Can bottom having improved pressure resistance and apparatus for making same

Abstract: A can base having an approximately frustoconical portion (8) extending downwardly and inwardly from the can side wall (4), an annular nose portion (16) extending downwardly from the approximately frustoconical portion, and a central portion (24) extending upwardly and inwardly from the nose. The nose (16) is formed by inner and outer circumferentially extending frustoconical walls (12,13) that are joined by a downwardly convex arcuate portion (18). The inner surface (29) of the arcuate portion (18) of the nose (16) has a radius of curvature adjacent the nose inner wall (12) of at least 0.060 inch. The central portion (24) of the can base has a substantially flat disc-shaped central section (26), having a diameter of at least about 1.40 inches, and an annular portion (25) approximately dome-shaped and downwardly concave having a radius of curvature no greater than 1.475 inches. In a preferred embodiment of the invention, the inner surface (29) of the arcuate portion (18) of the nose (16) is formed by a sector of a circle and has radius of curvature no greater than about 0.070 inch. An apparatus for making the can base comprises a nose punch (52) whose distal end has a radius of curvature that is equal to the radius of curvature of the can base nose and a die whose radius of curvature equals that of the dome.

Description: This invention is directed to a can, such as a metal can used to package carbonated beverages. More specifically, the current invention is directed to a can base having improved strength. In the past, cans for packaging carbonated beverages, such as soft drinks or beer, have been formed from metal, typically aluminium. Such cans are conventionally made by attaching a can end, or lid, to a drawn and ironed can body that has an integrally formed base. Certain parameters relating to the geometry of the can base play an important role in the performance of the can. In can bases employing an annular nose, discussed further below, the diameter of the nose affects the ability to stack or nest the base of one can into the top end of another can. Nose diameter also affects the resistance of the can to tipping over, such as might occur during filling. In addition to stackability and anti-tipping stability, strength is also an important aspect of the performance of the can base. For example, since its contents are under pressure, which may be as high as 90 psi (620,5 kPa), the can must be sufficiently strong to resist excessive deformation due to internal pressurisation. Therefore, an important strength parameter for the can base is buckle strength, which is commonly defined as the minimum value of the internal pressure required to cause reversal, or inversion, of the domed portion of the can base, that is, the minimum pressure at which the centre portion of the can base flips from being outwardly concave to outwardly convex. Another important parameter is drop resistance, which is defined as the minimum height required to cause dome inversion when a can filled with water and pressurised to 60 psi (413 kPa) is dropped onto a hard surface. In addition to satisfying performance requirements, there is tremendous economic incentive for can makers to reduce the amount of metal used. Since billions of such cans are sold each year, even slight reductions in metal usage are desirable. The overall size and general shape of the can is specified to the can maker by the beverage industry. Consequently, can makers are constantly striving to reduce the thickness of the metal by refining the details of the can geometry to obtain a stronger structure. Only a few years ago, aluminium cans were formed from metal having a thickness of about 0.0112 inch (0.285 mm). However, aluminium cans having thicknesses as low as 0.0108 inch (0.274 mm) are now available. One technique for increasing the strength of the can base that has enjoyed considerable success is the forming of an externally concave dome in the can base. Beverage cans, such as those for soft drinks and beer, typically have a side wall diameter of about 2.6 inches (66.04 mm). Conventionally, the radius of curvature of the dome is at least 1.550 inch (39.37 mm). For example, U.S. Patent No. 4,685,582 (Pulciani et al.), assigned at issue to National Can Corporation, discloses a can according to the preamble of claim 1 having a side wall diameter of 2.597 inches (65.96 mm)and a dome radius of curvature of 2.120 inches (53.85 mm). Similarly, U.S. Patent No. 4,885,924 (Claydon et al.), assigned at issue to Metal Box plc, discloses a can having a side wall diameter of 2.59 inches (65.786 mm) and a dome radius of curvature of 2.0 inches (50.8 mm), while U.S. Patent No. 4, 412,627 (Houghton et al.), assigned at issue to Metal Container Corp, discloses a can having a side wall diameter of 2.6 inches (66.04 mm) and a dome radius of curvature of 1.75 inches (44.45 mm). The strength of a domed can base is further increased by forming a downwardly and inwardly extending frustoconical wall on the periphery of the base that terminates in an annular bead, or nose. The nose has circumferentially extending inner and outer walls, which may also be frustoconical. The inner and outer walls are joined by an outwardly convex arcuate portion, which may be formed by a sector of a circle. The base of the arcuate portion forms the surface or stand bead on which the can rests when upright. According to conventional can making technology, the radius of curvature of the inner surface of the arcuate portion of the nose in such domed, conically walled can bases was generally 0.05 inch (1.27 mm) or less. For example, prior to the development of the current invention, the parent of the assignee of the instant application, Crown Cork & Seal Company, sold aluminium cans with 202 ends (i.e., the diameter of the can end opposite the base is 2-2/16 inch (54 mm)) in which the radius of curvature of the inside surface of the nose was 0.05 inch (1.27 mm). Similarly, U.S. Patent Nos. 3,730,383 (Dunn et al.), assigned at issue to Aluminium Company of America, and U.S. Patent No. 4,685,582 (Pulciani et al.), assigned at issue to National Can Corporation, disclose a nose having a radius of curvature of 0.040 inch (1.016 mm). Moreover, it was heretofore generally thought that the smaller the radius of curvature of the nose, the greater the pressure resistance of the can base, as discussed, for example, in the aforementioned U.S. Patent No. 3,730,383. Consequently, U.S. Patent No. 4,885,924 (discussed above), U.S. Patent No. 5,069,052 (Porucznik et al.), assigned at issue to CMB Foodcan plc, and U.S. Patent No. 5,351,852 (Trageser et al.), assigned at issue to Aluminium Company of America, all disclose methods for reducing the radius of curvature of the nose in order to increase the strength of the can base. U.S. Patent No. 5,351,852 suggests reworking the nose so as to reduce its radius of curvature to 0.015 inch (0.381 mm), while U.S. Patent No. 5,069,052 suggests reworking the nose so as to reduce its radius of curvature on the inside surface to zero and on the outside surface to 0.040 inch (1.016 mm) or less. In addition to its geometry, the manufacturing apparatus and techniques employed in forming the can base can affect its strength. For example, small surface cracks can be created in the chime area of the can base if the metal is stretched excessively, when the nose is formed. If, as sometimes occurs, these cracks do not initially extend all the way through the metal wall, they may go undetected during inspection by the can maker. This can result in failure of the can after it has been filled and closed, which is very undesirable from the standpoint of the beverage seller or the ultimate customer. The smaller the radius of curvature of the nose, the more likely that such cracking will occur. Since the radius of curvature of the nose adjacent its inner wall is thought to have a greater impact on buckle strength than the radius adjacent the outer wall, some can manufacturers have utilised a nose shape that is more complex than a simple circle sector by employing two radii of curvature: a first inside surface radius of curvature adjacent the outer wall that is above 0.060 inch (1.524 mm) and a second inside surface radius of curvature adjacent the inner wall that is below 0.060 inch (1.524 mm). For example, U.S. Patent No. 4,431,112 (Yamaguchi), assigned at issue to Daiwa Can Company, discloses a domed can base, although one that does not have a conical peripheral wall, with a nose having a first radius of curvature adjacent its inner wall of about 0.035 inch (0.9 mm) and a second radius of curvature adjacent its outer wall of about 0.091 inch (2.3 mm). Another can manufacturer has employed a domed, conically walled base in a 204 end can in which the inner surface of the nose, whose outer wall is inclined at an angle of about 26.5° with respect to the can axis, has a first radius of curvature adjacent the nose inner wall of about 0.054 inch (1.37 mm) and a second radius of curvature adjacent the outer wall of about 0.064 inch (1.626 mm). Notwithstanding the improvements heretofore achieved in the art, it would be desirable to provide a can base having a geometry that optimised performance, especially with respect to buckle resistance, drop resistance, and stackability and manufacturability. It is an object of the current invention to provide a can base having a geometry that optimised performance, especially with respect to buckle resistance, stackability and manufacturability. This and other objects are accomplished in a can comprising a side wall portion and a base portion formed integrally with the side wall portion according to claim 1. The base portion comprises (i) an approximately frustoconical portion that extends downwardly and inwardly from the side wall portion, (ii) an annular nose portion that extends downwardly from the approximately frustoconical portion, (iii) a substantially flat disc-shaped central section, and (iv) an annular dome section disposed between the substantially flat central section and the nose, the annular dome section being arcuate in transverse cross-section and downwardly concave, the annular dome section having a radius of curvature no greater than about 1.475 inches (37.465 mm). The can side wall has a diameter of about 2.6 inches (66.04 mm). In a preferred embodiment, the radius of curvature of the annular dome section is about 1.45 inches (36.83 mm), the substantially flat disc-shaped central section has a diameter of at least about 0.14 inches (3.556 mm), and the substantially flat disc-shaped central section is displaced from a base portion of the nose by a height that is at least about 0.41 inches (10.414 mm). The invention also encompasses an apparatus for forming a can base that has an annular nose formed therein according to claim 11. The apparatus comprises (i) a centrally disposed die having a forming surface that is approximately dome-shaped and upwardly convex, (ii) a nose punch movable relative to the die, the nose punch having a distal end, the distal end formed by inner and outer circumferentially extending walls joined by a downwardly convex arcuate portion, the arcuate portion having a radius of curvature adjacent the inner wall that is within a range of 0.06 inch (1.524 mm) to 0.07 inch (1.778 mm), and (iii) a ram for causing relative motion between the nose punch and the die. The centrally disposed die has a forming surface having a radius of curvature no greater than about 1.475 inches (37.465 mm). A preferred embodiment of the invention is now described, by way of example only, with reference to the drawings, in which: Figure 1 is an isometric view of a can having a base according to the current invention. Figure 2 is a cross-section taken through line II-II shown in Figure 1, showing the can base according to the current invention. Figure 3 is a cross-section through the can base of the current invention nested into the, end of a similar can. Figure 4 is a graph showing the effect of varying the radius of curvature of the inner surface of the nose on the buckle strength of a can base. Figure 5 is a graph showing the effect of varying the radius of curvature of the inner surface of the nose on the buckle strength of a can base when the diameter of the nose is varied so as to maintain approximately constant depth of penetration at nesting. Figure 6 is a longitudinal cross-section taken through a base forming station according to the current invention. Figure 7 is a longitudinal cross-section taken through the nose punch according to the current invention shown in Figure 6. A can 1 according to the current invention is shown in Figure 1. As is conventional, the can comprises an end 3, in which an opening is formed, and a can body. The can body is formed by a cylindrical side wall 4 and a base 6 that is integrally formed with the side wall. The side wall 4 has a diameter D 1 . As is also conventional, the can body is made from a metal, such as steel or, more preferably, aluminium, such as type 3204, 3302 or 3004 aluminium plate having an H-19 temper. As shown in Figure 2, the can base 6 comprises an approximately frustoconical portion 8 that extends downwardly and inwardly from the side wall 4. The frustoconical portion 8 includes an arcuate section 10, having a radius of curvature R 1 , that forms a smooth transition into the side wall 4. The frustoconical portion 8 also preferably includes a straight section that forms an angle a with respect to the axis 7 of the side wall 4. As also shown in Figure 2, an annular nose 16 extends downwardly from the frustoconical portion 8. The nose 16 preferably comprises inner and outer approximately frustoconical walls 12 and 13, respectively. It should be noted that the inner wall 12 is sometimes referred to in the art as the "chime". Preferably, the inner wall 12 has a straight section that forms an angle γ with respect to the axis 7 of the side wall 4, while the outer wall 13 has a straight section that forms an angle β with respect to the axis. The inner and outer walls 12 and 13 are joined by a circumferentially extending arcuate section 18. The inner wall 12 includes an arcuate section 22, having a radius of curvature R 5 , that forms a smooth transition into a centre portion 24 of the base 6. The outer wall 13 includes an arcuate section 14, having a radius of curvature R 2 , that forms a smooth transition into the frustoconical portion 8. In transverse cross-section, the portion of the inner surface 29 of the arcuate section 18 of the nose 16 adjacent the inner wall 12 has a radius of curvature R 3 . Similarly, the portion of the inner surface 29 of the arcuate section 18 adjacent the outer wall 13 has a radius of curvature R 4 . The radii of curvature of the outer surface 30 of the nose 16 will be equal to the radii of curvature of the inner surface 29 plus the thickness of the metal in the arcuate portion 18 of the nose, which is generally essentially the same as the starting sheet metal. Preferably, R 3 equals R 4 . Most preferably, the inner surface 29 of the arcuate portion 18 is entirely formed by a sector of a circle so that only one radius of curvature forms the entirety of the arcuate portion 18 of inner surface of the nose 16, as shown in Figure 2. The centre 19 of the radius of curvature R 3 forms a circle of diameter D 2 as it extends around the circumference of the base 6. The base 27 of the nose 16, on which the can 1 rests when in the upright orientation, is also formed around diameter D 2 . The centre 21 of radius of curvature R 1 of the arcuate section 10 is displaced from the centre 19 of radius of curvature R 3 in the axial direction by a distance Y. Preferably, as the value of R 3 is increased, as discussed below, the value of Y is decreased so that the sum of Y + R 3 remains constant. An approximately dome-shaped centre portion 24 extends upwardly and inwardly from the nose 16. The most central section 26 of the centre portion 24 is disc-shaped, having a diameter D 3 and being substantially flat. An annular portion 25 of the centre portion 24 is arcuate in transverse cross-section, having a radius of curvature R 6 , and connects the central section 26 to the inner wall 12 of the nose 16. The can base 6 has a dome height H that extends from the base 27 of the nose 16 to the top of the centre portion 24. As shown in Figure 3, when two similarly constructed cans are stacked one on top of the other, the base 6 of the upper can will penetrate into the end 3 of the lower can so that the base 27 of the nose 16 of the upper can extends a distance d below the lip formed on the seaming panel 40 of the lower can. Figure 4 shows the results of a finite element analysis, or FEA, aimed at showing how the buckle strength, defined as discussed above, varies with the radius of curvature of the nose 16 in the base of a can having a 202 end and employing the geometry defined in Table I and shown in Figure 24. A 202 end can having a base defined by the geometry specified in Table I and with a nose 16 having an inner surface 29 with a radius of curvature R 3 of 0.05 inch (1.27 mm) is known in the prior art. As shown in Figure 4, increasing the radius of curvature R 3 of the nose inner surface 29 to 0.06 inch (1.524 mm) results in a dramatic increase in buckle strength. Specifically, the finite element analysis predicted that, contrary to the conventional wisdom in the can making art, increasing the nose inner surface radius from 0.05 inch (1.27 mm) to 0.06 inch (1.524 mm) in such a can base would increase the buckle strength by almost 10%, from 95 psi to 104 psi (655 to 717 kPa). Can Base Geometric Parameters For FEA Diameter D 1 2.608 inches (66.24 mm) Diameter D 2 1.904 inches (48.36 mm) Diameter D 3 0.100 inch (2.54 mm) Radius R 1 0.170 inch (4.32 mm) Radius R 2 0.080 inch (2.03 mm) Radius R 3 Variable Radius R 4 Equals R 3 Radius R 5 0.060 inch (1.52 mm) Radius R 6 1.550 inch (39.37 mm) Distance Y + R 3 0.361 inch (9.17 mm) Dome Height H 0.405 inch (10.29 mm) Angle α 60° Angle β 25° Angle γ 8° Unfortunately, increases in the nose inner surface radius of curvature beyond 0.06 inch (1.524 mm) did not yield continued increases in buckle strength, but actually reduced buckle strength, although the buckle strength remained above that obtained with the 0.05 inch (1.27 mm) radius of curvature previously employed for such a can base. In order to check these theoretical predictions, twelve ounce beverage cans having 202 ends were made using base geometries specified in Table I and shown in Figure 2 with three different radii of curvature R3 for the inner surface 29 of the nose arcuate portion 18 - 0.05, 0.055 and 0.06 inch (1.27, 1.34 and 1.524 mm). Cans with each size radius of curvature were made using two different dome heights H and from two different types of 0.0108 inch (0.27 mm) thick aluminium plate - type 3204 H-19 and type 3304C5 H-19 so that, altogether, there were twelve different types of cans. The cans were tested for four strength related parameters - (i) buckle strength, defined above, (ii) base strength, obtained by measuring the minimum axial load required to collapse the can base when the side wall is supported, (iii) drop resistance, obtained by dropping water-filled cans pressurised to 60 psi (413 kPa) from varying heights, and (iv) axial load, obtained by measuring the minimum axial load required to collapse the unsupported can side wall. The results of these tests, which are averaged for at least six cans of each type, are shown in Table II. In addition, the penetration depth d at stacking was measured and is shown in Table III. The comparative strength test results shown in Table II confirm the fact that, contrary to the conventional wisdom, increasing the radius of curvature R 3 of the inner surface 29 of the arcuate portion 18 of the nose 16 on can bases of the type specified in Table I and shown in Figure 2, at least up to 0.06 inch (1.524 mm), increases, rather than decreases, the buckle resistance. Comparative Test Results - Variable Nose Radius Of Curvature Buckle Strength Base Strength Drop Resistance Axial Load inches (mm) psi (kPa) lbs (Kg) inches (mm) lbs (Kg) Type 3204 H-19 Aluminium H=0.0405 (1.028) R 3 =0.050 (1.27) 96.7 (666) 273.7(124.1) 6.7(170) 232.8 (105.5) R 3 =0.055 (1.34) 98.3 (677) 274.7 (124.6) 6.9 (175) 229.6 (104.1) R 3 =0.060 (1.524) 103.8 (715) 284.7 (129.1) 7.6 (193) 205.1 (93) H=0.0415 (1.054) R 3 =0.050 (1.27) 97.7 (673) 273.0 (123.8) 6.7 (170) 227.6 (103.2) R 3 =0.055 (1.34) 99.5 (686) 276.7 (125.5) 6.8 (172) 231.2 (104.8) R 3 =0.060 (1.524) 105.0 (723) 283.7 (128.6) 6.8 (172) 220.9 (100.1) Type 3304C5 H-19 Aluminium H=0.0405 (1.028) R 3 =0.050 (1.27) 95.7 (659) 268.7 (121.8) 5.9 (149) 245.3 (111.2) R 3 =0.055 (1.34) 99.5 (686) 278.0 (126) 5.9 (149) 237.8 (107.8) R 3 =0.060 (1.524) 100.5 (692) 268.3 (121.6) 6.8 (172) 245.7 (114.4) H=0.0415 (1.054) R 3 =0.050 (1.27) 96.7 (666) 269.3 (122.1) 6.0 (152) 238.8 (108.3) R3=0.055 (1.28) 99.5 (686) 275.7 (125) 6.1 (154) 242.7 (110) R 3 =0.060 (1.524) 100.8 (614) 272.0 (123.3) 6.3 (160) 237.0 (107.5) Comparative Test Results - Nose Radius vs. Stacking Depth Radius of Curvature, R 3 Stacking Depth, d 0.05 inch (1.27 mm) 0.083 inch (2.11 mm) 0.055 inch (1.34 mm) 0.069 inch (1.75 mm) 0.060 inch (1.524 mm) 0.062 inch (1.575 mm) Unfortunately, as shown in Table III, it was found that although increasing the radius of curvature R 3 of the nose 16 at its inner surface 29 from 0.05 inch (1.27 mm) to 0.06 inch (1.524 mm) dramatically increased buckle strength, it reduced the depth of penetration at stacking from 0.083 inch (2.108 mm) to 0.062 inch (1.575 mm). This undesirable aspect, which compromises the stackability of the can, occurred because increasing the radius R 3 of the nose inner surface 29 pushes the nose outer wall 13 radially outward. Figure 5 shows the results of a finite element analysis of a can base having the geometry specified in Table I and shown in Figure 2 except that the diameter D 2 of the nose 16 was decreased as its radius of curvature R 3 at the nose inner surface increased in the manner shown in Table IV: Variation of Nose Diameter With Nose Radius of Curvature Nose Radius, R 3 (inches) Nose Diameter, D 2 (inches) 0.050 (1.27 mm) 1.904 (48.36 mm) 0.060 (1.524 mm) 1.890 (48 mm) 0.065 (1.65 mm) 1.884 (47.85 mm) 0.070 (1.778 mm) 1.877 (46.68 mm) As can be seen in Figure 5, coupling increases in the nose radius of curvature R 3 with appropriate decreases in the nose diameter D 2 theoretically results in constantly increasing buckle strength within the 0.05 inch (1.27 mm) to 0.07 inch (1.778 mm) nose radius range. In fact, the most dramatic increase occurs as the radius of curvature of the inside surface of the nose is increased from 0.065 inch (1.65 mm) to 0.07 inch (1.778 mm). In order to test the theoretical predictions from the finite element analysis discussed above, twelve ounce cans having 202 ends, and bases as shown in Figure 2, were made from Alcoa 3004 H-19 aluminium plate having an initial thickness of 0.0108 inch (0.27 mm). Half of the cans were made using a base geometry that is known in the prior art, which is designated A in Table V, and the other half were made using one embodiment of the geometry of the current invention, which is designated B. Consistent with the theoretical analysis discussed above, the two can base geometries differed in two respects. First, contrary to conventional thinking, the radius of curvature R 3 of the nose 16 at its inner surface 29 was increased to 0.06 inch (1.524 mm). Second, the diameter D 2 of the nose was decreased to 1.89 inch (48 mm). Can Base Geometric Parameters For Comparative Testing - Nose Dim. Can Base A Can Base B Diameter D 1 2.608 inches (66.24 mm) 2.608 inches (66.24 mm) Diameter D 2 1.904 inches (48.36 mm) 1.890 inches (45.95 mm Diameter D 3 0.100 inch (2.54 mm) 0.100 inches (2.54 mm) Radius R 1 0.170 inch (4.32 mm) 0.170 inch (4.32 mm) Radius R 2 0.080 inch (2.03 mm) 0.080 inch (2.03 mm) Radius R 3 0.050 inch (1.27 mm) 0.060 inch (1.52 mm) Radius R 4 0.050 inch (1.27 mm) 0.060 inch (1.52 mm) Radius R 5 0.060 inch (1.52 mm) 0.060 inch (1.52 mm) Radius R 6 1.550 inch (39.37 mm) 1.550 inch (39.37 mm) Distance Y + R 3 0.361 inch (9.17 mm) 0.361 inch (9.17 mm) Height H 0.405 inch (10.29 mm) 0.405 inch (10.29 mm) Angle α 60° 60° Angle β 24° 25° Angle γ 8° 8° Comparative testing was again performed on the two groups of cans and the results, which are reported as the average for at least six cans, are shown in Table VI. Comparative Test Results - Varying Nose Radius And Nose Diameter Can Base A Can Base B Buckle Strength 93.7 psi (646 kPa) 100.1 psi (690 kPa) Base Strength 267.2 lbs (121.1 Kg) 269.7 lbs (122.3 Kg) Drop Resistance 7.3 inches (185 mm) 6.8 inches (173 mm) Axial Load 224.1 lbs (101.6 Kg) 236.8 lbs (107.4 Kg) Penetration Depth d 0.085 inch (2.16 mm) 0.086 inch (2.18 mm) As can be seen, the buckle strength of the cans made according to the current invention was almost 7% greater than that of the prior art cans ( i . e ., 100.1 psi (690 kPa) versus 93.7 psi (646 kPa). Such an increase is very significant. For example, it is expected that this increase in buckle strength will allow the 90 psi (620 kPa) buckle strength requirement commonly imposed by carbonated beverage bottlers to be satisfied even if the thickness of the initial metal plate is reduced from 0.0108 inch (0.274 mm) to 0.0104 inch (0.264 mm) - a reduction of almost 4%. Such a reduction in plate thickness will yield significant cost savings. The slight reduction in drop resistance is not thought to be statistically significant. The thickness of the metal in the inner chime wall 12 was also measured for the two types of cans. These measurements showed that the chime wall thickness for the can base according to the current invention (type B) was 0.0003 inch (0.0076 mm) greater than that for the can base of the prior art (type A) - i . e . 0.0098 inch (0.249 mm) versus 0.0095 (0.241 mm). The increase in chime wall thickness is also significant because it shows that the current invention results in less stretching of the metal in the critical chime area (the more the metal is stretched, the thinner it becomes). Manufacturing trials have shown that this reduction in metal stretching reduces the incidence of can failure due to chime surface cracking. Finally, by decreasing the nose diameter D 2 , the depth of penetration d was maintained, thereby ensuring that the increase in nose radius of curvature did not compromise stackability even in a can having a relatively small end ( i . e ., size 202). In this regard, the relatively small angle β of the nose outer wall 13 ( i . e ., 25°) also aids in obtaining good penetration. Thus, if good stackability is a requirement, (i) the radius of curvature R 3 of the inner surface 29 of the arcuate portion 18 of the nose 16 should be maintained within the 0.06 inch (1.524 mm) to 0.070 inch (1.778 mm) range, (ii) the angle β of the outer wall 13 of the nose should be no greater than about 25°, and (iii) the diameter D 2 of the nose should be no greater than 1.89 inch (48 mm) for cans having ends of size 202 or smaller. Unfortunately, decreasing the nose diameter D 2 will reduce the tipping stability of the can when upright. Tipping stability is important since a wobbly can may not fill properly during processing and may cause an annoyance to the ultimate consumer. Therefore, it may be undesirable to increase the nose radius of curvature to values beyond 0.07 inch (1.778 mm) in cans having 202 ends, since that would result in nose diameters less than 1.877 inch (47.68 mm) if the stacking penetration is maintained constant. Moreover, although the greatest increase in buckle strength was obtained with a 0.070 inch (1.778 mm) value for the nose inner surface radius R 3 , this value also results in the smallest nose diameter D 2 . Therefore, depending on the relative importance of the stackability versus the tipping stability requirements, the optimum value of the radius of curvature R 3 of the inner surface 29 of the arcuate portion 18 of the nose 16 may be less than 0.07 inch (1.778 mm), such as about 0.06 inch (1.524 mm) or about 0.065 inch (1.65 mm). According to the invention, the strength of the base 6 can also be increased by careful adjustment of the radius R 6 of the centre portion 24. Specifically, it has been found that a surprising increase in the drop resistance can be achieved by reducing the radius R 6 . This reduction in R 6 is preferably accompanied by an increase in the diameter D 3 of the substantially flat central section 26 and an increase in the dome height H. Table VII shows the results of drop resistance and buckle strength testing for 12 ounce 202 cans having three different base geometries. The base geometries were the same as those of Can Base B shown in Table V unless otherwise indicated. Each can base was formed from aluminium (Alcoa 3104) of three different initial thicknesses on a pilot line. Twelve cans were tested in each geometry/thickness. The results of tests on these cans are shown in Tables VII and VIII below. Comparative Test Results - Varying Dome Dimensions - Pilot Line Can Base B Can Base C Can Base D Radius R 6 1.550 in (39.37 mm) 1.475 in (37.47 mm) 1.450 in (36.83 mm) Diameter D 3 0.100 in (2.54 mm) 0.140 in (3.56 mm) 0.139 in (3.53 mm) Height H 0.405 in (10.29 mm) 0.405 in (10.29 mm) 0.410 in (10.41 mm) Remaining parameter the same as Table I 0.0108 inch (0.274 mm) Thickness Drop Resistance Average 6.07 inches 6.64 inches 8.00 inches (154 mm) (169 mm) (203 mm) Maximum 7 inches 8 inches 9 inches (178 mm) (203 mm) (229 mm) Minimum 5 inches 6 inches 7 inches (127 mm) (152 mm) (178 mm) Buckle Strength Average 99.8 psi (688 kPa) 98.2 psi (677) 98. 7 psi (680) Maximum 100.4 psi (692) 99.0 psi (682) 99.5 psi (686) Minimum 99.2 psi (683) 97.6 psi (672) 97.5 psi (672) 0.0106 inch (0.269 mm) Thickness Drop Resistance Average 5.50 inches 6.07 inches 7.29 inches (139.7 mm) (154 mm) (185 mm) Maximum 6 inches 7 inches 8 inches (152.4 mm) (177.8 mm) (203 mm) Minimum 5 inches 5 inches 6 inches (127 mm) (127 mm) (152.4 mm) Buckle Strength Average 95.2 psi 94.0 psi 94.6 psi (656.4 kPa) (648 kPa) (652kPa) Maximum 95.7 psi 95.6 psi 95.8 psi (660kPa) (659kPa) (660.5kPa) Minimum 94.2 psi 93.2 psi 93.7 psi (649.5kPa) (642.6kPa) (646kPa) 0.0104 inch (0.264 mm) Thickness Drop Resistance Average 4.79 inches 5.79 inches 6.36 inches (121.7 mm) (147 mm) 161.5 mm) Maximum 5 inches 7 inches 7 inches (127 mm) (177.8 mm) (177.8 mm) Minimum 4 inches 4 inches 6 inches (101.6 mm) (101.6 mm) (152.4 mm) Buckle Strength Average 94.1 psi 92.3 psi 93.3 psi (648.8 kPa) (636.4 kPa) (643.3 kPa) Maximum 95.9 psi 93.4 psi 93.8 psi (661.2 kPa) (644 kPa) (646.74 kPa) Minimum 93.7 psi 91.6 psi 92.3 psi (646 kPa) (631.6 kPa) (636.4 kPa) % Change In Drop Resistance and Buckle Strength Over Base B Metal Thickness Base C Base D Drop Buckle Drop Buckle 0.0108 inch (0.274 mm) +8.6% -1.6% +31.8% -1.1% 0.0106 inch (0.269 mm) +10.4% -1.2% +32.5% -0.6% 0.0104 inch (0.264 mm) +20.9% -1.9% +32.8% -0.8% As can be readily seen, by reducing the dome radius R 6 to values no greater than 1.475 inches (37.465 mm) results in increased drop resistance. Specifically, reducing the dome radius R 6 by 0.075 inches (1.905 mm) from 1.55 inches (39.37 mm) to 1.475 inches (37.465 mm), while simultaneously increasing the diameter D 3 of the substantially flat central dome section 26 by 0.040 inches (35.56 mm) from 0.1 inches (2.54 mm) to about 0.14 inches (3.556 mm) (base C), results in an increase in drop resistance of about 10 to 20% depending on the metal thickness and a reduction in buckle strength of only about 1 to 2%. Further reducing the dome radius R 6 another 0.025 inches (0.635 mm) to about 1.45 inches (36.83 mm), while maintaining D 3 at about 0.14 inches (3.56 mm) and simultaneously increasing the dome height H by 0.005 inches (0.127 mm) to about 0.41 inches (10.41 mm)(base D) increases the improvement in drop resistance to over 30% for all three metal thicknesses without further decreases in buckle strength. In order to confirm these results, 12 ounce 202 cans were made having base geometries B and D, as above, as well as geometries E and F, defined generally in Table IX below, at two different commercial can manufacturing plants from 3004 aluminium having an initial thickness of 0.0106 inches (0.269 mm). Base Geometries - Varying Dome Dimensions - Manufacturing Plants Can Base E Can Base F Radius R 6 1.55 in (39.37 mm) 1.50 in (38.1 mm) Diameter D 3 0.100 in (2.54 mm) 0.110 in (2.79 mm) Height H 0.41 in (10.41 mm) 0.41 in (10.41 mm) Twelve can were made in each of the four geometries. The results of testing on these cans is shown in Table X below. Comparative Tests Results - Varying Dome Dimensions Plant #1 Base B Base E Base F Base D Avg. Height H 0.406 in (10.3 mm) 0.411 in (10.43 mm) 0.410 in (10.41 mm) 0.411 in (10.43 mm) Drop Resistance - inches (mm) Average 5.5 inches (139.7) 5.3 inches (134.6) 6.0 inches (152.4) 6.9 inches (175.2) Maximum 6 inches (152.4) 6 inches (152.4) 7 inches (177.8) 8 inches (203.2) Minimum 5 inches (127) 5 inches (127) 5 inches (127) 6 inches (152.4) Buckle Strength - psi (kPa) Average 96.9 psi (668) 97.5 psi (672) 96.2 psi (663) 96.4 psi (664) Maximum 97.6 psi (672) 98.2 psi (677) 96.0 psi (661) 97.0 psi (668) Minimum 96.0 psi (661) 96.2 psi (663) 94.5 psi (651) 96.0 psi (661) Axial Load lbs (Kg) Average 215.7 lbs (97.8) 235.41bs (106.7) 239.8 lbs (108.7) 209.1 lbs (94.8) Maximum 249 lbs (112.9) 250 lbs (113.3) 257 lbs (116.5) 246 lbs (111.5) Minimum 192 lbs (87) 192 lbs (87) 220 lbs (99.7) 184 lbs (83.4) Plant #2 Base B Base E Base F Base D Avg. Height H 0.405 in (10.28 mm) 0.411 in (10.43 mm) 0.411 in (10.43 mm) 0.411 in (10.43 mm) Drop Resistance inches (mm) Average 6.3 inches (160) 5.75 inches (146) 6.4 inches (162.5) 6.6 inches (167.6) Maximum 7 inches (177.8) 6 inches (152.4) 7 inches (177.8) 8 inches (203.2) Minimum 5 inches (127) 5 inches (127) 6 inches (152.4) 6 inches (152.4) Buckle Strength psi (kPa) Average 96.7 psi (666) 96.7 psi (666) 96.7 psi (666) 96.2 psi (663) Maximum 97.6 psi (672) 97.6 psi (672) 97.8 psi (674) 96.9 psi (668) Minimum 96.0 psi (661) 95.8 psi (660) 95.9 psi (661) 94.9 psi (654) Axial Load lbs (Kg) Average 224.5 lbs (101.8) 235.4 lbs (106.7) 232.5 lbs (105.4) 223.6 lbs (101.4) Maximum 238 lbs (107.9) 245 lbs (111.1) 246 lbs (111.5) 232 lbs (105.2) Minimum 218 lbs (98.8) 227 lbs (102.9) 180 lbs (81.6) 209 lbs (14.8) Since plant #1 had been running 0.0108 inch (0.274 mm) thick metal just prior to the test, it was suspected that the reduction in axial load for base geometry D may have been due to insufficient time to stabilise the process. Consequently, a second batch of geometry D cans were run and found to have about the same drop resistance (6.8 inches (172.7 mm) average) and buckle strength (95 psi average) but significantly higher' axial load (244 lbs (110,6 kg) average). As can be seen by comparing the test results for base geometry D with those for base geometry B, reducing the dome radius R 6 to 1.45 inches (36.83 mm), along with simultaneously increasing the substantially flat central section diameter D 3 to 0.14 inches (3.556 mm) and increasing the dome height H to 0.410 inches (10.414 mm), resulted in a 25.5% increase in drop resistance at plant #1, although only a 4.8% increase at plant #2, with minimal effect on buckle strength (less than 1%). Also, comparing the results for base geometry E to base geometry B shows that increasing the dome height H without reducing the dome radius R6 actually decreases drop resistance. Therefore, according to the current invention, in order to optimise the strength of the base of a can, such as a can having a side wall diameter of about 2.6 inches (66 mm), the radius R 6 of the dome should be no greater than about 1.475 inches (37.47 mm) and, more preferably, should be about 1.45 inches (36.8 mm). In addition, the diameter D 3 of the substantially flat central section should be at least about 0.14 inches (3.6 mm), and preferably should equal about 0.14 inches (3.556 mm), and the dome height H should be at least about 0.41 inches (10.4 mm), and preferably should be equal to about 0.41 inches (10.414 mm). A preferred apparatus and method for forming the can base 6 disclosed above is discussed below. In conventional can forming processes, metal stock is placed into a press in which it is deformed into the shape of a cup. The cup is then conveyed to a wall ironing machine and redrawn into the general shape of the side wall and base of the finished can. Next, the redrawn cup is passed through ironing stations that eventually form the side wall into the final shape of the finished can. In addition, a base forming station is employed to shape the base of the can. A can base forming station is disclosed in aforementioned U.S. Patent No. 4,685,582 (Pulciani et al.). As shown in Figure 6, an apparatus 41 for making the can base 6 of the current invention comprises (i) a ram 42, (ii) a nose punch 52, discussed further below, (iii) a substantially cylindrical punch sleeve 44 encircling the nose punch, (iv) a centrally disposed doming die 50 having an upwardly convex forming surface, (v) a support surface 48, (vi) an extractor 46, and (vii) a central retaining bolt 54. In operation, the unformed base metal stock is placed over the punch sleeve 44 and nose punch 52. The travel of the ram 42 then moves the punch sleeve 44 and nose punch 52 toward the doming die 50 so that the metal stock is eventually pressed against the doming die forming surface and drawn over the distal surfaces of the punch sleeve and the nose punch, as shown in Figure 6, thereby forming the can base 6. As shown in Figure 6, the doming die 50 has a radius of curvature R 6 ' that approximates the radius R 6 of curvature of the dome section 24. The radius of curvature R 6 ' is displaced from the axial centreline by a distance X that approximates one half the diameter D 3 of the substantially flat central section 26. Thus the radius of curvature R 6 ' of the doming die 50 should be no greater than about 1.475 inches (37.47 mm), and more preferably about 1.45 inches (36.8 mm). In addition, the centre of R 6 ' should be displaced from the axial centreline by at least about 0.07 inches (1.8 mm) and the dome height H should be at least about 0.41 inches (10.4 mm). As shown in Figure 7, according to the current invention the distal end 61 of the nose punch 52 has (i) a radius of curvature R 3 ' adjacent its inner wall 62, (ii) a radius of curvature R 4 ' adjacent its outer wall 63, and (iii) a diameter D 2 '. According to the current invention; (i) the radii of curvature R 3 ' and R 4 ' of the nose punch 52 are equal to the radii of curvature R 3 and R 4 of the inner surface 29 of the nose 16 of the can base 16 discussed above, and (ii) the diameter D 2 ' of the nose punch is equal to the diameter D 2 of the nose of the can base discussed above. Thus, preferably, the radius of curvature R 3 ' of the distal end of the nose punch 52 adjacent its inner wall 62 is greater than 0.06 inch (1.524 mm). Most preferably, (i) the distal end 61 of the nose punch 52 is formed by a sector of a circle so that the radius of curvature R 4 ' adjacent the outer wall 64 is equal to R 3 ', (ii) the radius of curvature R 3 ' is also less than 0.070 inch (1.778 mm), and (iii) the diameter D 2 ' is no greater than 1.89 inch (48 mm) when making a can having a size 202 end or smaller.

Claims: A can (1) comprising a side wall (4) having a diameter of about 2.6 inches (66.04 mm) and an integral base (6), the base comprising: (i) an approximately frustoconical portion (8) extending downwardly and inwardly from said side wall portion; (ii) an annular nose portion (16) extending downwardly from said approximately frustoconical portion, (iii) a substantially flat disc-shaped central section (26), and (iv) an annular dome section (24) disposed between said substantially flat central section (26) and said nose (16), said annular dome section being arcuate in transverse cross-section and downwardly concave, characterised in that said annular dome section (24) has a radius of curvature (R6) no greater than about 1.475 inches (37.47 mm). The can (1) according to claim 1, wherein said radius of curvature (R6) of said annular dome section is about 1.45 inches (36.83 mm). The can (1) according to claim 1 or claim 2, wherein said substantially flat disc-shaped central section (26) has a diameter (D3) of at least 0.14 inches (3.6 mm). The can (1) according to any one of claims 1 to 3, wherein said nose (16) has a base portion, and wherein said substantially flat disc-shaped central section (26) is displaced from said nose base portion by a height (H) that is at least about 0.41 inches (10.414 mm). The can (1) according to any one of claims 1 to 4, wherein said nose portion (16) is formed by inner and outer circumferentially extending walls (12, 13) joined by an externally convex arcuate portion (18), said arcuate portion having inner and outer surfaces (29, 30), said inner surface (29) of said arcuate portion having a radius of curvature (R3) adjacent said nose inner wall (12) of at least 0.060 inch (1.524 mm), or at least 0.060 inch (1.524 mm) and no greater than about 0.070 inch (1.778 mm), or about 0.060 inch (1.524 mm), about 0.065 inch (1.65 mm), or about 0.070 inch (1.778 mm). The can (1) according to any one of claims 1 to 5, in which the nose (16) is formed of aluminium having a thickness of less than 0.011 inch (0.279 mm). A can (1) according to claims 1 and 3, or 2 and 3, wherein, the annular nose portion (16) extending downwardly from said approximately frustoconical portion (8) forms inner and outer walls (12, 13), and wherein the annular dome section (24) connects said substantially flat central section (26) to said inner wall (12) of said nose. The can (1) according to claim 7, wherein said substantially flat disc-shaped central section (26) has a diameter (D3) of 0.139 inches (3.556 mm). The can (1) according to claim 7 or claim 8, wherein said nose (16) has a base portion (18), and wherein said substantially flat disc-shaped central section (26) is displaced from said nose base by a height (H) that is at least about 0.41 inches (10.44 mm). The can (1) according to any one of claims 7 to 9, wherein said nose portion (16) is formed by inner and outer circumferentially extending walls (12, 13) joined by a downwardly convex arcuate portion (18), said arcuate portion having inner and outer surfaces (29, 30), said inner surface (29) of said arcuate portion having a radius of curvature (R3) adjacent said nose inner wall (12) of at least 0.060 inch (1.524 mm), or at least 0,060 inch (1.524 mm) and no greater than about 0.070 inch (1.778 mm), or about 0.060 inch (1.524 mm). An apparatus for forming the base of a can according to claims 1 and 5, said can base having an annular nose formed therein, comprising: a) a centrally disposed die (50) having a forming surface that is approximately dome-shaped and upwardly convex, said forming surface having a radius of curvature no greater than about 1.475 inches (37.47 mm); b) a nose punch (52) movable relative to said die, said nose punch having a distal end, said distal end formed by inner and outer circumferentially extending walls (62, 63) joined by an externally convex arcuate portion (60), said arcuate portion having a radius of curvature (R'3) adjacent said inner wall (62) that is within the range of 0.060 to 0.070 inches (1.524 mm to 1.778 mm); and c) a ram (42) for causing relative motion between said nose punch and said die. The apparatus according to claim 11, wherein said forming surface has a radius of curvature (R'3) no greater than about 1.45 inches (36.83 mm).

Inventors: CHENG GIN-FUNG, JONES FLOYD A, CHENG, GIN-FUNG, JONES, FLOYD A.
Applicants: CROWN CORK & SEAL TECH CORP, CROWN CORK & SEAL TECHNOLOGIES CORPORATION
Application year: 1999
Main classification: B65D1
IPC codes: B21D22, B65D1