed of the same material as the die guide 94A.
[0202] Alternatively, the flange 106 is formed separately from the
die guide 94A. In one embodiment, the flange 106 is joined to the
die guide 94A. Optionally, the flange 106 can be removably fixed to
the die guide 94A. For example, the flange may be joined to the die
guide by a mechanical fastener 184 (such as a screw or bolt), by
welding, by a friction fit, by a threaded engagement, or by any
other suitable method known to those of skill in the art.
[0203] Additionally, or alternatively, in one embodiment, the
flange 106 is formed of a different material than the die guide.
For example, in one embodiment, the flange is formed of a nylon, a
plastic or a rubber. Optionally, the flange can be formed of a
polymetric material. Alternatively, the flange can be formed of a
metal or a ceramic. The flange may be formed of a plastic, such as
PEEK. Alternatively, the flange is formed of a bronze alloy.
[0204] In one embodiment, the die guide 94A is formed of a first
material and the flange 106 is formed of a second material.
Optionally, the die guide 94A is formed of a metal.
[0205] The flange 106 has an inner wall 107 (generally illustrated
in FIG. 5) configured to contact the container shoulder 12. The
inner wall 107 has a predetermined height 113 that generally
extends approximately parallel to the center axis 44. Optionally,
the height is between approximately 0.01 inches and approximately
0.5 inches. The inner wall 107 may have any predetermined shape. In
one embodiment, the inner wall 107 is concave.
[0206] In one embodiment, the inner wall 107 of the flange 106 is
the only portion of the die guide 94A that will contact the
container body during a necking operation performed by the tooling
assembly 42A. Accordingly, the die guide 94A of the present
disclosure does not slide along (or rub against) the container body
(such as the exterior surface 6) during operation of the necker
40A.
[0207] The die guide 94A reduces or eliminates the generation of
friction compared to prior art neckers. Further, the die guide
eliminates the buildup of metal particles and the detrimental
effects the metal particles cause in prior art neckers.
Additionally, in the embodiments in which the flange 106 is
removably fixed to the die guide 94A, longevity is further
increased as the flange 106 may be replaced once it has worn.
[0208] The die guide 94A improves alignment of the container body 4
with the necking die 78 to improve aesthetics of the container body
4 by reducing wrinkles and by eliminating non-conical and irregular
shapes of the container neck 14. Specifically, the die guide 94A of
embodiments of the present disclosure forms container necks 14 that
or more accurately aligned (i.e., substantially coaxially aligned)
with a longitudinal axis 44 of the metallic container 2 than prior
art neckers 20. In addition, the die guide 94A can help guide
"thin" walled (or "lightweight") metallic container bodies into the
necking die 78 which reduces spoilage. As will be appreciated by
one of skill in the art, lightweight metallic container bodies
reduce the amount of material and the cost of metallic
containers.
[0209] In one embodiment, an aperture 110 is formed through the
body 96 of the die guide. The aperture 110 is adapted to receive
the post 58 extending from the housing 46. Optionally, a seat 112
is formed in the aperture 110 to engage the biasing element 60. For
example, the aperture 110 may include a first portion 110A with a
first diameter and a second portion 110B with a second diameter
that is less than the first diameter.
[0210] In one embodiment, the die guide 94A can be used for all
necking operations required to form a neck 14 with a desired
diameter. More specifically, the flange 106 of the die guide 94A
can have an inner wall 107 with an inner diameter 108 and a height
113 selected to engage a shoulder 12 formed on a metallic container
2 in a first necking operation. Thereafter, the flange 106 can
engage the shoulder 12 regardless of how many necking operations
are performed to reduce the exterior diameter 16 of the container
neck 14. This is beneficial because a single die guide 94A can be
used in different neckers 40A without changing the geometry or
dimensions of the flange 106. More specifically, two die guides 94A
with the same geometry and dimensions may be used in two different
neckers 40A that perform necking operations that form necks 14 of
different dimensions on container bodies. However, as will be
appreciated by one of skill in the art, in one embodiment of the
present disclosure, a different necking die 78 will be used for
each necking operation.
[0211] As will be appreciated by one of skill in the art, the
flexibility of using a die guide 94A of a single design will
decrease the cost of spare parts required for a metallic container
production line which may have 14 different neckers to form a neck
on a two-piece can or 30 or more different neckers to form a neck
on a metallic bottle. The use of a single design of the die guide
94A may also decrease the time required to service or replace the
die guide because maintenance personnel will not need to obtain
different die guides for different neckers. This will also
eliminate the possibility of installing an improper die guide on a
necker.
[0212] Alternatively, the dimensions or geometry of the die guide
94A of the present disclosure may be altered for different necking
operations. For example, in one embodiment a flange 106 of a first
die guide 94A used in a first necking operation has a first inner
diameter 108. A second die guide 94A used in a subsequent second
necking operation has a second inner diameter that is greater than
the first inner diameter.
[0213] In one embodiment, the height 113 of the inner wall is based
on a stage of a necking operation performed by the necker 40A. For
example, a first die guide 94A associated with a second stage
necker 40A may have a flange inner wall 107 with a first height
113. A second die guide interconnected to a third stage necker 40A
can have a flange inner wall 107 with a second height 113 that is
greater than the first height. This is because after each necking
operation, the height of the shoulder will increase. Accordingly,
the height 113 of the flange inner wall 107 may be larger to
provide more engagement with the container shoulder 12. In one
embodiment, the height 113 of the flange inner wall 107 increases
successively from a first height for a first die guide 94A used in
a second stage necker to a final height for a final stage necker,
the final height being greater than the first height. As previously
discussed, some container production lines include from 2 to 14
neckers. Metallic bottles typically require more necking operations
and a metallic bottle production line may include 30 or more
neckers. Accordingly, in some embodiments, thirty or more different
die guides 94A according to the present disclosure may be formed
which each have flanges 106 with an inner wall 107 having a height
113 adapted to engage a shoulder of a metallic container during one
stage of thirty or more different necking operations.
[0214] Referring now to FIG. 7, the container body 4 is generally
illustrated engaged with the necker 40A during a necking operation.
In one embodiment, the tooling assembly 42A moves along the center
axis 44 toward the container body 4. The container body 4 can be
held immobile relative to the center axis. Alternatively, the
container body 4 can be moved toward the tooling assembly along the
center axis 44. In another embodiment, both the tooling assembly
42A and the container body 4 can move toward each other along the
center axis 44. Regardless, as the container body 4 is engaged with
the tooling assembly 42A, the flange 106 of the die guide 94A
engages the shoulder 12 of the container body (as generally
illustrated in FIG. 5). Thereafter, as one or more of the tooling
assembly 42A and the container body 4 move toward each other along
the center axis 44, the die guide 94A moves from the first clamping
position generally shown in FIG. 3 to the second necking position
as generally illustrated in FIG. 7.
[0215] The open end 18 of the container body 4 passes through the
cylindrical bore 100 and past the first end 98 of the die guide 94A
toward the necking die 78. The open end 18 then contacts the
transition surface 84 of the necking die 78. As described
previously, the transition surface 84 directs the open end 18
inwardly toward the center axis 44 to reduce the diameter of the
open end and extend the shoulder 12 inwardly. The container open
end 18 then contacts the cylindrical sidewall 68 of the knockout 66
which directs the open end 18 substantially parallel to the
exterior surface 6 of the container body and the center axis 44 to
form the neck 14 with a reduced diameter. In one embodiment, in the
second necking position, the first end 98 of the die guide 94A is
separated from the retention ring 62 by a distance 116 of at least
approximately 0.03 inch. Optionally, the distance 116 is between
approximately 0.03 inch and approximately 0.07 inch. In one
embodiment, the distance is less than about 0.057 inch. Notably, in
the second necking position, the first end 98 of the die guide 94A
remains separated from the free end 82 of the necking die 78 by a
predetermined second distance 122.
[0216] After the necking operation is complete, such as when the
die guide reaches the second necking position, one or more of the
tooling assembly 42A and the container body 4 move away from each
other along the center axis 44. The container body 4 is
subsequently removed from the tooling assembly 42A. Thereafter,
another container body is positioned in the tooling assembly 42A to
be necked.
[0217] Referring now to FIGS. 8-12, another embodiment of a necker
40B of the present disclosure is generally illustrated. The necker
40B includes a tooling assembly 42B, a housing 46 with a body 47, a
knockout 66, and a necking die 78 that are the same as or similar
to those of the necker 40A described in conjunction with FIGS. 3-7.
Notably, the necker 40B includes an outer guide 140, a die guide
94B of another embodiment of the present disclosure, and a keeper
170. The necker 40B provides many benefits over prior art neckers.
For example, the outer guide 140 has an inner wall 156 that orients
and guides a body 96B of the die guide 94B. Moreover, the die guide
body 96B has a plurality of channels or flutes 132 with an upper
end 136 that defines a stop. By positioning a projection 180 of the
keeper 170 in a flute 132 of a desired height 138, a stroke of the
die guide 94B of a predetermined length can be selected. To change
the stroke length, the keeper 170 can be removed and then rotated
clockwise or counter-clockwise relative to the die guide body 96B
to position the projection 180 in a different flute with a second
length.
[0218] Referring now to FIGS. 9A-9D, the outer guide 140 is
generally illustrated. The outer guide replaces the retention ring
62 and retains the necking die 78 in the housing 46. The outer
guide 140 generally comprises a cylindrical body 142 with an upper
end 144, a lower end 148, and a central bore 154.
[0219] The body has an outer diameter 150 and a predetermined
height 152. Optionally, the height 152 is between about 1.0 inch
and about 1.6 inches. However, the height and other dimensions of
the outer guide 140 may be altered in other embodiments to
accommodate neckers for metallic containers 2 of any diameter and
height.
[0220] In one embodiment, a dowel pin 146 extends from the upper
end 144. The dowel pin 146 is oriented approximately parallel to
the longitudinal axis 44. Optionally, the dowl pin is positioned in
an aperture extending into the cylindrical body 142. The dowel pin
146 is positioned to fit into a hole formed in the open end 56 of
the housing to orient the outer guide 140 with respect to the
housing 46. In one embodiment, the outer guide 140 includes two
dowel pins 146. However, the outer guide 140 may have any number of
apertures to receive dowel pins.
[0221] A fastener aperture 166 extends through the body from the
first end to the second end. The fastener aperture 166 is oriented
approximately parallel to the longitudinal axis 44. Optionally, the
outer guide 140 has from two to six fastener apertures. In one
embodiment, there are four fastener apertures 166 substantially
evenly spaced around the cylindrical body 142.
[0222] The central bore 154 has an inner wall 156 with a
predetermined interior diameter 158. In one embodiment, the
interior diameter 158 is between about 3.19 inches and about 3.23
inches, or about 3.21 inches.
[0223] A ring 160 extends into the central bore 154 proximate to
the upper end 144. The ring 160 is configured to engage the necking
die 78 in a manner similar to the retention ring 62 of the necker
40A described in conjunction with FIG. 3. The ring 160 has an
interior diameter 164 that is greater than the maximum interior
diameter 86 of the transition surface of the necking die 78 (as
illustrated in FIG. 4). In one embodiment, the ring interior
diameter 164 is between about 2.76 inches and about 2.86 inches, or
about 2.81 inches.
[0224] A hole 162 is formed through the ring to retain a biasing
element 60A, such as a spring. The hole 162 is oriented
approximately parallel to the longitudinal axis 44. In one
embodiment, the outer guide 140 has from two to fourteen of the
holes 162. Optionally, the outer guide may have twelve holes
162.
[0225] Referring now to FIGS. 10A-10L, the die guide 94B is
generally illustrated. Die guide 94B is similar to the die guide
94A described in conjunction with FIGS. 3-7 and has many of the
same, or similar, features, and dimensions and operates in a
similar manner. The die guide 94B is retained in a spaced
relationship to the housing end 56 and to the necking die 78 by the
outer guide 140 and the keeper 170.
[0226] The die guide 94B has a flange 106 configured to engage a
shoulder 12 of a container body 4 and align the container body 4
with the knockout 66 and the necking die 78 of the necker 40B. The
die guide 94B is moveably interconnected to the housing 46 and
moves from a first clamping position to a second necking position
during operation of the necker 40B similar to the die guide 94A. In
this way, the die guide 94B aligns the open end 18 of the container
body 4 with the forming profile (for example, the transition
surface 84) of the necking die 78.
[0227] The die guide 94B generally has a body 96B with a
cylindrical bore 100 and a flange 106. The body 96B has an exterior
diameter 124 that is less than the interior diameter 158 of the
central bore 154 of the outer guide 140. Accordingly, the body 96B
can fit in, and move relative to, the outer guide as generally
illustrated by comparing FIGS. 8A-8C with FIGS. 12A, 12B.
[0228] The cylindrical bore 100 is coaxially aligned with the
center axis 44 and has an interior wall 102 that is approximately
parallel to the center axis 44. In one embodiment, the interior
wall 102 has an interior diameter 104 that is substantially
constant. The wall interior diameter 104 is greater than an
exterior diameter 8 of the container body 4. Accordingly, the
interior wall 102 is spaced from the exterior surface 6 of the
container body 4 by a recess 118 (such as generally illustrated in
FIG. 5) with a predetermined width. In one embodiment, the interior
diameter 104 is between about 2.56 inches and about 2.66 inches, or
about or 2.61 inches. However, one of skill in the art will
appreciate that the die guide 94B may be formed with any
appropriate size to work with metallic containers 2 of any size.
Accordingly, in other embodiments, the interior diameter and other
dimensions of the die guide 94B may be greater or less than those
described herein. In one embodiment, the first end 98 of the die
guide has a protrusion 109 (best seen in FIG. 10H). The protrusion
extends away from the first end 98 in a direction generally
parallel to the center axis 44. In some embodiments, the flange 106
extends inwardly from the protrusion and into the cylindrical bore
100.
[0229] The protrusion 109 has an exterior diameter 111 of between
about 2.77 inches and about 2.83 inches, or about 2.80 inches. In
one embodiment, the ring interior diameter 164 of the outer guide
140 is greater than the protrusion exterior diameter 111. In this
manner, when the die guide 94B is in the second necking position,
the protrusion 109 can fit into the interior of the ring 160 as
generally illustrated in FIG. 12A.
[0230] The protrusion 109 may have any desired height 126. In one
embodiment, the height 126 is determined based on the size of the
metallic container 2 the necker 40 is configured to receive.
Additionally, or alternatively, the height 126 may be related to a
necking stage performed by the necker. In one embodiment, the
height is between about 0.09 inches and about 0.15 inches or about
0.12 inches. However, other heights 126 are contemplated for the
protrusion 109.
[0231] A passage 128 extends into the first end 98 of the body 96B.
The passage 128 is alignable with the hole 162 in the outer guide
ring 160 and has a closed end. A biasing element 60A may be
positioned with a first end in the hole 162 and a second end within
the passage 128 as generally illustrated in FIG. 8B. In this
manner, the biasing element 60A can apply a force to the body 96B
and urge the die guide 94B to the first clamping position spaced
from the open end 56 of the housing.
[0232] The body 96B may include any number of the passages 128. In
one embodiment, the body 96B has from two to fourteen, or twelve,
of the passages 128. The passages 128 have a predetermined depth
130.
[0233] Optionally, one or more of the passages 128 have different
depths 130. For example, and referring now to FIGS. 10D-10G, a
passage 128A may have a first depth 130A. Another passage 128B can
optionally have a second depth 130B that is less than the first
depth 130A. Additionally, or alternatively, a passage 128C may have
a third depth 130C less the second depth 130C. In this manner, a
biasing element 60A can be compressed between the outer guide 140
and the die guide 94B by a predetermined amount by positioning a
second end of the biasing element in one of the passages 128A,
128B, or 128C.
[0234] In one embodiment, the die guide 94B includes two pairs of
each of the passages 128A, 128B, 128C. The first depth 130A is
optionally between about 0.66 inches and about 0.69 inches, or
about 0.675 inches. The second depth 130B may be between about
0.535 inches and about 0.565 inches, or about 0.550 inches.
Similarly, the third depth 130C is optionally between about 0.285
inches and about 0.315 inches, or about 0.300 inches. However,
other depths 130 of the passages 128 are contemplated.
[0235] Referring now to FIG. 10H, the flange 106 of the die guide
94B extends from the body 96B into the cylindrical bore 100. In one
embodiment, the flange extends from the first end 98 of the body
96B. Optionally, the flange 106 extends continuously around the
cylindrical bore 100. Alternatively, the flange 106 comprises a
plurality of individual flanges that project into the cylindrical
bore 100.
[0236] An inner diameter 108 of the flange 106 (illustrated in FIG.
10G) is less than the interior diameter 104 of the interior wall
102 and less than the exterior diameter 8 of the container body 4.
In this manner, the flange 106 will engage a shoulder 12 of the
container body 4 while the interior wall 102 of the die guide 94B
remains spaced from the exterior surface 6 of the container body 4.
The minimum interior diameter 88 of the transition surface 84 of
the necking die 78 (illustrated in FIG. 4) is less than the inner
diameter 108 of the flange 106.
[0237] The inner diameter 108 of the flange 106 is greater than the
exterior diameter 16 of the container neck 14. Accordingly, the
container neck 14 and the open end 18 of the container body 4 will
pass through the cylindrical bore 100 of the die guide 94B without
contacting the flange 106.
[0238] In one embodiment, the flange 106 is integrally formed with
the die guide 94B. Accordingly, in one embodiment, the flange 106
is formed of the same material as the die guide 94B.
[0239] Alternatively, the flange 106 is formed separately from the
die guide 94B. In one embodiment, the flange 106 is joined to the
die guide 94B. Optionally, the flange 106 can be removably fixed to
the die guide 94B. For example, the flange may be joined to the die
guide by a mechanical fastener (such as a screw or bolt), by
welding, by a friction fit, a snap fit, by a threaded engagement,
or by any other suitable method known to those of skill in the
art.
[0240] Additionally, or alternatively, in one embodiment, the
flange 106 is formed of a different material than the die guide.
For example, in one embodiment, the flange is formed of a nylon, a
plastic or a rubber. Optionally, the flange can be formed of a
polymetric material. Alternatively, the flange can be formed of a
metal or a ceramic. The flange may be formed of a plastic, such as
PEEK. Alternatively, the flange is formed of a bronze alloy.
[0241] In one embodiment, the die guide 94B is formed of a first
material and the flange 106 is formed of a second material.
Optionally, the die guide 94B is formed of a metal.
[0242] The flange 106 has an inner wall 107 (generally illustrated
in FIG. 10H) configured to contact the container shoulder 12. The
inner wall 107 has a predetermined height 113 that generally
extends approximately parallel to the center axis 44. Optionally,
the height is between approximately 0.01 inches and approximately
0.5 inches. In one embodiment, the height 113 is about 0.09
inches.
[0243] In one embodiment, the inner wall 107 of the flange 106 is
the only portion of the die guide 94B that will contact the
container body during a necking operation performed by the tooling
assembly 42B. Accordingly, the die guide 94B of the present
disclosure does not slide along (or rub against) the container body
(such as the exterior surface 6) during operation of the necker
40B.
[0244] Referring now to FIGS. 10I-10L, the die guide 94B includes a
flute 132 that extends into an exterior surface of the body 96B.
The flute 132 extends from the second end 99 in a direction toward
the first end 98. However, the flute 132 does not extend to the
first end. The flute 132 is oriented approximately parallel to the
longitudinal axis 44 and has a predetermined height 138 between a
flute opening 134 and flute end 136. The flute end 136 defines a
stop which prevents movement of the die guide 94B away from the
housing 46 and out of the central bore 154 of the outer guide 140
when the flute end 136 is engaged by a projection 180 of the keeper
170 as shown in FIGS. 8B-8C. Accordingly, the height 138 of the
flute 132 defines a length of a stroke of the die guide.
[0245] As shown in FIG. 10I, the flute 132 may have a curved
cross-sectional shape that is generally concave. For example, the
cross section of the flute 132 may have a radius of curvature of
about 0.26 inches.
[0246] The die guide 94B may have any number of flutes 132. In one
embodiment, the body 96B has from two to fourteen of the flutes
132. Optionally, the body 96B has twelve flutes. The flutes are
offset from the passages 128. More specifically, in one embodiment
and as generally illustrated in FIG. 10A, each passage 128 may be
formed between two adjacent flutes.
[0247] The flutes 132 have a predetermined height 138. Optionally,
one or more of the flutes 132 have different heights 138. For
example, and referring now to FIGS. 10J-10L, a flute 132A may have
a first height 138A. Another flute 132B can optionally have a
second height 138B that is less than the first height 138A.
Additionally, or alternatively, a flute 132C may have a third
height 138C that is less the second height 138C. In this manner, a
length of a stroke of the die guide 94B can be altered by adjusting
the keeper 170 with a flute 132 as generally described herein.
[0248] In one embodiment, the die guide 94B includes two pairs of
each of the flutes 132A, 132B, 132C. The first height 138A is
optionally between about 0.95 inches and about 1.25 inches, or
about 1.10 inches. The second height 138B may be between about 0.70
inches and about 1.00 inch, or about 0.850 inches. Similarly, the
third height 138C is optionally between about 0.45 inches and about
0.75 inches, or about 0.60 inches. However, other heights 138 of
the flutes are contemplated to work with container bodies that
require a greater or lesser stroke length during a necking
operation.
[0249] The die guide may be formed of any suitable material. In one
embodiment, the die guide 94B is formed of a first material and the
outer guide 140 is formed of a second material. In one embodiment,
the first and second materials are the same. Alternatively, the
second material is different from the first material.
[0250] Optionally, the die guide 94B is formed of a metal
(including, but not limited to, a bronze alloy or a carbide, such
as a tungsten carbide) a polymer, or a plastic (such as a PEEK) and
the outer guide 140 is formed of a ceramic. Alternatively, the die
guide 94B is formed of a ceramic and the outer guide 140 is formed
of a metal, a polymer, or a plastic. Other suitable materials known
to those of skill in the art may be used to form the die guide and
the outer guide of embodiments of the present disclosure.
[0251] Referring now to FIGS. 11A-11C a keeper 170 of an embodiment
of the present disclosure is generally illustrated. The keeper 170
has an exterior 172 that is generally cylindrical and a central
cutout 174. The cutout has an interior diameter 176 that is greater
than the exterior diameter 124 of the die guide body 96B.
Accordingly, the body of the die guide 94B may move through the
central cutout 174 as generally illustrated in FIGS. 12A-12B.
[0252] An aperture 178 extends through the keeper between the
exterior 172 and the central cutout 174. The aperture 178 is
adapted to align with the fastener aperture 166 of the outer guide
140. Accordingly, the outer guide and the keeper can be
interconnected by a fastener, such as a screw or a bolt, that
extends through apertures 166, 178 and into the housing 46.
[0253] A projection 180 extends into the central cutout 174. The
keeper 170 optionally includes two to six projections 180 that are
substantially evenly spaced apart. In one embodiment, the keeper
has four projections 180. The projections 180 have a shape that
generally corresponds to a shape of the flutes 132. More
specifically, the projections are adapted to fit into the flutes
132 as generally illustrated in FIGS. 8B and 12B. In one
embodiment, the projection 180 is convex and has a radius of
curvature of about 0.25 inches.
[0254] An interior diameter 176 between two opposing projections is
less than the exterior diameter of the die guide 94B at a flute end
136. Accordingly, the die guide 94B can move between the first
clamping position and the second necking position through the
central cutout 174 of the keeper. However, the keeper 170 and its
projection 180 prohibit movement of the die guide 94B away from the
housing 46 and its necking die 78 by a predetermined amount based
on which of the flutes 132A, 132B, or 132C the projection is
positioned within.
[0255] To increase the stroke length of the die guide 94B relative
to the housing 46, the keeper 170 can be removed from the outer
guide 140 and rotated axially (clockwise or counterclockwise) such
that the projection 180 is positioned within a flute 132 of a
desired height 138. For example, for a stroke of a first length or
amount, the projection 180 may be positioned in flute 132A. If a
shorter stroke length is desired, the projection 180 is positioned
in flute 132B. Finally, the projection 180 may be positioned in
flute 132C to provide a stroke with a length that is less than the
stroke length possible using flute 132B.
[0256] In operation, the necker 40B performs similar to the necker
40A. More specifically, and referring again to FIGS. 8C and 12A,
the flange 106 of the die guide 94B engages the shoulder 12 of the
container body. Then one or more of the tooling assembly 42B and
the container body 4 move toward each other along the center axis
44 and the die guide 94B moves from the first clamping position
shown in FIGS. 8A-8C to a second necking position shown in FIGS.
12A-12B. The open end 18 of the container body 4 passes through the
cylindrical bore 100 and past the first end 98 of the die guide 94B
toward the necking die 78. The open end 18 then contacts the
transition surface 84 of the necking die 78. As described
previously, the transition surface 84 directs the open end 18
inwardly toward the center axis 44 to reduce the diameter of the
open end and extend the shoulder 12 inwardly. The container open
end 18 then contacts the cylindrical sidewall 68 of the knockout 66
which directs the open end 18 substantially parallel to the
exterior surface 6 of the container body and the center axis 44 to
form the neck 14 with a reduced diameter.
[0257] After the necking operation is complete, such as when the
die guide 94B reaches the second necking position, one or more of
the tooling assembly 42B and the container body 4 move away from
each other along the center axis 44. The container body 4 is
subsequently removed from the tooling assembly 42B. Thereafter,
another container body is positioned in the tooling assembly 42B to
be necked.
[0258] Referring now to FIG. 13, a container body 4 for a two-piece
can 2 is generally illustrated. The container body 4 includes a
closed end 10 with an optional dome 11, a sidewall 5 with a
cylindrical exterior surface 6 extending upwardly from the closed
end, a shoulder 12 extending upwardly from the sidewall, a neck 14
with a reduced diameter, and an open end 18 opposite to the closed
end. The shoulder 12 and neck 14 of the container body 4 have been
formed by a necking apparatus 40 with a necking die 78 and die
guide 94 of embodiments of the present disclosure. Other shapes and
geometries for the shoulder 12 and neck 14 are contemplated and can
be formed by the necking apparatus 40A or 40B.
[0259] Referring now to FIG. 14, a container body 4 for a metallic
bottle 2 is illustrated. The bottle body 4 includes a closed end 10
with an inwardly oriented dome 11, a sidewall 5 with a cylindrical
exterior surface 6 extending upwardly from the closed end, a
shoulder 12 extending upwardly from the sidewall, a neck 14
extending upwardly from the shoulder and having a reduced diameter,
and an open end 18 opposite to the closed end. Threads may
subsequently be formed on the neck 14. The shoulder 12 and neck 14
of the container body 4 have been formed by a plurality of necking
apparatus 40 with necking dies 78 and die guides 94 of embodiments
of the present disclosure. Other shapes and geometries of the
shoulder 12 and neck 14 can be formed for the bottle body 4 by the
necking apparatus 40 of the present disclosure.
[0260] While various embodiments of the system have been described
in detail, it is apparent that modifications and alterations of
those embodiments will occur to those skilled in the art. It is to
be expressly understood that such modifications and alterations are
within the scope and spirit of the present disclosure. Further, it
is to be understood that the phraseology and terminology used
herein is for the purposes of description and should not be
regarded as limiting. The use of "including," "comprising," or
"having" and variations thereof herein are meant to encompass the
items listed thereafter and equivalents thereof, as well as,
additional items.
[0261] To provide additional background, context, and to further
satisfy the written description requirements of 35 U.S.C. .sctn.
112, the following references are incorporated by reference herein
in their entireties: U.S. Pat. Nos. 4,403,493; 4,693,108;
4,732,027; 4,774,839; 5,138,858; 5,297,414; 5,448,903; 5,469,729;
5,497,900; 5,713,235; 5,737,958; 5,778,723; 6,032,502; 6,094,961;
6,167,743; 6,343,496; 6,484,550; 7,140,223; 7,418,852; 7,530,445;
8,601,843; 8,807,325; 9,290,329; U.S. Pat. Pub. 2004/0099036; U.S.
Pat. Pub. 2008/0295558; U.S. Pat. Pub. 2014/0061212; U.S. Pat. Pub.
2016/0214164; U.S. Pat. Pub. 2018/0207705; U.S. Pat. Pub.
2019/0344325; U.S. Pat. Pub. 2019/0344326; U.S. Pat. Pub.
2019/0345958; and U.S. Pat. Pub. 2020/0254506.
* * * * *