专利摘要:
CAN MANUFACTURING A method for making a metal can body is described in which two or more drawing operations are used in order to reduce the thickness of the central portion of a cup base, before extracting the cup side wall and form a tin body. By using two or more drawing operations, it was found possible to control the thickness of the base without significantly reducing the pressure performance of the finished can. Alternative modalities of the apparatus comprising tools for carrying out this method are also described.
公开号:BR112014002481B1
申请号:R112014002481-2
申请日:2012-07-24
公开日:2020-11-10
发明作者:Alain Presset;Keith Alan Vincent;Stuart Alexander Monro
申请人:Crown Packaging Technology, Inc.;
IPC主号:
专利说明:

TECHNICAL FIELD
[001] This invention relates to the production of metal cups and, in particular (but not exclusively) to metal cups suitable for the production of "two-piece" metal containers or tin bodies. TECHNICAL FUNDAMENTALS
[002] US 4095544 (National Steel Corporation) 20/06/1978 details Extraction and Forming by Metal Wall (DWI) and Extraction and Re-extraction (DRD) processes for the manufacture of tin bodies from glass sections to the manufacture of two-piece metal containers. [Note that in the United States of America, DWI is instead commonly referred to as D&I]. The term "two pieces" refers to i) the can body, and ii) the closure that would later be attached to the open end of the filled can body to form the container.
[003] In a DWI (D&I) process (as illustrated in Figures 6 to 10 of US 4,095,544), a flat circular void (typically) taken from a sheet metal roll is embedded via a die inlay, under the action of a puncture, to form a shallow first stage cup. This stage of embedding results in any intentional thinning of the void. Thereafter, the cup, which is typically mounted on the end face of a close-fitting punch or ram, is pushed through one or more annular wall metal forming molds for the purpose of effecting a reduction in the thickness of the sidewall of the cup, thus resulting in a stretch in the side wall of the cup and the formation of a can body. The metal forming process alone will not result in any change in the nominal diameter of the first stage cup.
[004] Figure 1 shows the distribution of metal in a container body (or "can") resulting from conventional DWI (D&I) processes. Figure 1 is only illustrative, and is not intended to be precisely in scale. Three regions are indicated in Figure 1: - Region 1 represents the non-metal material of base 1. It maintains approximately the same thickness as the entry caliber of the plate, that is, it is not affected by the manufacturing operations separate from a process Conventional DWI. - Region 2 represents the middle section formed by metal 2 of the side wall. Its thickness (and therefore the amount of metal forming required) is determined by the performance required for the container body. - Region 3 represents the top section formed by metal 3 of the side wall. Typically in can manufacturing, this metal top section is about 50-75% of the thickness of the entry gauge.
[005] In a DRD process (as illustrated in Figures 1 to 5 of US 4,095,544), the same inlay technique is used to form the first stage cup. However, instead of employing a metal forming process, the first stage cup is then subjected to one or more rebounding operations that act to progressively reduce the diameter of the cup and thereby elongate the side wall of the cup. By itself, most conventional rebound operations are not intended to cause a change in the thickness of the glass material. However, taking the example of container bodies manufactured from a typical DRD process, in practice, there is usually some thickening at the top of the finished container body (on the order of 10% or more). This thickening is a natural effect of the rebounding process and is explained by the compression effect on the material when refilling from a large diameter cup to a smaller one.
[006] Note that there are known alternative DRD processes that achieve a reduction in thickness on the side wall of the cup through the use of composite or small radius inlay molds to tune the side wall by stretching in the extraction and re-extraction stages.
[007] Alternatively, a combination of metal forming and rebuilding can be used on the first stage cup, which thereby reduces both the diameter of the cup and the thickness of the side wall. For example, in the field of manufacturing two-piece metal containers (cans), the container body is typically made by injecting a void into a first stage cup and subjecting the cup to a number of rebound operations until it arrives to a container body of the desired nominal diameter, followed by metal forming the side wall to provide the desired thickness and height of the side wall.
[008] However, DWI (D&I) and DRD processes used on a large commercial scale have a serious limitation in that they do not act to reduce the thickness (and therefore the weight) of the material at the base of the glass. In particular, embedding does not result in a reduction in the thickness of the object being embedded, and metal forming only acts on the side wall of the can body. Essentially, for DWI (D&I) and DRD processes known for the manufacture of tin bodies for two-piece containers, the thickness of the base remains virtually unchanged from that of the vacuum inlet gauge. This can result in the base being much thicker than necessary for performance purposes.
[009] The metal packaging industry is highly competitive, with weight reduction being a primary objective, as it reduces transportation and raw material costs. Typically, containers such as cans for packaging food or beverage products are formed from a single reduced steel coil at least 0.35 mm thick. By way of example, about 65% of the costs of manufacturing a typical two-piece metal food container with side walls formed by 0.127 millimeter (0.005 "(5 thou)) metal are derived from raw material costs.
[010] There is therefore a need to improve the lightness of the weighting of the metal cup sections in a cost effective manner.
[011] Unpublished patent application PCT / EP11 / 051666 in the name of Crown Packaging Technology, Inc. describes a method of manufacturing a can body which uses a stretch operation to achieve a base that is thinner than the metal plate entry gauge before drawing, without the need for metal loss or waste. The present patent application is in the name of the same Applicant and represents an improvement of the invention of this unpublished application which refers to improving the efficiency of the stretching process by completing it in two or more separate stretching stages. The improvement of the present invention increases stretch in previously unstretched and / or under-stretched portions of the cup sections.
[012] Note that in this document, the terms "cup section" and "cup" are used interchangeably. In addition, the term "container" and "can" are often used to refer to the same product. SUMMARY OF THE INVENTION
[013] In accordance with the present invention, a method is provided for manufacturing a metal can body, the method comprising the following stages: i) a first stretching stage comprising: picking up a cup having a side wall and a integral base, the cup being formed of sheet metal, fix an annular region on the base to define a delimited portion that includes a central part of the base, and deform and stretch at least part of this delimited portion to thereby increase the surface area and reduce the base thickness; ii) a second stretching stage comprising: stretching an additional closed portion of the base, which may include the same or a different area of the first delimited portion and comprising the central portion of the base, in which the ring fixation operation is adapted for restrict or prevent flow of metal from radially outside the region fixed in the bounded portion during stretching, and iii) a filling operation which comprises embedding the cup in a tin body by pulling and transferring the material out from the base stretched and tuned.
[014] In the packaging industry, where cans for the packaging of both food and beverage products are manufactured, it is considered essential to use lightweight material, for example, less than 0.35 mm thick for single reduced steel.
[015] Typically, the second drawing operation comprises fixing a second annular region of the base to define a second delimited portion which defines a different area from the first delimited portion, but which comprises the central part of the base, and deforming and stretching by the less part of the second closed area, to reduce the thickness of the base even more, in which the ring fixing operations are adapted to restrict or prevent the flow of metal from radially outside the fixed regions in the delimited portion during stretching.
[016] The method of the present invention focuses even more on the region with the least amount of stretch (i.e., percentage of thinning) in the practically spherical stretch method of unpublished patent application PCT / EP11 / 051666, which is in the center of the base of the cup.
[017] The method of the present invention is aimed at increasing the stretch level in this area of the glass even more for a number of reasons: This area is in the center of the finished can, and is normally not an important area in performance. Therefore, the thickness of the metal is also not critical, and the further stretching of the cup base achieved in the present invention provides the benefit of a further reduction of the metal content in the can, without significantly reduced pressure performance. - When using an additional stretch of the central part of the cup, as opposed to the periphery of the stretched area on the cup base, when the cup is returned to the body manufacturer, a greater amount of metal is transferred to the body wall. This is because the periphery of the cup base is thicker, and a greater volume of metal is transferred to a given area. - When using two or more stretching operations, it was found to be possible to control the thickness of the base even more.
[018] In a first embodiment, the first stretching operation stretches only from a first delimited portion which is the central portion of the cup base, typically in a domed profile. The second drawing operation of this modality can provide a drawing punch having a larger diameter and a deeper profile than that used for the first operation. The second operation may include supporting the vault formed in the first drawing operation while forming the outer portion of the vault. Thus, the second bounded portion may have a larger area than the first bounded portion. When working specifically on the central portion of the cup in the first drawing operation, there is an increase in drawing material in this region, compared to the single operation process of PCT / EP11 / 051666.
[019] In another embodiment, the first drawing operation may include drawing substantially the entire base of the cup, and forming a first drawn profile with a large diameter and flat central portion. This modality includes fixing a second annular region by fixing only the central portion of the base. In other words, the step of fixing a second annular region comprises fixing a second annular region, defining a second delimited portion, which comprises substantially only a central part of the base. The two stretching operations of this modality are completely independent of each other.
[020] In a third method of the present invention, the second drawing operation may comprise an inverse drawing of a central part of the base. The corresponding apparatus used for this modality may include a cup holder with a central inverse forming feature (domed former) and the drawing punch may have a corresponding recess in its central portion. Stretching in the method of this mode is generally in two stages, but in a single movement of the press. By stretching both the inner and outer portion of the vault in this single movement, this can increase the risk of separation. Alternatively, it is preferable to use an apparatus with a driving component independently of the reverse forming tool and central vault forming machine instead of being incorporated with the cup holder. The method therefore includes advancing a central vault former and stretching the inverted vault after the first stretch and, therefore, completing the outer portion of the vault.
[021] In accordance with another aspect of the present invention, an apparatus is provided for the manufacture of a metal tin body from a cup made of sheet metal, wherein the cup has a side wall and an integral base , the apparatus comprising: i) a cup holder on which a cup is mountable, ii) a first fixing ring which is adapted to fix a first annular region on the base to define a first delimited portion which includes a central part of the base, and iii) a first stretch punch that is adapted to deform and stretch at least part of this central part of the base to thereby increase its surface area and reduce the thickness of the base; and iv) a second fixing ring that is adapted to fix a second annular region at the base and defines a second delimited portion having an area different from that of the first delimited portion, but including the central portion stretched from the first stretching operation, in which both fixations are adapted to restrict or prevent the metal from radially outside the respective regions fixed in the portions delimited during stretching; v) a second drawing punch which is adapted to deform and stretch at least part of the second delimited portion to further reduce the thickness of the base, and vi) means for embedding the cup in a can body by pulling and transferring material to the outside of the stretched and tuned base.
[022] The apparatus of the present invention has characteristics that are provided for carrying out corresponding steps of the alternative stretching methods as described above. Thus, in one embodiment, the second drawing punch includes a complementary support surface for supporting the stretched portion of the bounded portion.
[023] In another embodiment, the second fixing ring restricts the radially outer material from the central portion of the base to flow into the delimited portion and the second drawing tool contacts the central drawing part from the first drawing operation for drawing additional part.
[024] In yet another embodiment, the stretch punch has a central recess and the apparatus includes a central protrusion in the cup holder, which, in use, contacts the central portion of the cup in order to reverse the stretching of this central part.
[025] In this mode, both stretching operations are performed using the same device and in a single action. Alternatively, the central protrusion of the cup holder comprises a double-acting press with a second independent punch that acts as a reverse forming tool and central dome maker and the stretch punch has a profile that is adapted to form the larger outer dome so, in use, the central portion of the cup is formed in a separate operation, during or after the completion of the formation of the larger outer vault. BRIEF DESCRIPTION OF THE DRAWINGS
[026] The invention will now be described, by way of example only, with reference to the drawings, in which:
[027] Figure 1 is a side view of a prior art container body resulting from a conventional DWI process;
[028] Figure 2 is a schematic side view of a first embodiment of the invention showing first and second operations (Figures 2b and 2c, respectively) of a two-stage process;
[029] Figure 3 is a schematic side view of a second embodiment of the invention showing first and second operations (Figures 3a and 3c, respectively) of a two-stage process;
[030] Figure 4 is a schematic side view of a third embodiment of the invention showing two stages with a single press movement and
[031] Figure 5 is a schematic side view similar to Figure 4, but having a double action press. DESCRIPTION OF THE MODALITIES
[032] Figure 1 shows the distribution of the material in the base 1 and side wall 2 of a prior art container body, resulting from a conventional DWI process.
[033] An initial "cup formation" operation is performed as described in detail in unpublished patent application PCT / EP11 / 051666. The cup forming operation can be summarized as follows:
[034] A cup forming press (also known as a "cup former") has an inlay block and an inlay matrix. An inlay punch is coaxial with the inlay die, and a circumferential cutting element surrounds the inlay block. In use, a flat section of sheet metal is held in position between opposite surfaces of the inlay block and the inlay matrix. Steel tinplate (Temper 4) with an inlet gauge thickness (tin-going) of 0.280 mm was used for the sheet metal. Although neither the PCT / EP11 / 051666 invention nor the present invention is limited to certain gauges or metals and even polymer-coated metal can be used, it is considered essential in the metal packaging industry that the gauge is kept as low as possible , typically less than 0.35mm for single reduced steel. A disk is cut from the metal plate to form a circular flat void.
[035] The cup former forms a cup profile from the void by progressively embedding the flat void against the forming surface of an inlay matrix. The cup thus formed has a side wall and an integral base. The wall thickness of the cup is basically unchanged from that of the vacuum inlet gauge, ie insignificant stretching or thinning must have occurred. The cup that results from this initial filling operation was referred to in PCT / EP11 / 051666, and will also be referred to in the present application as "the first stage cup".
[036] In a first embodiment of the present invention, the first stage tool comprises, as shown in Figure 2a, a cup holder 10, on which is mounted a first stage cup 5. The lower tools shown in Figure 2a comprise a fixing ring 20 and stretch punch 15.
[037] In the first operation, the cup holder 10 enters the cup 5 and advances in the direction of the arrow to secure the outer annulus of the cup base against the fixing ring 20. The cup support 10 continues to advance with the fixation 20 by moving the cup down over the stationary stretch punch 15. Figure 2b shows the position of the tools at the end of the first operation. The area enclosed within the fixing ring 20 corresponds to the central portion of the cup face so that relative movement between the cup holder, and cup, and the stretch punch leads to the stretching of only the central portion of the cup face to one domed profile.
[038] The cup was removed from the cup holder of the first operating tools and placed in a different holder for the second operation. The two stages are in completely separate tool stations.
[039] The second stage tools used for the second drawing operation are shown in Figure 2c. The second operating tools are similar to those of the first operation with the stretch punch 25 having a larger diameter and a deeper profile. The cup with a stretched inner base, that is, vault 8, is mounted on a second cup support 29 and fixed against the larger inner diameter fixing ring 27. In the example of Figure 2c, the central portion of the second stretch punch Operation 25 coincides with the profile of the first operation punch 15, although matching profiles is not essential, as shown by the dashed line in Figure 2c. The central puncture portion supports the vault 8 formed in the first operation cup, while the outer portion 9 of a second operation vault is formed. Second stretching is carried out as in the first operation.
[040] In this modality, in contrast to the single-stage stretch known from the previously unpublished technique, that is, PCT / EP11 / 051666, the first stretching operation acts specifically on the central portion of the cup. As a result, there is a better opportunity to stretch the central region, compared to the current single operation process. In other words, the total chord length of the stretched base following the two stages and two operations is increased over that obtained by a single PCT / EP11 / 051666 stretching operation.
[041] A second embodiment (method / device) of the present invention using two stages and two operations is shown in Figure 3. The first operation tools in Figure 3a include a cup holder 30 for holding cup 31 as before, but with a first stretch punch 35 and a fixation ring 40 which has larger diameters (internal in the case of the fixation ring) than those of the apparatus of Figure 2a, so that in the first operation the punch extends the entire base of the cup 31. The punch profile 35 has a flat central portion 32 so that the first operation predominantly stretches the outer portion of the domed profile.
[042] Figure 3b shows the second operation tools at the beginning of the operation. These include an inner fixing ring 45 and a second stretch punch 50, which has a smaller diameter than the first operation punch 35.
[043] Initially, the lifting block 55 is in line with the fixing ring 45 and stretching punch 50. The drawn cup 31 from the first operation is on the lifting block 55. The second operation cup holder 48 enters in the first operation cup and advances to the cup base. As cup holder 48 continues to advance, it pushes down the lifting block 55 until the central portion of the cup vault is secured against the fixing ring 45. Continued advancement of the cup holder 48, fixing ring 45 and elevation 55 stretch the central portion of the vault over the second stretch punch 50 until the cup is stretched to its final shape 59, as shown in Figure 3c.
[044] Although this method requires two operations, these stretching actions of the inner and outer portion of the cup base are completely independent of each other.
[045] A third embodiment of the invention, which combines two-stage stretching in a single press motion, is shown in Figure 4. The tools for this method are similar to the first operation for the second embodiment shown in Figure 3a, except that the cup holder 60 of Figure 4 has a central inverse forming tool 64 and the stretch punch 66 has a corresponding recess 68 in its central portion.
[046] In use, the cup holder 60 enters the cup and advances to fix the outer ring 72 of the cup base against the fixing ring 70. The cup holder 60 continues to advance with the fixing ring (70), thus moving the cup over the stretch punch 66 and beginning to stretch an outer portion 74 of the base in a domed shape by stretching.
[047] The inverse forming tool (domed former) 64 on the cup holder, then contacts the center of the cup and when the tools advance further, the cup base stretches so that the rest of the outer portion 74 of the vault and inverse formed feature (inverted part) 76 are formed at the same time.
[048] Although it is advantageous that the two stretching stages are carried out in a single movement of the press, by stretching both the outer and inner portion of the vault in this single movement, this may increase the risk of separating the cup base. The double action press and tools in Figure 5 provide a solution to this.
[049] In Figure 5, the inverse forming tool 80 is an independently driven component instead of being incorporated in the cup holder 85. In operation, the inverse forming tool 80 can be advanced to stretch the inverted vault 76 during stretching or upon completion of the drawing of the outer portion 74 of the vault by drawing punch 66. This double-acting press has the advantages of drawing in two independent stages and reducing the risk of separation.
[050] An example of an inlay operation that causes the stretched and tuned material from the base of any of the above modalities to be progressively pulled out and transferred from the base to a reduced diameter side wall is described in the patent application no. PCT / EP11 / 051666 published with reference to Figure 10 of this application. This inlay operation has the effect of flattening the stretched regions of the base.
[051] The invention has been described above by means of different examples only and modifications can be made within the scope of the invention, as defined claims. LIST OF REFERENCE SIGNS
[052] Figure 1 1 can base 2 bottom can side wall 3 top can side wall
[053] Figure 2 5 first stage cup (not formed) 8 first operation vault 9 external operation second vault portion 10 first operation cup holder 15 first operation stretch punch 20 first operation fixation ring 25 punch second operation stretch 27 second operation fixing ring 29 second operation cup holder
[054] Figure 3 30 first operation cup holder 31 first operation cup 32 central punch portion 35 first operation stretch punch 40 first operation ring fixing 45 second operation ring 48 second operation cup holder 50 punch second operation stretch 55 lift block 59 second operation
[055] Figures 4 and 5 60 cup holder and upper tool 64 reverse forming feature (central vault) on the upper tool 66 lower puncture tool 68 recess in the lower puncture tool 70 fixing ring 72 outer vault ring 74 outer portion vault 76 inverted vault (inverse formation feature) 80 independent tool for inverse formation (central vault former) 85 cup holder
权利要求:
Claims (11)
[0001]
1. Method for making a metal can body, the method characterized by the fact that it comprises the following stages: i) a first stage of stretching comprising: taking a cup (5) having a side wall (2,3) and an integral base (1), the cup (5) being formed of sheet metal, fix an annular region on the base (1) to define a delimited portion that includes a central part of the base (1), and deform and stretch at least part of this portion delimited to thereby increase the surface area and reduce the thickness of the base (1), and; ii) a second stretching stage comprising: stretching an additional delimited portion of the base (1), which may include the same or a different area of the first delimited portion and which includes the central portion of the base (1), in which the operation ring fixing is adapted to restrict or prevent the flow of metal from radially out of the region fixed in the bounded portion during stretching, and iii) an inlay operation comprising embedding the cup (5) in a can body by pulling and transferring material out from the base (1) stretched and tuned.
[0002]
2. Method, according to claim 1, characterized by the fact that the two stretching stages are performed in two independent press operations, in which: i) the first stretching stage is a first press operation, ii) the second stretch stage is a second press operation, and comprises: fixing a second annular region of the base (1) to define a second delimited portion that defines an area different from the first delimited portion and that includes the central part of the base (1) ; and deform and stretch at least part of the second delimited portion, to reduce the thickness of the base (1) even further, iii) the ring fixing operation of each stretch stage is adapted to restrict or prevent the flow of metal from radially outside the regions fixed in the bounded portion during stretching.
[0003]
Method according to claim 2, characterized by the fact that the second drawing operation also includes supporting the stretched part of the delimited portion.
[0004]
Method according to claim 2 or 3, characterized in that the step of fixing a second annular region defines a second delimited portion that has a larger area than the first delimited portion.
[0005]
Method according to claim 2, characterized in that the step of fixing a second annular region comprises fixing a second annular region, defining a second delimited portion comprising only a central portion of the base (1).
[0006]
6. Method according to claim 2, characterized in that the second drawing operation comprises inverse drawing of a central portion of the base (1).
[0007]
7. Apparatus for manufacturing a metal can body from a cup (5) formed of sheet metal, in which the cup (5) has a side wall (2, 3) and an integral base (1), the apparatus characterized by the fact that it comprises: i) a cup holder (10, 30) on which a cup is mountable, ii) a first fixing ring (20, 40), which is adapted to fix a first annular region in the base (1) to define a first delimited portion that includes a central part of the base, and iii) a first stretch punch (15, 35) that is adapted to deform and stretch at least part of that central portion of the base (1) to thus increasing its surface area and reducing the thickness of the base (1), iv) a second fixing ring (27, 45) which is adapted to fix a second annular region on the base and defines a second delimited portion having an area different from that of the first delimited portion, but including the central portion drawn from the first drawing operation, in which both fixings (20, 27; 40, 45) are adapted to restrict or prevent metal flow from radially out of the respective regions fixed in the bounded portions during drawing, v) a second drawing punch (25, 50) which is adapted to deform and stretch at least part the second portion delimited to reduce the thickness of the base even further, and vi) means for embedding the cup in a tin body by pulling and transferring material to the outside of the stretched and tuned base.
[0008]
Apparatus according to claim 7, characterized in that the second drawing punch (25) includes a complementary support surface for supporting the stretched part of the bounded portion.
[0009]
Apparatus according to claim 7, characterized in that the central portion of the first drawing tool (32) is flat.
[0010]
Apparatus according to any one of claims 7 to 9, characterized in that the second fixing ring (27) restricts material radially outside the central portion of the base to flow into the closed portion and the second drawing tool (25, 50) contacts the central stretched part of the first drawing operation and stretches this part further.
[0011]
11. Apparatus according to claim 10, characterized by the fact that it comprises a second operation cup holder (48), and the second drawing tool (50) acts as a central vault forming and drawing stretch punch. the first operation (35) has a profile which is adapted to form the larger outer vault whereby, in use, the central portion of the cup is formed in a separate operation, during or after the completion of the formation of the larger outer vault.
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同族专利:
公开号 | 公开日
CA2843795C|2019-08-20|
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ES2680094T3|2018-09-03|
EA201490391A1|2014-05-30|
NZ620614A|2016-05-27|
JP2014521518A|2014-08-28|
AU2012292220B2|2017-01-12|
AU2012292220A1|2014-02-20|
MX2014001172A|2014-05-13|
US20140161566A1|2014-06-12|
CA2843795A1|2013-02-07|
WO2013017485A1|2013-02-07|
CN103702780A|2014-04-02|
MX360821B|2018-11-16|
HUE039635T2|2019-01-28|
BR112014002481A2|2017-02-21|
EP2739412B1|2018-05-02|
PL2739412T3|2018-10-31|
JP6058002B2|2017-01-11|
CN103702780B|2016-05-11|
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法律状态:
2018-12-11| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
2019-11-05| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|
2020-04-07| B09A| Decision: intention to grant|
2020-11-10| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 24/07/2012, OBSERVADAS AS CONDICOES LEGAIS. |
优先权:
申请号 | 申请日 | 专利标题
EP11176206.8|2011-08-01|
EP11176206|2011-08-01|
PCT/EP2012/064530|WO2013017485A1|2011-08-01|2012-07-24|Can manufacture|
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