![]() molded metal container, and process for forming it
专利摘要:
MOLDED METALLIC CONTAINER, AND PROCESS FOR FORMING THE SAME. The present invention relates to a molded metallic container (700, 190) comprising less metal than the metallic containers (700, 190) of the prior art, still capable of handling a sufficient axial load and undergoing molding processes, including strangulation , without wrinkling, bulging, deformation or other physical defect, which is described. The processes for molding a metal container (700, 190), having a side wall (800,192) of variable thickness, in which a part of the side wall (800, 192) having a variable thickness is molded using one or more dies, are also described. 公开号:BR112013004004B1 申请号:R112013004004-1 申请日:2011-08-22 公开日:2020-11-10 发明作者:Robert E. Dick;Anthony J. Fedusa;Gary L. Myers 申请人:Alcoa Usa Corp; IPC主号:
专利说明:
RECIPROCAL REMISSION ON RELATED PATENT APPLICATION [0001] This patent application claims the priority of provisional patent application US 61 / 375,746, entitled "Shaped Aluminum Container and Method for Making Same", filed on August 20, 2010, which is fully incorporated by reference in this specification . FIELD OF THE INVENTION [0002] The present invention relates to metal containers and processes for producing metal containers. BACKGROUND [0003] In the metal container industry, substantially identical molded beverage containers are mass-produced. The dies have been used to strangle the tops of the containers. SUMMARY [0004] In some embodiments, a molded aluminum container has a side wall, which comprises a top strangulated part and a bottom strangulated part. In some embodiments, the thickness of the sidewall on the bottom strangulated parts varies by at least 0.0254 millimeter (0.001 inch). In some embodiments, the thickness of the sidewall on the top strangulated parts varies by at least 0.0254 millimeter (0.001 inch). In other embodiments, the thickness of the sidewall, in either the top or bottom part, varies by at least 0.0381 or 0.0508 millimeter (0.0015 "or 0.002"). In some embodiments, the thickness of the sidewall varies by no more than 0.0381, 0.0508, 0.0635, 0.0762 or 0.1016 millimeter (0.0015 ", 0.002", 0.0025 ", 0.003 "or 0.004"). [0005] In some embodiments, the molded aluminum container is manufactured by a process comprising: throttling a lower part of the side wall with a first throttling die, so that an operational surface of the first throttling die contacts a first section of the throttle. side wall and reduces a diameter of the first section of the side wall by at least 3% in a single die stroke, where the thickness of the first section of the side wall varies along the height of the side wall by at least 0.0254 mm ( 0.001 inch); and throttling an upper part of the sidewall with a second throttling matrix, so that an operational surface of the second throttling matrix contacts a second sidewall section and reduces a diameter of the second sidewall section by at least 2% in a single course. In some embodiments, the thickness of the second section varies over the height of the side wall by at least 0.0254 millimeter (0.001 inch). In some embodiments, the thickness of the sidewall on either the top or bottom, or both, varies by at least 0.0381 or 0.0508 millimeter (0.0015 "or 0.002"). In some embodiments, the thickness of the sidewall varies by no more than 0.0381, 0.0508, 0.0762 or 0.1016 millimeter (0.0015 ", 0.002", 0.003 "or 0.004"). In some embodiments, the bottom and / or the top is or are strangled with a series of strangle matrices. A series of choke matrices can comprise two or more choke matrices. In one embodiment, the bottom part is strangled with two choke matrices. In one embodiment, the first die to strangle the bottom reduces the diameter of the container by 6%, and the second die to strangle the bottom reduces the diameter of the container by a further 4% of the original diameter. In some embodiments, a single choke matrix can reduce the diameter of the container by 2%, 3%, 4%, 5%, 9%, 12% or more. [0006] In some embodiments, the process further comprises expanding the diameter of an intermediate part of the side wall, before strangling the upper part of the side wall. In some embodiments, a thickness of the intermediate part varies by at least 0.0254 millimeter (0.001 inch). In some embodiments, the thickest part is at or near the top part of the container. In some embodiments, the thinnest or thinest part may be at or near the top of the container. [0007] In some embodiments, the first and second choke matrices are or are configured for use in a metallic bottle charge, and comprise a choke surface and a relief. The choke surface comprises a base part, a neck radius part and a shoulder radius part, all having an internal diameter. The base part is between the neck radius part and the relief. The internal diameter of the base is a minimum diameter of the die. The inner diameters of the neck radius part and the shoulder radius part are greater than the inner diameter of the base. The relief comprises a relief surface, in which an internal diameter of the relief surface is at least 0.254 millimeter (0.01 inch) greater than the internal diameter of the base part, and an internal diameter of the relief surface is not greater than a maximum diameter, in order to reduce, but not eliminate, the frictional contact between the side wall and the relief surface, while maintaining the strangulation performance, when the side wall is strangled. In some embodiments, the diameter of the relief surface is 0.1905 to 0.889 millimeter (0.0075 to 0.035 inch) greater than the inner diameter of the base part. In other embodiments, the relief surface diameter is 0.254, 0.508 or 0.762 millimeter (0.01.0.02 or 0.03 inch) greater than the inner diameter of the base part. In some embodiments, the length of the base part is between 0.508 to 2.032 millimeters (0.02 "to 0.08"). In some embodiments, the length of the base is 0.762 to 1.778 mm (0.03 "to 0.07"). In most other embodiments, the length of the base part is between 1.016 to 1.524 mm (0.04 "to 0.06"). In one embodiment, the length of the base part is 1.016 millimeter (0.04 "). In some embodiments, the choke matrix is dimensioned so that, when the metallic bottle load is strangled, all the base and the reliefs move relative to the side wall in an axial direction, and at least part of the relief travels beyond a top of the side wall. [0008] In some embodiments, the base has a surface finish Ra ranging from 203.2 microns to 812.8 microns (8 microns to 32 microns). In some embodiments, the relief has a surface finish Ra ranging from 203.2 micrometers to 812.8 micrometers (8 micro to 32 micro), from 50.8 micrometers (2 micro to inches) to 152.4 micrometers (6 micro) or from 50.8 micrometers (2 microinches) to 812.8 micrometers (32 microinches). In some embodiments, the neck radius part and the shoulder radius part have a surface finish Ra ranging from 50.8 mi-chromimeters to 152.4 micrometers (2 micro-inches to 6 micro-inches). [0009] In some embodiments, an expansion matrix for the manufacture of metallic containers expands the diameter of the intermediate part of the side wall. The expansion matrix for the manufacture of metal containers comprises an operating surface and a recessed part, wherein the operating surface is configured to expand a diameter of a metal container having a closed bottom. The operating surface comprises a progressively expanding part and a base part. The base part is between the progressively expanding part and the lowered part. The outer diameter of the base part is a maximum diameter of the die. In some embodiments, the length of the base part is a minimum of 3.048 millimeters (0.12 "). In some embodiments, the length of the base part is between 0.254 and 3.048 millimeters (0.01" and 0.12 ") In some embodiments, the length of the base part is between 0.50 and 2.032 millimeters (0.02 "and 0.08"). In other embodiments, the length of the base is 0.762 and 1.778 millimeters (0.03 "and 0, 07 "). In more other embodiments, the length of the base part is between 1.016 and 1.524 millimeter (0.04" and 0.06 "). In one embodiment, the length of the base part is 1.016 millimeter (0.04 "). The recessed part comprises a recessed surface having an outside diameter. The outside diameter of the recessed surface is at least approximately 0.254 millimeter (0.01 inch) smaller than the outside diameter of the base part and not less than a minimum diameter, in order to reduce, but not eliminate, the frictional contact between the recessed surface and the metal container. The outside diameter of the recessed surface is dimensioned to minimize deformation, fracture, wrinkling and all other physical defects that can occur during expansion. The operating surface is dimensioned so that, when inserted in the aluminum container, the entire base part and at least a part of the lowered part enter the aluminum container, causing the intermediate part of the side wall to expand. [00010] In some embodiments, an initial part of the operating surface of the expansion matrix has a geometry to form a transition in a container, from a part of original diameter to a part of expanded diameter. In some embodiments, the transition is gradual or gradual. In some embodiments, the base portion of the expansion die is sized to provide an expanded diameter of a container load worked by the operating surface. [00011] In some embodiments, at least a part of the operating surface of the expansion matrix has an average surface roughness (Ra) of approximately 203.2 to 812.8 microns (8 microns to 32 microns). In some embodiments, at least part of the recessed part has an average surface roughness (Ra) of approximately 203.2 to 812.8 microns (8 microns to 32 microns). In some embodiments, the outer diameter of the base portion of the expansion die is substantially constant along the length of the base. [00012] In some embodiments, the diameter of the intermediate part of the side wall is expanded with a series of expansion dies. [00013] In some embodiments, the top part of the container is sized to receive a closure. In some embodiments, a closure covers an opening at the top of the container. In some embodiments, the closure comprises one of: an ear, a crown, a slip-proof closure, or a threaded closure. [00014] In some embodiments, a can end, having a cutable pouring spout, encloses a top of the container. [00015] A process for forming a metal container comprises: providing a container having a side wall, in which the side wall has a thickness and height, and in which the thickness varies along the height of the side wall by at least minus 0.0254 millimeter (0.0010 inch); and strangle the container with a choke matrix, so that an operating surface of the choke matrix contacts a section of the sidewall and reduces a diameter of the sidewall section by at least 2% in a single stroke, where the The thickness of the side wall section varies over the height of the side wall by at least 0.0254 millimeter (0.0010 inch), before and after strangulation. [00016] In some embodiments, the choke matrix used in the process of forming a metal container comprises: a choke surface and a relief; wherein the throttling surface comprises a base part, a neck radius part and a shoulder radius part, all having an internal diameter; wherein the base part is between the neck radius part and the relief, and the internal diameter of the base is a minimum diameter of the die; wherein the internal diameters of the neck radius part and the shoulder radius part are greater than the internal diameter of the base; wherein the relief comprises: (a) a relief surface; (b) an internal diameter of the relief surface is at least 0.254 millimeter (0.01 inch) greater than the internal diameter of the base part; (c) an internal diameter of the embossed surface is not greater than a maximum diameter, in order to reduce, but not eliminate, the frictional contact between the metallic container and the embossed surface, while maintaining the strangulation performance of the container metallic; and wherein the throttling matrix is dimensioned so that when the metal container, all the base and the relief travel relative to the container, in an axial direction, and at least part of the relief moves beyond the top of the container. [00017] In some embodiments, the process of forming a metal container further comprises expanding the diameter of a part of the side wall. [00018] In some embodiments, the process of forming a metal container further comprises strangling the container with a series of choke dies. [00019] In some embodiments, the process of forming a metal container further comprises expanding the diameter of the side wall part with a series of expansion dies. [00020] In some embodiments, at least one of the expansion matrices comprises: an operating surface comprising a progressively expanding part and a base part; and a lowered part; wherein the base part is between the progressively expanding part and the recessed part, and an outside diameter of the base part is a maximum diameter of the die; wherein the recessed portion comprises: (a) a recessed surface; and (b) an outside diameter of the recessed surface, where the outside diameter of the recessed surface is: (i) at least approximately 0.254 millimeter (0.01 inch) smaller than the outside diameter of the base part; and (ii) not less than a minimum diameter in order to reduce, but not eliminate, the frictional contact between the recessed surface and the aluminum container; and where the operating surface is dimensioned so that, when inserted into the metal container, the entire base part and at least part of the recessed part enter the metal container, causing the diameter of at least part of the side wall to expand . [00021] In some embodiments, a process for forming a metal container comprises: providing a container having a side wall, where the side wall has a thickness and height, and where the thickness varies over the height of the side wall at least 0.254 millimeter (0.01 inch); and expand the diameter of the container with an expansion die, so that an operating surface of the expansion die contacts a section of the sidewall, and expand a diameter of the sidewall section by at least 2% in a single stroke, where the thickness of the side wall section varies over the height of the side wall by at least 0.0254 millimeter (0.001 inch), before and after expansion. In some embodiments, the process further comprises strangling the container. In some embodiments, the process further comprises expanding the diameter of the container with a series of expansion dies. In some embodiments, the expansion matrix comprises: an operating surface comprising a progressively expanding part and a base part; and a lowered part; wherein the base part is between the progressively expanding part and the recessed part, and an outside diameter of the base part is a maximum diameter of the die; wherein the recessed portion comprises: (a) a recessed surface; and (b) an outside diameter of the recessed surface, where the outside diameter of the recessed surface is: (i) at least approximately 0.254 millimeter (0.01 inch) smaller than the outside diameter of the base part; and (ii) not less than a minimum diameter in order to reduce, but not eliminate, the frictional contact between the recessed surface and the aluminum container; and where the operating surface is dimensioned so that, when inserted into the metal container, the entire base part and at least part of the recessed part enter the metal container, causing the diameter of at least part of the side wall to expand . BRIEF DESCRIPTION OF THE DRAWINGS [00022] The following detailed description, shown by way of example and not intended to limit the invention only to it, will be better considered in conjunction with the attached drawings, where similar reference numbers indicate similar elements and parts, on what: [00023] Figure 1 is an illustrative representation of a 14-stage matrix choke progression for a 53 mm diameter can body according to the present invention; [00024] Figure 2 represents a side cross-sectional view of an embodiment of an initial choke matrix, according to the present invention; [00025] Figure 2a represents an enlarged view of the contact angle illustrated in Figure 2, in which the contact angle is measured from where the bottle load contacts the choke surface; [00026] Figure 3 represents a surface mapping of an embodiment of a polished choke surface, according to the present invention; [00027] Figure 4 represents a surface mapping of an embodiment of an unpolished choke surface according to the present invention; [00028] Figure 5 shows a side view in cross section of an embodiment of an intermediate choke matrix, according to the present invention; [00029] Figure 6 shows a side cross-sectional view of an embodiment of a final choke matrix, according to the present invention; [00030] Figure 7 shows a side view in cross section for the shoulder choke surface of each choke matrix in a 14 stage choke system, according to the present invention; [00031] Figure 8 is a graph of the strangulation force, necessary to strangle an aluminum bottle in a partially unpolished choke matrix, and the force, necessary to strangle a bottle in a polished choke matrix, in which the axis y represents a force in kilogram-force - kgf (pound-force - Ibf) and the x-axis represents the distance in millimeters (inches) at which the bottle is inserted into the choke matrix; [00032] Fig. 9 is a perspective view of an embodiment of an expansion matrix used to expand a 53.001 mm (2.087 ") diameter container to a 57.0738 mm (2.247") diameter container, according to an embodiment of the present invention; [00033] Fig. 10 is a view from the top of the expansion matrix of Fig. 9 showing line A - A; [00034] Fig. 11 is a cross-sectional view of the Figurass expansion matrix. 9 and 10 along line A - A; [00035] Fig. 12 is a cross-sectional view of an expansion die used to expand a container of 57,073 mm (2,247 ") in diameter to a container of 60,02 mm (2,363") in diameter, according to an embodiment of the present invention; [00036] Fig. 13 is a cross-sectional view of an expansion die, which can be used to expand a 60.02 millimeter (2.363 ") diameter container to a 62.97 millimeter (2.479 diameter) container. "); [00037] Fig. 14 is a cross-sectional view of an expansion die, which can be used to expand a 62.97 mm (2.479 ") diameter container to a 65.90 mm (2.595 diameter) container. "); [00038] Fig. 15 is a cross-sectional view of a matrix, which can be used to adjust the shape of the lower profile; [00039] Fig. 16 is a side view of five containers, where each container represents an expansion stage from a 53.00 mm (2.087 ") diameter container to a 65.90 mm (2.595 diameter) container "), according to an embodiment of the invention; [00040] Fig-17 is a top view of the five containers of Fig. [00041] Fig. 18 is a bottom view of the five containers of the [00042] Fig. 19 is a cross-sectional view of a metal container having a side wall of varying thickness; [00043] Fig. 20 is a cross-sectional view of a choke matrix strangling a lower part of the side wall of the metal container shown in Figure 19; [00044] Figure 21 shows a cross-sectional view of the choke matrix in Figure 20; [00045] Figure 21a is a partial cross-sectional view from the nose to the choke matrix, shown in Figures 20 and 21; [00046] Figure 22 shows a cross section of an ejector, used in conjunction with the choke matrix in Figures 20, 21 and 21a; [00047] Figure 23 is a cross-sectional view of an expansion matrix expanding an intermediate part of the side wall of the metal container shown in Figure 19; [00048] Figure 24 shows a cross-sectional view of the expansion matrix in Figure 23; [00049] Figure 25 illustrates a metallic container, after a lower part has been strangled and an intermediate part has been expanded; [00050] Figure 26 shows a cross-sectional view of a choke matrix, which can be used to strangle an upper part of the side wall of the metal container shown in Figure 19; [00051] Figure 27 shows a cross-sectional view of a choke matrix, which can be used to strangle an upper part of the side wall of the metal container shown in Figure 19; and [00052] Figure 28 shows a cross section of an ejector used in conjunction with the choke matrix in Figure 27. DESCRIPTION [00053] For the purposes of this specification, terms such as top, bottom, below, above, under, over, etc. they are relative to the position of a finished metal container leaning on a flat surface, regardless of the orientation of the metal container during manufacturing or forming steps or processes. A finished metal container is a metal container that will not undergo additional training steps before being used by an end consumer. In some embodiments, the top of the container has an opening. [00054] The term "bottle load" is used throughout this specification. However, all processes, products and apparatus described therein are applicable to all metal containers, including beverage cans and cups, aerosol cans and food containers. A quotation mark or "in" designates inch (s). [00055] Figure 1 illustrates a bottle load, after each stage of choke by a choke system, according to an embodiment of the present invention, in which the inventive choke system provides a more aggressive choke reduction scheme, which was previously available with prior art strangulation systems, and the ability to strangle a container by thick-walled and thin-walled parts, that is, containers having side walls that vary in thickness by at least 0.0254 mm (0.001 inch), and the choke matrix moves past the thick-walled part and the thin-walled part in a single stroke. Figure 1 illustrates the strangulation progression from an initial bottleneck matrix to produce the first bottled bottle load 1 to a final bottleneck matrix to produce the final bottled bottle load 14. Although Figure 1 illustrates a system of strangulation including 14 stages, the description presented below is not intended to be limited to it, since the number of strangulation stages may vary, depending on the material of the bottle load, one or more thicknesses of the side wall of the load. bottle, the initial diameter of the bottle load, the final diameter of the bottle load, the required shape of the neck profile, and the strangulation force. Therefore, any number of choke matrices has been considered and is within the scope of the present invention, as long as the progression provides choke without deformation or other physical defect of the bottle load. [00056] Figure 2 illustrates a cross-sectional view of a choke matrix, including at least one partially textured choke surface 10 and a textured relief following the choke surface 10. In one embodiment, the partially textured choke surface 10 includes a shoulder radius part or body 11, a neck radius part 12 and a base part 13. [00057] In some embodiments, a choke matrix includes a partially textured choke surface 10, which reduces the surface contact between the choke surface and the bottle load being strangled, in a way that reduces the force, which is necessary for strangle the bottle (hereinafter referred to as "strangulation force"). It has been unexpectedly found that a choke surface, having a textured surface, provides less resistance to a bottle load being strangled than a non-textured surface. Contrary to the previous expectation that a highly polished, non-textured, smooth surface would provide less resistance, and therefore less strangulation force, it was determined that a surface with a relatively low Ra value, that is, </ ~ 152.4 microns (6 microns), has greater surface contact with the bottle being strangled, resulting in greater resistance and requiring greater strangulation force. In some embodiments of the present invention, the greater surface roughness (a higher Ra value) reduces the surface contact between the strangulation surface and the bottle being strangled, thereby reducing the necessary strangulation force. [00058] The reduction of the choke force, necessary to choke the bottle load, allows the choke dies to have a greater percentage reduction than that previously available in the prior art choke dies. It also helps to allow the matrix to strangle through varying thicknesses of the metal sidewall. [00059] In one embodiment, a textured surface has an average surface roughness (Ra) ranging from equal to or greater than 203.2 micrometers (8 micro inches) to less than or equal to 812.8 micrometers (32 micro inches), provided that the textured strangulation surface does not shatter the aesthetic aspects of the superficial finish (coating) of the bottle load, in a significantly observable manner. In one embodiment, a non-textured surface has an average surface roughness (Ra) finish ranging from 50.8 to 152.4 micrometers (2 micro to 6 micro). Figure 3 represents a surface mapping of an embodiment of a non-textured base part 13 of the bottleneck matrix generated by ADE / Phase Shift Analysis and MapVue EX - Surface Mapping software. In this example, the surface roughness (Ra) value was approximately 124.206 micrometers (4.89 microinches). Figure 4 represents a surface mapping of an embodiment of a textured base part 13 of the bottleneck matrix, according to an embodiment of the present invention generated by ADE / Phase Shift Analysis and MapVue EX - Surface Mapping software. In this example, the surface roughness value (Ra) was approximately 652.78 micromilimeters (25.7 microinches). [00060] Referring to Figure 2, in one embodiment, the partially textured choke surface 10 includes a textured base part 13, an un-textured neck radius part 12 and an un-textured boss radius part 11. In another In one embodiment, the at least partially textured choke surface 10 can be entirely textured. With reference to Figure 2a, the contact angle α of the bottle load 50 with the choke surface 10 can be less than 32 °, where the contact angle is the angle included between 54 (the radius extending perpendicular to the base ) and 51 (the radius extending perpendicular from the tangent of the plane to the point of contact by the bottle load with the choke surface). In some embodiments, the operating surface and / or the relief may be entirely non-textured. In some embodiments, the operating surface and / or the relief is / are turned (s) hard and slightly polished to eliminate rough edges, to obtain a surface finish of 203.2 - 254.0 micrometers (8-10 microinches), or 203.2 - 406.4 micrometers (8-16 microinches), or 203.2 - 812.8 micrometers (8 - 32 microinches). [00061] The textured base part 13 in Figure 2, together with the ejector (not shown), provide an operational surface for forming an upper part of the bottle load in a bottle neck during strangulation. The ejector (not shown) fits inside the container or bottle load during the choke and helps to remove the container from the matrix after the choke. In one embodiment, the textured base 13 extends from the tangent point of the neck radius portion 12 of the matrix wall, parallel to the center line of the choke matrix. The textured base part 13 can extend along the choke direction (along the y axis) for a distance Y1, which is less than 12.7 millimeters (0.5 "), or which is on the order of approximately 1 , 5875 millimeter (0.0625 "). In some embodiments, the length of the base part is between 0.50 and 2.032 millimeters (0.02 "and 0.08"). In some embodiments, the length of the base part is between 0.762 and 1.778 mm (0.03 "and 0.07"). In some embodiments, the length of the base part is between 1.016 and 1.524 mm (0.04 "and 0.06"). In some embodiments, the length of the base part is approximately 1.016 millimeter (0.04 "). [00062] Another aspect of some embodiments of the present invention is a relief 20, positioned on the wall of the choke matrix following the choke surface 10. The dimensions of the relief 20 are provided to reduce, but not eliminate, frictional contact with the bottle load and the choke matrix, once the bottle load has been strangled by the base 13 and the ejector. Therefore, in some embodiments, the relief 20, together with the partially textured choke surface 10, contributes to the reduction of frictional contact between the choke matrix wall and the bottle load being choked, in which the frictional contact Reduced maintenance maintains the choke performance, reducing the incidence of deformation, bulging, rupture, wrinkling and other physical defects, and optimizing the extraction of the bottle load. [00063] In one embodiment, the relief 20 extends to the wall of the choke matrix by an X2 dimension of at least 0.127 mm (0.005 inch), measured from the support 13a of the base 13, in other embodiments, at least 0.254 or 0.381 millimeter (0.010 inch or 0.015 inch). In some embodiments, the relief extends to the matrix wall no more than 0.635 millimeter (0.025 "). The relief 20 can extend along the direction of strangulation (along the y axis) along the entire length of the top of the bottle load, which enters the choke matrix, to reduce, but not eliminate, the friction coupling between the bottle load and the choke matrix wall, to reduce the incidence of deformation, bulging, rupture, wrinkling and other physical defects, while still maintaining the choke performance. In one embodiment, the relief 20 is a textured surface. The transition from the base to the relief is combined, without any sharp corners, so that the metal bottle load can move through the base, in any direction, without being damaged. [00064] In some embodiments of the present invention, a choke system is provided, in which at least one of the choke dies can provide an aggressive reduction in the diameter of the bottle load. Although Figure 2 represents an introductory matrix, the discussion presented above regarding the radius of the shoulder 11, radius of the neck 12, base 13 and relief 20 is equally applicable, and can be present in each choke matrix of the choke system. The geometry of the strangulation surface of at least one of the successive matrices provides an increase in the reduction, where the term "reduction" corresponds to the decrease in the diameter of the bottle load, from the initial diameter to a final diameter of the bottle load. [00065] In one embodiment, the introductory matrix reduced the diameter of the container by being strangled by more than 5% in a single strangulation course, or more than 9% in a single strangulation course. The level of reduction that is achieved by the choke system matrices is partly dependent on the surface finish of the choke surface, choke force, bottle load material, required neck profile, and side wall thickness (s). In one embodiment, an introductory choke matrix provides a reduction of more than 9%, where the initial choke matrix is configured to produce an aluminum bottle strangled package of aluminum foil, composed of Aluminum Association 3104 alloy, having a upper sidewall thickness of 0.2159 millimeter (0.0085 inch) or less, and a conventional post-cook elasticity limit of 234.42 to 255.1 MPa (34 to 37 ksi). In some embodiments, the thickness of the upper sidewall can be 0.2159, 0.2032, 0.1755, 0.1778, 0.1524, 0.1270 mm (0.0085, 0080, 0.0075, 0.0070 , 0.0060, 0050 inch), just to name a few examples. In some embodiments, the thickness of the sidewall on the bottom strangulated parts varies by at least 0.0254 millimeter (0.0010 inch). In some embodiments, the thickness of the sidewall on the top strangulated parts varies by at least 0.0254 millimeter (0.0010 inch). In other embodiments, the thickness of the sidewall on either the top or bottom, or both, varies by at least 0.0381 or 0.0508 millimeter (0.0015 "or 0.002"). In some embodiments, the thickness of the sidewall varies by no more than 0.0381, 0.0508, 0.0635, 0.0762 or 0.1016 millimeter (0.0015 ", 0.002", 0.0025 ", 0.003 "or 0.004"). [00066] Figure 5 illustrates an embodiment of an intermediate matrix according to the present invention, in which the intermediate choke matrix can be employed once the bottle charge has been choked with an initial choke matrix. In comparison with the introductory choke matrix, shown in Figure 2, the intermediate choke matrix, illustrated in Figure 5, provides a less aggressive reduction. In one embodiment, several intermediate choke matrices all provide a reduction ranging from 4 to 7%. The number of intermediate choke dies depends on the initial diameter of the bottle load, required final diameter, neck profile, side wall thickness and side wall thickness variability. [00067] Figure 6 illustrates an embodiment of a final strangulation matrix, according to the present invention. The final choke matrix is used once the bottle load has been choked by the intermediate choke matrices. The final choke matrix has a choke surface that results in the bottleneck dimension of the final product. In a concretization, the final choke matrix provides a reduction of less than 4%. In one embodiment, the final strangulation matrix may be reduced by 1.9%. [00068] In one embodiment, a choke system is provided, in which several choke matrices include an introductory choke matrix, having a reduction of more than 9%, 12 intermediate matrices, having a reduction ranging from 4.1 to 6, 1%, and a final bottleneck matrix, with a reduction of 1.9%. [00069] In one embodiment of the present invention, a process of strangling metal containers, using a strangulation system as described above, is provided, including the steps of: providing an aluminum outline, such as a disc or ingot; shape the outline into an aluminum bottle load; and strangling the aluminum bottle charge, wherein the strangulation comprises at least one strangulation matrix having a strangulation surface at least partially textured. [00070] Some embodiments of the present invention provide a bottleneck system, including a reduced number of dies and ejectors, therefore, advantageously reducing the machine cost associated with tooling for bottle bottleneck operations. [00071] By reducing the number of bottleneck dies stages, the present invention advantageously reduces the time associated with bottle bottlenecks. [00072] Although the invention has been described generically above, the examples presented below are provided to further illustrate the present invention and to demonstrate some advantages that stem from it. It is not intended that the invention be limited to the specific examples described. EXAMPLE [00073] Table 1 below shows the reduction provided by a 14-stage matrix choke program, in which the geometry of the choke matrix was configured to form an aluminum bottle strangled package from an aluminum bottle load, having an upper sidewall sheet thickness of approximately 0.2159 millimeter (0.0085 inch) and a conventional post-cook elastic limit of 234.42 to 255.1 MPa (34 to 37 ksi). The aluminum composition is Aluminum Association (AA) 3104 alloy. As indicated in Table 1, the bottle load is strangled from an initial diameter of approximately 0.5301 mm (2.0870 ") to a final diameter of 0.2603 mm (1.025 ") without failure, such as wall deformation. Table 1 [00074] As shown in Table 1, the strangulation system includes a first strangulation matrix, which provides a reduction of approximately 9%, intermediate matrices having a reduction ranging from approximately 4.1 to 6.1%, and a matrix of final strangulation having a reduction of 1.9%. Figure 7 represents a cross-sectional side view for the shoulder strangulation surface of each choke matrix of the 14 stage choke system, shown in Table 1. In this example, the part of the bottle load being choked has a substantially uniform thickness. [00075] Figure 8 illustrates the force required to strangle a bottle in a choke matrix, having a textured base, according to the invention, as indicated by reference line 100, and the force required to strangle a metal container in a non-textured choke matrix, as indicated by reference line 105, where the non-textured choke matrix represents a comparative example. The geometry of the choke matrix, having the textured base and the control matrix, is similar to the choke matrix illustrated in Figure 2. The bottle being choked had an upper sidewall sheet thickness of approximately 0.2159 millimeter (0, 0085 inch), a conventional post-cooking yield limit of 234.42 to 255.1 MPa (34 to 37 ksi), and an aluminum composition being an Aluminum Association 3104 alloy. [00076] With reference to Figure 8, a significant decrease in the strangulation force is made at the beginning, at which point the bottle being strangled contacts the textured base, as illustrated by data point 110 in reference line 100, compared to a non-textured choke surface, illustrated by reference line 105. [00077] Returning then to the expansion matrix, a gradual expansion of a container, comprised of a hard tempered alloy, using multiple expansion matrices of increasing diameters, in comparison with the use of an expansion matrix, allows the diameter of the container be expanded to 40%, without fracture, wrinkling, bulging or other type of metal damage comprising the container. When expanding a container made of a softer alloy, it may be possible to expand the container by 25% using an expansion matrix. The number of expansion dies used to expand a container to a desired diameter, without significantly damaging the container, is dependent on the degree of expansion desired, the material of the container, the hardness of the container material, and the thickness of the container sidewall. . For example, the greater the degree of expansion desired, the greater the number of expansion matrices required. Similarly, if the metal comprising the container has a hard temper, a greater number of expansion dies will be required, compared to expanding a container comprised of a softer metal to the same degree. Also, the thinner the side wall, the greater the number of expansion dies that will be needed. The progressive expansion using a series of expansion dies can provide increases in the diameter of the container of the order of 25%, where greater expansions have been considered, provided that the metal is not significantly damaged during the expansion. In some embodiments, the diameter of the container is expanded by more than 8%. In other embodiments, the diameter of the container is expanded by less than 8%, more than 10%, more than 15%, more than 20%, more than 25% or more than 40%. Other expansion percentages are considered and are within the scope of some embodiments of the invention. [00078] Even more, when expanding a coated container, a gradual expansion will help maintain the integrity of the coating. Alternatively, a container can be expanded before coating. [00079] The strangulation of an expanded container, formed according to some embodiments of the invention, to a diameter equal to or greater than the original diameter of the container X does not require the use of an ejector, because the side wall of the container is in a state of circumferential tension following expansion. In some embodiments of the invention, an ejector can be used when strangling the container. [00080] With reference to Figures 9 - 16, in some embodiments, the expansion die is comprised of tool steel A2, hardener 58 - 60 Rc, finish 32, although any suitable container molding matrix material can be used. In some embodiments, the expansion matrix 500 includes an operating surface 100, having a progressively expanding part 150, a base part 200 and a recessed part 350. An initial part 300 of the operating surface 100 has, in the illustrated embodiment, a geometry to make the gradual transition of the diameter of the side wall 800 of the container 700. The progressively expanding part 150 has dimensions and a geometry that, when inserted in the open end of a container 700, works the side wall of the container 800 to expand radially the diameter of the container in a progressive manner, as the container moves along the operating surface 100. In some embodiments, the expansion matrix 500 provides the proper expansion and forming operations, without the need for an ejector or structure similar. In some embodiments, an ejector can be used. [00081] The base part 200 has dimensions and a geometry to adjust the final diameter of the container forming by that expansion matrix 500. In one embodiment, the base part 200 can extend a distance equal to or greater than 3.048 mm (0.12 "). In other embodiments, the base can extend to 0.254, 0.508, 1.016, 1.27, 2.032 or 2.54 millimeters (0.010, 0.020, 0.04, 0.05, 0.08 or 0.10 ") or more. A lowered part 350 follows the base part 200. The transition from the base part 200 to the lowered part 350 is combined. The recessed part 350 extends at least beyond the opening of the container, when the die is at the bottom of the expansion stroke, to allow the die to maintain control of the metal as it expands, and to minimize the container from sticking. oval. [00082] The operating surface 100 can be an un-textured surface or a textured surface. In one embodiment, a non-textured surface has an average surface roughness (Ra) ranging from 50.8 to 152.4 micrometers (2 to 6 microinches). In one embodiment, the operating surface 100 can be a textured surface having an average surface roughness (Ra) ranging from more than or equal to 203.2 micrometers (8 microinches) to less than or equal to 812.8 micrometers (32 microinches), provided that the textured operating surface 100 does not significantly degrade the side coating of the product, disposed along the inner surface of the container. [00083] In some embodiments, immediately after the base part 200, the expansion die surface passes evenly to a recessed part 350, to reduce, but not eliminate, the frictional contact between the container 700 and the expansion die 500 , as the container is worked by the progressively expanding part 150 and the base part 200 of the operating surface 100. The reduced friction contact minimizes the incidence of deformation, bulging, rupture, wrinkling and other physical defects, and improves extracting container 700 during the expansion process. In some embodiments, the recessed part 350 is a textured surface having an average surface roughness (Ra) ranging from more than or equal to 203.2 micrometers (8 micro inches) to less than or equal to 812.8 micrometers (32 micro inches). In some embodiments, the recessed portion 350 may extend into the expansion die wall by a dimension L of at least 1.27 millimeter (0.05 inch), in other embodiments, at least 0.381 or 0.635 millimeter (0.015 inch or 0.025 "). In some embodiments, the recessed portion extends to the die wall no more than 0.635 millimeter (0.025"). [00084] A matrix system for container production is provided including expansion matrix 500. The matrix system includes at least one first expansion matrix 500, having an operating surface 100 configured to increase a diameter of the container, and at least one progressive expansion matrix, in which each successive matrix in the series of progressive expansion matrices has an operational surface, configured to provide an increasing degree of expansion in the diameter of the container, starting from the previous expansion matrix. In one embodiment, the matrix system may also include one or more bottleneck matrices. [00085] Although the invention has been described generically above, the example presented below is provided to further illustrate the present invention and demonstrate some advantages, which may derive from it. It is not intended that the invention be limited to the specific example described. [00086] In one example, the four expansion matrices, illustrated in Figs. 11 - 14, are used to increase the internal diameter of the container 700 from 0.5301 millimeter (2.087 ") to a diameter of (2.595"), as shown in Figures 16 - 18. The expansion matrix 500, illustrated in Figures 9 -11, can be used to expand the 0.5301 millimeter (2.087 ") diameter container to a 0.5707 millimeter (2.247") diameter container. The expansion matrix shown in Figure 12 can be used to expand the 0.5707 millimeter (2.247 ") diameter container to a 0.6002 millimeter (2.363") diameter container. The expansion matrix shown in Figure 13 can be used to expand the 0.6002 millimeter (2.363 ") diameter container to a 0.6297 millimeter (2.479") diameter container. The expansion matrix shown in Figure 14 can be used to expand the 0.6297 millimeter (2.479 ") diameter container to a 0.6002 millimeter (2.363") diameter container. It should be noted that as the diameter of the container expands, it also becomes shorter. [00087] In one embodiment, the containers of Figures 16-18 are comprised of aluminum alloy 3104 having an H19 temper. The thickness of the side wall is 0.2235 mm (0.0088 "). It should be noted that with the use of some embodiments of the invention, it is possible to expand varying amounts of thin-walled aluminum cans (equal to or less than 0.1041 mm - 0.0041 "), stretched by hard temper (H19, H39) and armored with iron, including the expansion of the diameter of these containers by more than 8%, more than 10%, more than 15% and more than 20%. [00088] In one example, Figure 19 shows a container 190, having a side wall 192 with a thickness ranging between 0.1524 and 0.2032 millimeter (0.006 "and 0.008"). The container 190 is, in this example, aluminum, but can be comprised of any metal, such as, for example, steel. [00089] Figure 20 shows a choke matrix 196 by strangulating a bottom part 194 of the side wall 192. A strangled bottom part 198 is also illustrated, as well as an ejector 220. [00090] Figures 21 and 21a show a choke matrix 196, shown in Figure 20, representing a series of choke matrices, used to create the choked bottom part 198 of container 190. The table shown below in Figures 21 and 21a shows that the dimensions vary between the first and second matrices, which comprise the series of two matrices used to form the strangulated bottom part 198 (shown in Figures 20 and 25) of the container 190. Part of the operational surface 197 of the strangulation matrix 196, including base 199, has a textured surface with an Ra value of 304.8 micrometers (12 microinches). The Ra value of the operating surface 197, which was not textured, had a Ra value of 203.2 to 254.0 micrometers (8 - 10 microinches). [00091] Figure 22 shows an ejector 220, representative of the two ejectors used in conjunction with the choke matrices 196, shown in Figures 20, 21 and 21a. The table shown below in Figure 22 shows the dimensions that vary between the first and second ejectors 220, which were used with the series of two dies, to form the strangled bottom part 198 of the container 190. [00092] The table below shows the dimensions of the container 190, before and after each strangulation step of the bottom part 194 of the side wall 192. [00093] The dimensions are in millimeters (inches). The "span" is the radial distance between the inner diameter of the base 199 of the choke dies 196 and the outer diameter of the ejectors 220. The "estimated thickness of the metal" is the maximum thickness of the metal being formed by the choke matrix. As mentioned above, the thickness of the metal of the side wall 192 of the containers formed in this example varies by 0.0508 millimeter (0.002 ") in the part of the side wall 192 being formed, that is, the choke matrices 196 are displaced by the metal, which varies in thickness by 0.0508 millimeter (0.002 "). The choke dies 196 and the associated ejectors 200 are designed to accommodate the thicker metal as well as the thinner metal through which they pass in the choke process. The thickest metal in the side wall 192 is, in this example, close to the top part of the container 190. This information also applies to the tables presented later in this specification. [00094] Figures 23 and 24 show an expansion matrix 230, used to expand the diameter of an intermediate part 236 of the side wall 192 of the container 190, after the two strangulation steps. In this example, two expansion steps follow two strangulation steps. The table shown under Figure 24 shows the dimensions that vary between the first and second expansion matrices 230, which comprise a series of two expansion matrices. None of the expansion matrices 230 were textured in this example. [00095] In the table below, "body radius" and "neck radius" refer to the expansion matrix radii. [00096] Figure 25 shows the container, after strangulation with the two choke matrices shown in Figures 20, 21 and 21a and expansion with the two expansion matrices shown in Figures 23 and 24. The thin wall part 234 and the part thick-walled 232 are shown. The transition between the thin wall and the thick wall can be short or long and gradual. The strangulation steps followed by the expansion steps form a squeeze 242 on the container 190. [00097] Figure 26 shows a choke matrix 260 forming the choke top part 262, in an upper part 240 of the container 190. Due to the scale of the design, the bases and relief in the choke matrix are not shown. The strangled top portion 262 has been strangled at multiple strangulation stations, with a series of different strangulation matrices. Other choke stations and dies can be used to obtain a bottle or other desired shape. A representative matrix of the five matrices used in stations 1 - 5 is shown in Figure 27. The dimensions that vary between all five matrices used to produce the strangled top part are shown in the table indicated "Profile I" under Figure 27. None of the matrices in this series of five was textured. Figure 28 shows an ejector 280, representing the ejectors used in conjunction with the five choke arrays, shown in Figure 27. The table following Figure 28 lists the dimensions that vary between the five ejectors 280. In this example, the outside diameter of the top of the container, before the choke, was 53 mm (2,087 inches). [00098] With the description of the currently preferred embodiments, it is to be understood that the invention may otherwise be represented within the scope of the appended claims. [00099] Although the specific embodiments of the invention have been described in detail, those skilled in the art will consider that various modifications and alternatives to those details can be developed in the light of the global teachings of the description. Consequently, the particular provisions described are mentioned to be illustrative only and not to limit the scope of the invention, which will be presented in the full range of the appended claims and in any of their equivalents.
权利要求:
Claims (10) [0001] 1. Molded aluminum container (700, 190), characterized by the fact that it comprises: an upper side wall (800, 192) having a thickness in the range of 0.127 millimeter (0.005 inch) to 0.2159 millimeter (0.0085 inch) , wherein the side wall (800, 192) comprises a strangled top part (262) and a bottom strangulated part (198), wherein the thickness of the side wall (800, 192) at the strangled bottom part (198) it ranges from the thickness of the upper side wall (800, 192) by at least 0.0254 millimeter (0.001 inch) to no more than 0.102 millimeter (0.004 inch); wherein the entire outer surface of the side wall (800, 192) is smooth. [0002] 2. Process for forming a metallic container (700, 190), as defined in claim 1, characterized by comprising: providing a container (700, 190) having a side wall (800, 192), in that the sidewall (800, 192) has a thickness, a thinner portion, and a height, and the thickness varies along the height of the sidewall (800, 192) by at least 0.0254 millimeter (0.001 inch) ); throttle the container (700, 190) with a choke matrix (196), so that an operational surface (197) of the choke matrix (196) contacts a side wall section (800, 192) and reduce the diameter of the side wall section (800, 192) by at least 2% in a single stroke, where the thickness of the side wall section (800, 192) varies along the height of the side wall (800, 192) by at least 0 .254 millimeter (0.001 inch), before and after strangulation, where the section of the side wall (800, 192) being strangled includes the thinnest portion of the side wall (800, 192). [0003] Process according to claim 2, characterized by the fact that the choke matrix (196) comprises: a choke surface (10) and a relief (20); wherein the throttle surface (10) comprises a base part (13, 199, 200), a neck radius part (12) and a shoulder radius part (11), each having an internal diameter; wherein the base part (13, 199, 200) is between the neck radius part (12) and the relief (20), and the internal diameter of the base is a minimum diameter of the die; wherein the inner diameters of the neck radius part (12) and the shoulder radius part (11) are greater than the inner diameter of the base (13, 199, 200); wherein the relief (20) comprises: (a) a relief surface; (b) an internal diameter of the relief surface is at least 0.254 millimeter (0.01 inch) greater than the internal diameter of the base part (13, 199, 200); (c) an internal diameter of the relief surface is not greater than a maximum diameter, in order to reduce, but not eliminate, the frictional contact between the metallic container (700, 190) and the relief surface, while maintaining the strangulation performance when strangling the metal container (700, 190); and where the choke matrix (196) is dimensioned so that, when the metallic container is choked (700, 190), the entire base (13, 199, 200) and the relief (20) move relative to the container ( 700, 190) in an axial direction, and at least part of the relief (20) moves beyond a top of the container (700, 190). [0004] Process according to claim 2, characterized by the fact that it also comprises the expansion of the diameter of a part of the side wall (800, 192). [0005] 5. Process according to claim 2, characterized by the fact that it also comprises the choke of the container (700, 190) with a series of choke matrices (196). [0006] Process according to claim 2, characterized by the fact that it also comprises the expansion of the diameter of the part of the side wall (800, 192) with a series of expansion dies (500, 230). [0007] Process according to claim 4, characterized by the fact that an expansion matrix (500, 230) expands the part of the side wall (800, 192), wherein the expansion matrix (500, 230) comprises: a operating surface comprising a progressively expanding part (150) and a base part (13, 199, 200); and a lowered part (350); wherein the base part (13, 199, 200) is between the progressively expanding part (150) and the recessed part (350), and an outside diameter of the base part (13, 199, 200) is a diameter matrix maximum; wherein the recessed portion (350) comprises: (a) a recessed surface; and (b) an outside diameter of the recessed surface, where the external diameter of the recessed surface is: (i) at least approximately 0.254 millimeter (0.01 inch) smaller than the external diameter of the base part (13, 199, 200); and (ii) not less than a minimum diameter, in order to reduce, but not eliminate, the frictional contact between the recessed surface and the aluminum container (700, 190); and where the operating surface is dimensioned so that, when inserted into the metal container (700, 190), the entire base part (13, 199, 200) and at least a part of the recessed part (350) enter the metal container (700, 190), causing expansion of the diameter of at least part of the side wall (800, 192). [0008] 8. Process according to claim 2, characterized in that the thickness of the side wall section (800, 192) being strangled varies along the height of the side wall (800, 192) by at least 0.038 mm (0, 0015 inches). [0009] 9. Process according to claim 2, characterized in that the thickness of the side wall section (800, 192) being strangled varies along the height of the side wall (800, 192) by at least 0.050 mm (0.002 inches) ). [0010] Process for forming a metallic container (700, 190), as defined in claim 1, characterized in that it comprises: providing a container (700, 190) having a side wall (800, 192), wherein the side wall (800, 192) has a thickness ranging between 0.127 mm (0.005 inch) to 0.2159 mm (0.0085 inch), a thinner portion, and a height, and in which the thickness varies along the height of the side wall (800, 192) by at least 0.0254 millimeter (0.001 inch) and not more than 0.102 millimeter (0.004 inch); and throttle the container (700, 190) with a choke matrix (196), so that an operating surface (197) of the choke matrix (196) contacts a side wall section (800, 192) and reduce the diameter of the side wall section (800, 192) by at least 2% in a single stroke, where the thickness of the side wall section (800, 192) varies along the height of the side wall (800, 192) by at least 0.0254 millimeter (0.001 inch) and no more than 0.102 millimeter (0.004 inch) in locations that directly contact the choke matrix (196), where the side wall section (800, 192) being strangled includes the thinnest portion the side wall (800, 192).
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同族专利:
公开号 | 公开日 ES2879442T3|2021-11-22| US9707615B2|2017-07-18| KR20130137158A|2013-12-16| GT201300042A|2014-01-29| KR101853088B1|2018-04-27| US10464707B2|2019-11-05| WO2012024671A2|2012-02-23| MY175342A|2020-06-19| EP3851223A1|2021-07-21| US20170341128A1|2017-11-30| RS62162B1|2021-08-31| WO2012024671A3|2012-04-12| KR20190108656A|2019-09-24| AU2011291482A1|2013-02-21| KR20180050415A|2018-05-14| MX2013001802A|2013-08-01| CN103068498A|2013-04-24| US20120043294A1|2012-02-23| AU2011291482B2|2015-07-30| CA2807696C|2019-01-08| CL2013000476A1|2013-12-27| CN103068498B|2016-05-04| BR112013004004A2|2016-06-28| EA025944B1|2017-02-28| EP2605873B1|2021-04-14| MX351082B|2017-10-02| EA201390258A1|2013-07-30| KR102101137B1|2020-04-14| CA2807696A1|2012-02-23| NZ606434A|2015-02-27| EP2605873A2|2013-06-26|
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法律状态:
2018-01-02| B25A| Requested transfer of rights approved|Owner name: ALCOA USA CORP (US) | 2018-12-26| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]| 2019-09-17| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]| 2020-03-24| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]| 2020-06-23| B09A| Decision: intention to grant [chapter 9.1 patent gazette]| 2020-11-10| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 22/08/2011, OBSERVADAS AS CONDICOES LEGAIS. |
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申请号 | 申请日 | 专利标题 US37574610P| true| 2010-08-20|2010-08-20| US61/375,746|2010-08-20| PCT/US2011/048603|WO2012024671A2|2010-08-20|2011-08-22|Shaped metal container and method for making same| 相关专利
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