Note: Descriptions are shown in the official language in which they were submitted.
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SYSTEMS AND METHODS FOR FORMING A DOUBLE DOME CONTAINER
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent
Application No. 63/250,806,
filed September 30, 2021, which is incorporated by reference herein in its
entirety.
FIELD OF THE INVENTION
10002] This application relates to systems and methods of forming shaped
containers, and, more
specifically, to systems and methods for forming; shaped metal containers from
metal such as
aluminum or aluminum alloys.
BACKGROUND
10003] Many containers such as food and drink cans, fire extinguishers, gas
cans, oil filter
casings, damper casings, and many other types of articles are made from metal
materials such as
aluminum, aluminum alloys, stzinless steel, brass, low-carbon steel, and
various other suitable
materials. The process of forming the container from the metal material
:generally includes a
number of processes such as a drawing and wall ironing process, a shaping
process such as a
sequence of full-body necking steps or other mechanical shaping, and other
processes as desired
to shape a metal blank into a container having a shape as desired. Oftentimes,
metal containers
that are adapted to hold contents under pressure (e.g., carbonated beverages)
are provided with an
upwardly extending dome in a bottom wall of the container to resist
deformation under pressure.
However, existing dome geometries have a lower limit for a metal gauge of the
wall of the
container, or, stated differently, domes having a metal gauge below a lower
limit will fail and/or
deform under pressure.
SUMMARY
100041 Embodiments covered by this patent are defined by the claims below, not
this summary.
This summary is a high-level overview of various embodiments and introduces
some of the
concepts that are further described in the Detailed Description section below.
This summary is
not intended to identify key or essential features of the claimed subject
matter, nor is it intended
to be used in isolation to determine the scope of the claimed subject matter.
The subject matter
should be understood by reference to appropriate portions of the entire
specification of this
patent, any or all drawings, and each claim.
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10005] According to certain embodiments, a domer assembly for a bottom forming
system
includes a first domer and a second domer. The first domer includes a first
surface that may
engage a bottom of a metal container during a bottom forming process. The
second domer
includes a second surface that may engage the bottom of the metal container
during the bottom
forming process. The second domer is movable relative to the first domer.
[00061 According to some embodiments, a bottom forming system for forming a
metal
container includes a domer assembly that forms a double dome in a bottom of
the metal container
during a bottom forming process. The double dome formed in the bottom of the
metal container
may include a first dome having a first dome profile and a second dome having
a second dome
profile.
100071 According to various embodiments, a method of forming a bottom of a
metal container
includes forming a first dome profile in the bottom of the metal container
using a first domer and
a second domer of a domer assembly. The method includes forming a second dome
profile in the
bottom of the metal container by moving the second domer relative to the first
domer.
100081 Various implementations described herein may include additional
systems, methods,
features, and advantages, which cannot necessarily be expressly disclosed
lieretn but will be
apparent to one of ordinary skill in the art upon examination of the following
detailed description
and accompanying drawings. It is intended that all such systems, methods,
features, and
advantages be included within the present disclosure and protected by the
accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
10009] The specification makes reference to the following appended figures, in
which use of
like reference numerals in different figures is intended to illustrate like or
analogous components.
100101 FIG. l illustrates a bottom forming system with a domer assembly
according to
embodiments.
1001.1.1 FIG. 2 is a top view of a first domer of the domer assembly of FIG.
I.
1001.2j FIG. 3 is a top view of the domer assembly of FIG. I.
10013] FIG. 4 is a side view of the domer assembly of Fla 1 with the domer
assembly in a first
configuration.
100141 FIG. 5 is a side view of the domer assembly of FIG. I with the domer
assembly in a
second configuration.
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1001.5j FIG. 6 illustrates the bottom forming system of FIG. I during a first
stage of a bottom
forming process according to embodiments.
100161 FIG. 7 illustrates the bottom forming system of FIG. 1 during a second
stage of the
bottom forming process.
1001.71 FIG. 8 illustrates an example of a bottom of a metal container with a
double dome
accordim2 to embodiments.
100181 FIG, 9 illustrates an example of a bottom of a metal container wth a
double dome
according to embodiments.
DETAILED DESCRIPTION
100191 The subject matter of embodiments is described herein with specificity
to meet statutory
requirements, but this description is not necessarily intended to limit the
scope of the claims. The
claimed subject matter may be embodied in other ways, may include different
elements or steps,
and may be used. in. conjunction with other existing or -Uwe technologies.
This description
should not be interpreted as implying any particular order or arrangement
among or between
various steps or elements except when the order of individual steps or
arrangement of elements is
explictly described. Directional references such as "up," "down," "top,"
"bottom," "left,"
"right," "front," and "back," among others, are intended to refer to the
orientation as illustrated
and described in the figure (or figures) to which the components and
directions are referencing.
While the systems and methods described herein can be used with any metal,
they may be
especially useful with aluminum or aluminum alloys.
100201 Described herein are systems and methods for forming a bottom of a
metal container. in
various embodiments, the systems and methods provided herein may form, a metal
container with
a double dome. In certain embodiments, a domer assembly includes a first domer
and a second
dopier that is selectively movable relative to the first domer. During a first
stage of a bottom
forming process, the first domer and the second domer may together create a
dome profile and
engage a bottom of a metal container for forming a first dome profile. During
a second stage of
the bottom forming process, the second denier may move relative to the first
domer to further
engage the bottom of the metal container, which may change the geometry of the
first dome
profile and create a second dome profile such that the metal container
includes a double dome.
100211 The geometry of the double dome may withstand and improve dome reversal
pressure
compared to traditional domes, and the double dome may allow for containers to
be formed from
a metal haying a lower metal gauge compared to traditional containers with a
dome while still
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withstanding dome reversal pressure. The ability to use a metal having a lower
metal gauge may
in turn allow for cans to have a reduced weig.ht (e.g., due to less material),
which may provide
cost reductions for can makers. In certain aspects, the systems and methods
described herein may
increase a dome depth/height compared to traditional domes, change the
geometry of the dome
profile compared to traditional domes, increase work hardening and residual
stress, and/or
improve the dome reversal pressure for the container. Various other advantages
and benefits may
be realized with the systems and methods described herein, and the
aforementioned benefits
should not be considered limiting.
100221 FIGS, 1-7 illustrate a bottom forming system 100 for forming a metal
container
according to various embodiments. The bottom forming system 100 may be used to
at least
partially form various metal containers as desired, including but not limited
to beverage
containers. The bottom forming system 100 generally includes a domer assembly
102 for shaping
a bottom 104 for a metal container. The bottom forming system 100 may also
include a retainer
106 and. a punch 108, which may assist with the shaping of the bottom 104
during the bottom
forming process.
100231 The domer assembly 102 includes at least a first domer 110 and a second
domer 112. In
sonic embodiments, and as best illustrated in FIG. 2, the first domer 110
optionally may be a
sleeve having a central aperture 114. In these embodiments, the second domer
112 may be an
insert for the first domer 110 and may be at least partially positioned within
the central aperture
114 when the domer assembly 102 is assembled.. While the first domer 110 is
illustrated as
surrounding the second domer 112, it need not in other embodiments, and the
domer assembly
102 may have various other configurations of at least a first domer and a
second domer. As a non-
limiting example, in some embodiments, the domer assembly 102 may include two
domers, each
forming a half of the overall domer assembly 102, and that are positioned
adjacent to each other.
In this embodiment, the domers may be positioned adjacent to each other but
not necessarily
positioned within one another and/or one need not be surrounded b3., the
other. Other
confiurations of domers may be utilized with the domer assembly 102 as
desired. In some
embodiments, the domer assembly 102 may include more than two domers, such as
three domers.
in embodiments with more than two domers, one or more of the domers may be
movable relative
to a first domer and/or relative to each other.
100241 As best illustrated in FIGS. 2-5, the first domer 110 includes a first
surface 116, and the
second domer 112 includes a second surface 118. In the embodiment illustrated,
the first surface
116 and the second surface 118 have a nonlinear curvature. However, the first
surface 116 and
the second surface 118 may have various shapes or profiles as desired for
forming dome profiles
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on the bottom of a metal container during the bottom. forming process, As a
non-limiting
example, in other embodiments, a curvature of the first surface 116 and/or the
second surface 118
may be increased or decreased compared to that illustrated in FIGS. 1-7,
During the bottom
forming process, the first surface 116 and the second surface 118 may
selectively engage the
bottom 104 to shape the bottom 104.
100251 In vario-us embodiments, the second domer 112 is selectively movable
relative to the first
domer 110, in certain aspects, the second domer 112 is axially movable
relative to the first domer
110, although the second domer 112 may include additional movement relative to
the first (limier
110 in other embodiments. In embodiments where the second domer 112 is
positionable within
the central aperture 114 of the first domer 110, the second domer 112 may be
movable within the
central aperture 114. Various mechanisms, devices, or features may be utilized
such that the
second domer 112 is movable relative to the first domer, including but not
limited to various
mechanical systems, pneumatic systems, hydraulic systems, magnetic systems,
combinations
thereof, and/or other devices or systems as desired.
100261 Refenring to FIGS. 4 and 5, in certain embodiments, the domer assembly
102 includes at
least a first configuration and a second configuration of the first domer 110
and the second domer
112. Movement of the second domer 112 relative to the first domer 110 may
adjust the domer
assembly 102 to be in the first configuration or the second configuration. In
some embodiments,
in the first configuration, the second domer 112 may be in a first position
relative to the first
domer 110, and, in the second configuration, the second dopier 112 may be M a
second position
relative to the first domer 110 offset from the first position. In various
embodiments, and as
discussed in detail below, the second domer 112 may be in the first position
during a first stage of
the bottom forming process and may be in the second position during a second
stage of the
bottom forming process.
100271 FIG. 4 illustrates the domer assembly 102 in the first configuration
where the second
domer 112 is in the first position relative to the first domer 110. As
illustrated in FIG. 4, in the
first position, the second surface 118 may be continuous or flush with the
first surface 116 such
that the first surface 116 and the second surface 118 together form a first
dome profile.
100281 FIG. 5 illustrates the domer assembly 102 in the second configuration
where the second
domer 112 is in the second position relative to the first domer 110. As
diustrated M FIG. 5, in the
second position, the second domer 112 is moved relative to the first domer 110
such that the
second surface 118 is no longer continuous or flush with the first surface
116, in particular, a side
surface 120 of the second domer 112 may optionally extend above the first
surface 116. The
second surface 118 offset from the first surface 116 forms a second dome
profile, in FIGS, the
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offset position of the second domer 112 relative to the first domer 110 has
been exaggerated for
clarity of the figure, but during a bottom forming process, the second darner
112 need not be
moved or offset to the extent shown in FIG. 5.
100291 As mentioned, in addition to the domer assembly 102, the bottom forming
system 100
may optionally include the retainer 106 and the punch 108, In certain
embodiments, the retainer
106 includes a receiving area 122, and the domer assembly 102 may be
positionable and movable
within the receiving area 122 during the bottom forming process. The punch 108
and retainer 106
may be used to further shape the bottom 104 of the metal container during the
bottom forming
process. However, the particular punch 108 and retainer 106 illustrated should
not be considered
limiting, and in other embodiments punches and/or retainers with other shapes,
profiles, features,
etc. may be used as desired. In further embodiments, the bottom forming system
100 may include
fewer or additional features as desired.
100301 A bottom forming process using the bottom forming system 100 is
described in detail
below. Referring to FIG. 1, before bottom forming, the bottom 104 of a metal
container may be
supported relative to the darner assembly 102, optionally using the retainer
106 and/or the punch
108. In some embodiments, the punch 108 may move the bottom 104 into
engagement with the
retainer 106 prior to forming with the domer assembly 102.
100311 Referring to FIG. 6, during a first stage of the bottom forming
process, the domer
assembly 102 may engage the bottom 104 while the domer assembly is in the
first configuration.
In certain embodiments, the domer assembly 102 engages the bottom 104 by
moving the darner
assembly 102, moving the bottom 104 (e.g., using the punch 108), or a
combination thereof. A.s
illustrated in FIG. 6, the domer assembly 102 in the first configuration forms
a first dome in the
bottom 104 having the first dome profile. Optionally, in the first stage of
the bottom forming
process, the punch 108 may advance further towards the retainer 106 to further
shape the bottom
104.
100321 Referring to FIG. 7, during a second stage of the bottom forming
process, the second
darner 112 moves relative to the first domer 110 such that the domer assembly
102 is in the
second configuration. Movement of the second domer 112 relative to the first
domer 110 lifts up
and reshapes the bottom 104 to include a second dome such that the bottom 104
is double domed
includes a first dome 126, fumed during the first stage, and a second dome
128, formed
during the second stage). Optionally, and as illustrated in FIG. 7, the second
domer 112 moving
to the second position reshapes the bottom 104 such that at least a portion of
the bottom 104 does
not contact the first surface 116 or the second surface 118, and a gap 124 may
be at least partially
formed between the domer assembly 102 and a portion of the bottom 104. In
certain aspects, the
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movement of the second domer 112. against the bottom 104 to lift up the bottom
104 will increase
the maximum dome height/depth, change the geometry of the dome profile on the
bottom 104,
and increase th.e work hardening and residual stress in the bottom 104. In
certain aspects, the
movement of the second domer 112 in the second stage of the bottom forming
process may
improve the dome reversal pressure, which may allow for lower gauge metals to
be used as the
bottom 104 compared to traditional bottom forming processes.
100331 FIGS. 8 and 9 illustrate two non-limiting examples of bottoms of metal
containers
formed with domer assemblies described herein. The bottoms illustrated in FIG.
8 and 9 are
provided, as examples, and other bottoms may have various other profiles as
desired depending on
the dolma assembly used.
100341 FIG. 8 illustrates a non-limiting example of a bottom 804 of a metal
container formed by
domer assembly that may be similar to the domer assembly 102 and includes a
first domer and a
second domer, The bottom 804 includes an end 838 having a first dome 826 and a
second dome
828. As illustrated, the first dome 826 has a first dome depth 830 and the
second dome 828 has a
second dome depth 832. In the embodiment illustrated, the first dome depth 830
is 0.1638 inches
and the second dome depth 832 is 0.430 inches. in certain embodiments, the
second dome depth
832 is a maximum dome depth of the double dome, In the embodiment illustrated,
the second
dome 828 also includes a diameter 834 and a radius of curvature 836. In the
embodiment
illustrated, the diameter 834 is 1.550 inches, and the radius of curvature 836
is 0.050 inches. in
other embodiments, the first dome depth 830, the second dome depth 832, the
diameter 834, and
the radius of curvature 836 may be other values as desired and depending on
the domer assembly.
100351 FIG. 9 illustrates a non-limiting example of a bottom 904 of a metal
container formed by
a /Joiner assembly that may be similar to the domer assembly 102 and includes
a first domer and a
second domer. The bottom 904 includes an end 938 having a first dome. 926 and
a second dome
928. As illustrated, in this example, the first dome 926 has a first dome
depth 930 and the second
dome 928 has a second dome depth 932. In the embodiment illustrated, the first
dome depth 930
is 0.245 inches and the second dome depth 932 is 0..443 inches. In certain
embodiments, the
second dome depth 932 is a maximum dome depth of the double dome. In the
embodiment
illustrated, the second dome 928 also includes a diameter 934 and a radius of
curvature 936. In
th.e embodiment illustrated, the diameter 934 is 1.300 inches, and the radius
of curvature 936 is
0.050 inches. In other embodiments, the first dome depth 930, the second dome
depth 932, the
diameter 934, and the radius of curvature 936 may be other values as desired
and depending on
the domer assembly.
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10036] A collection of exemplary embodiments are provided below, including at
least some
explicitly enumerated as "illustrations" providing additional description of a
variety of example
embodiments in accordance with the concepts described herein. These
illustrations are not meant
to be mutually exclusive, exhaustive, or restrictive; and the disclosure not
limited to these
example illustrations but rather encompasses all possible modifications and
variations within the
scope of the issued claims and their equivalents.
100371 Illustration I. A domer assembly for a bottom forming system, the domer
assembly
comprising: a first domer comprising a first surface configured to engage a
bottom of a metal
container during a bottom forming process; and a second domer comprising a
second surface
configured to engage the bottom of the metal container during the bottom
forming process,
wherein the second domer is movable relative to the first domer.
100381 Illustration 2. The domer assembly of any preceding or subsequent
illustrations or
combination of illustrations, wherein the second domer is movable within the
first domer.
10039] illustration 3. The domer assembly of any preceding or subsequent
illustrations or
combination of illustrations, wherein the first domer is a sleeve and the
second domer is an insert
inovablewthM the sleeve.
100401 illustration 4. The domer assembly of any preceding or subsequent
illustrations or
combination of illustrations, wherein the second domer is axially movable
relative to the first
domer.
100411 Illustration 5. The domer assembly of any preceding or subsequent
illustrations or
combination of illustrations, wherein the domer assembly is posMonable in a
first configuration
and a second configuration, wherein, in the first configuration, the first
surface is continuous with
the second surface and together forms a first dome profile, and wherein, in
the second
configuration, the second surface is offset from the first surface and the
second surface forms a
second dome profile.
10042] Illustration 6. The domer assembly of any preceding or subsequent
illustrations or
combination of illustrations, wherein the first domer and the second domer are
configured to
together form a first dome in a bottom of a metal container during a first
stage of a bottom
forming process, and wherein the second domer is configured to form a second
dome in the
bottom of the metal container during a second stage of the bottom forming
process.
[00431 Illustration 7. A bottom forming system for forming a metal container,
the bottom
forming system comprising a domer assembly configured to form a double dome in
a bottom of
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the metal container during a bottom forming process comprising a first dome
having a first dome
profile and a second dome having a second dome profile.
100441 Illustration 8. The bottom forming system of any preceding or
subsequent illustrations or
combination of illustrations, wherein the domer assembly comprises a first
domer and a second
domer, wherein the second domer is selectively movable relative to the first
domer.
100451 Illustration 9. The bottom forming system of any preceding or
subsequent illustrations or
combination of illustrations, wherein the domer assembly comprises a first
configuration and a
second configuration, wherein, in the first configuration, the second domer is
at a first position
relative to the first domer such that the first domer and the second domer are
configured to
together form the first dome, and wherein, in the second configuration, the
second domer is at a
second position relative to the first domer such that the second domer is
configured to form the
second dome.
100461 Illustration 10. The bottom forming system of any preceding or
subsequent illustrations
or combination of illustrations, wherein the first domer is a sleeve, and
wherein second domer
an insert movable within the sleeve.
100471 Illustration 11. The bottom forming system of any preceding or
subsequent illustrations
or combination of illustrations, wherein the second domer is axially movable
relative to the first
domer.
100481 Illustration 12. The bottom forming system of any preceding or
subsequent illustrations
or combination of illustrations, wherein the first domer comprises a first
surface and the second
domer comprises a second surface, wherein the second domer is movable relative
to the first
domer such that, in a first position of the second domer relative to the first
cleaner, the first surface
is continuous with the second surface, and, in a second position of the second
domer relative to
the first domer, the second surface is offset from the first surface.
10049] Illustration 13. The bottom forming system of any preceding or
subsequent illustrations
or combination of illustrations, further comprising: a punch; and a retainer
comprising a receiving
area for a metal container, and wherein the domer assembly is movable within
the receiving area.
100501 Illustration 14. A method of thrilling a bottom of a metal container,
the method
comprising: forming a first dome profile in. the bottom of the metal container
using a first domer
and a second domer of a domer assembly; and thrming a second dome profile in
the bottom of the
metal container by moving the second dt-alier relative to the first domer.
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100511 Illustration 15. The method of any preceding or subsequent
illustrations or combination
of illustrations, wherein forming the second dome profile comprises axially
moving the second
domer relative to the first domer.
100521 Illustration 16. The method of any preceding or subsequent
illustrations or combination
of illustrations, wherein forming the first dome profile comprises axially
moving the first domer
and the second domer together in a first direction to engage the bottom of the
metal container,
and wherein forming the second dome profile comprises moving the second domer
relative to the
first domer in the first direction.
10053] Illustration 17. The method of any preceding or subsequent
illustrations or combination
of illustrations, wherein forming the first dome profile comprises using a
punch to father form
the first dome profile in the bottom of the metal container.
100541 Illustration 18. The method of any preceding or subsequent
illustrations or combination
of illustrations, wherein the first domer is a sleeve and the second domer is
an insert within the
sleeve, and wherein forming the second dome profile comprises moving the
second domer while
the second domer is at least partially within the sleeve.
10055i Illustration 19. The method of any preceding or subsequent
illustrations or combination
of illustrations, wherein fbrming the first dome profile comprises engaging a
first surface of the
first domer and a second surface of the second domer with the bottom of the
metal container.
[00561 Illustration 20. The method of any preceding or subsequent
illustrations or combination
of illustrations, wherein forming the second dome profile comprises moving the
second domer
relative to the first domer such that at least a portion of the bottom of the
metal container does not
contact the first surface or the second surface.
10057] illustration 21. A metal container comprising a bottom formed by the
method of any
preceding or subsequent illustrations or combination of illustrations.
10058i Illustration 22. The metal container of any preceding or subsequent
illustrations or
combination of illustrations, wherein the metal container comprises aluminum
or an aluminum
alloy.
00591 Illustration 23. The metal container of any preceding or subsequent
illustrations or
combination of illustrations, wherein the bottom comprises a reduced metal
gauge.
100601 The above-described aspects are merely possible examples of
implementations, merely
set forth for a clear understanding of the principles of the present
disclosure. Many variations and
modifications may be made to the above-described embodiment(s) without
departing
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substantially from the spirt and principles of the present disclosure. All
such modifications and.
variations are intended to be included herein within the scope of the present,
disclosure, and all
possible claims to individual aspects or combinations of dements or steps are
intended to be
supported by the present disclosure. Moreover, although specific terms are
employed herein, as
well as in the claims that follow, they are used only in a generic and
descriptive sense, and not for
the purposes of limiting the described embodiments, nor the claims that
follow.
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