Abstract:
The present invention describes a beverage container end closure that utilizes less material and has improved internal buckle strength based on the geometric configuration of a chuck wall, inner panel wall, outer panel wall, and central panel and that utilizes an outwardly oriented countersink.

Description:
FIELD OF THE INVENTION 
       [0001]    Embodiments of the present invention generally relate to containers and container end closures, and more specifically metallic beverage container end closures adapted for interconnection to a neck of a beverage container body. 
       BACKGROUND OF THE INVENTION 
       [0002]    Containers, and more specifically metallic beverage containers, generally contain a neck or an upper portion that is adapted for interconnection to a metallic end closure. The container end closure is formed from a flat sheet of metallic material and generally includes a pull tab or other form of stay on tab (SOT). Beverage containers commonly store carbonated beverages, thus, both the container body and the container end closure are required to sustain internal pressures up to 90 psi without catastrophic failure or permanent deformation. Further, depending on the various conditions that the sealed container is exposed to heat, over fill, high CO2 content, vibration, etc., the internal pressure in a typical beverage container may at times exceed 90 psi. Thus, the container and end closure must be designed to resist deformation and failure while utilizing thin metallic materials. 
         [0003]    Beverage containers are manufactured of thin and durable materials, such as aluminum, to decrease the overall cost of the manufacturing process and the weight of the finished product. It is also desirable to reduce the volume of material needed to fabricate the container end closure by optimizing the geometry and to more effectively improve buckle resistance and deformation. Accordingly, there exists a significant need for a durable beverage container end closure that can withstand high internal pressures associated with stored carbonated beverages and external forces applied during shipping, yet which is manufactured with durable, lightweight, reduced gage metallic materials with geometric configurations that reduce material requirements. 
         [0004]    In an attempt to decrease material costs and improve strength, end closure engineers position the central panel proximate to the upper portion of the peripheral curl, which can result in other performance issues. More specifically, container end closures with a raised central panel height may experience problems associated with “tab-over-chime.” “Tab-over-chime” refers to a geometry where the pull tab is located above the height of the container, which creates stacking problems and thus potential damage during shipping and increased expenses. Thus, it is a challenge to design a container end closure that has improved geometry so that reduced gauge aluminum materials may be used while maintaining buckling and deformation performance of the end closure. 
         [0005]    Previous attempts have been made to manufacture container end closures with unique geometric configuration in an attempt to provide material savings and improve strength. One example of a prior art beverage can end may be found in U.S. Pat. No. 7,100,789 to Nguyen et al., which is incorporated by reference in its entirety. Nguyen discloses a beverage container end closure that utilizes less material and has a chuck wall with improved buckle strength attributed to an inwardly oriented concave arch with a radius of curvature between about 0.015 inches and 0.080 inches. Container end closures that employ other unique geometries are disclosed in U.S. Pat. Nos. 7,506,779; 5,685,189; 6,460,723; 6,968,724 and U.S. Patent Application Publication Nos. 2002/015807 and 2005/0029269, which are each incorporated herein by reference. 
         [0006]    The following disclosure describes an improved container end closure that is adapted for interconnection to a container body and that employs countersink and chuck wall geometry that decreases material costs while maintaining or improving performance. 
       SUMMARY OF THE INVENTION 
       [0007]    It is thus one aspect of various embodiments of the present invention to provide a metallic container end closure with a novel geometry that can withstand significant internal pressures at times exceeding 90 psi, yet saves material costs. Although the end closures described herein generally apply to beverage containers for carbonated beverages, it should be appreciated by one skilled in the art that various aspects of the invention may be used for any type of container. In one embodiment of the present invention, these attributes are achieved by providing a countersink with an inner panel wall and an outer panel wall that are not parallel or slightly offset to a normal axis that passes through a horizontal plane of a substantially horizontal central panel. For example, one embodiment has an outer panel wall of the countersink that is interconnected to a lower portion of the chuck wall at an angle of about 21 degrees to define an outwardly disposed wall portion, and an inner panel wall, which is substantially parallel to the outer panel wall. 
         [0008]    It is a further aspect of the present invention to provide a container end closure with an inner panel wall oriented outwardly away from the normal axis of the central panel. In one embodiment, the inner panel wall is disposed at an angle between about 20° and 30° from the normal axis of the center panel. In a preferred embodiment, the inner panel wall is disposed at angle between about 24° and 26° from the normal axis. In a more preferred embodiment, the inner panel wall is disposed at angle of approximately 25° from the normal axis. 
         [0009]    In another aspect of the present invention, a method for forming a beverage can end closure is provided, wherein the container end closure is provided with a countersink radius of no greater than about 0.015 inches, and which is generally positioned at a depth no greater than about 0.084 inches from the central panel. Furthermore, the method forms a metallic end closure with a container having both inner and outer panel walls that are oriented outwardly from a vertical plane, and which utilizes a “reforming” process that alters the original geometry of the end closure or “shell.” 
         [0010]    In another aspect of the present invention, a container end closure is provided that is manufactured with conventional manufacturing equipment. Thus, existing and well-known manufacturing equipment and processes can be implemented to produce an improved beverage can container end closure as contemplated herein. In another embodiment standard punches and dies used in container manufacturing industry are utilized. After the end closure is initially formed, a “reforming” process is performed to alter the geometry of the container end closure. 
         [0011]    It is another related aspect of the present invention to provide a beverage container end closure that saves material costs by reducing the size of the blank material and/or utilizing thinner materials that have improved aluminum alloy properties. Thus, the integrity and strength of the beverage can end closure is not compromised, material costs are significantly reduced, and/or improved material properties are provided. 
         [0012]    It is thus one embodiment of the present invention to provide a container end closure adapted for interconnection to a container body, comprising: a peripheral curl adapted for interconnection to a side wall of the container body; a chuck wall interconnected to said peripheral curl and extending downwardly at an angle of at least about 8 degrees as measured from a vertical plane; an outer panel wall interconnected to the lower portion of the chuck wall, said outer panel wall being angled about 8 degrees relative to the vertical plane in an outward direction away from a central longitudinal axis of the container; a countersink interconnected to a lower portion of said outer panel wall and having a radius of curvature less than about 0.017 inches; an inner panel wall interconnected to said countersink and extending upwardly at an angle of between about 15 degrees and 30 degrees as measured from the vertical plane; a central panel interconnected to an upper end of said inner panel wall and raised above a lowermost portion of said countersink at least about 0.084 inches. 
         [0013]    It is yet another aspect of the present invention to provide a container end closure, comprising: a circular end wall adapted for interconnection to a side wall of a container; a chuck wall integrally interconnected to said circular end wall and extending downwardly, said chuck wall also interconnected to an outer panel wall; a countersink interconnected to a lower portion of said chuck wall and a lower portion of an inner panel wall and having a radius of curvature less than about 0.017 inches, said inner panel wall being outwardly angled about 25° relative to a vertical plane; and a central panel interconnected to an upper end of said inner panel wall and raised above a lowermost portion of said countersink no greater than about 0.084 inches. 
         [0014]    It is still yet another aspect of the present invention to provide a method of manufacturing a metallic end closure, comprising: providing a preformed metallic end closure comprised of: a peripheral curl and a chuck wall extending downwardly therefrom at an angle of at least about 13 degrees as measured from a vertical plane, a countersink having an inner panel wall and an outer panel wall, and a central panel interconnected to an upper end of said inner panel wall; providing a reforming tool which generally comprises an upper cap and a lower cap that provides pressure to deform said metallic end closure, said countersink being held in place by at least one lower key ring; reforming said preformed metallic end closure by: engaging said central panel with said upper cap; engaging an underside of said central panel with a lower insert, said lower insert engaging with a lower retainer via a plurality of springs; contacting an outer surface of said upper cap with said chuck wall; contacting said countersink with said at least one lower key ring; moving said upper cap adjacent to said lower insert; and bringing an outer surface of said lower retainer in contact with said inner panel wall to deflect the inner panel wall, where said inner panel wall is deflected outwardly with respect to an axis perpendicular to said central panel. 
         [0015]    The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention. Moreover, references made herein to “the present invention” or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to a particular description. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description of the Invention and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present invention will become more readily apparent from the Detailed Description, particularly when taken together with the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The accompanying drawings, which are incorporated herein, and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of these inventions. 
           [0017]      FIG. 1  is a cross-sectional view of a prior art container end closure; 
           [0018]      FIG. 2  is a detailed view of  FIG. 1 , showing the countersink portion, chuck, wall and inner and outer wall portion in more detail; 
           [0019]      FIG. 3  is a cross-section of a container end closure depicting one embodiment of the present invention; 
           [0020]      FIG. 4  is a detailed view of the countersink and chuck wall of  FIG. 3 ; 
           [0021]      FIG. 5  is a detail of  FIG. 3 , wherein dimensions associated with one embodiment of the present invention are provided; 
           [0022]      FIG. 6  is an exploded perspective view of a reforming tool used to make one embodiment of the present invention; 
           [0023]      FIG. 7  is a cross-sectional front elevation view of the countersink tool shown in 
           [0024]      FIG. 6 ; 
           [0025]      FIG. 8  is a cross-sectional view similar to that of  FIG. 7 , wherein a container end closure is shown positioned within the tool; 
           [0026]      FIG. 9  is a cross-sectional view of the countersinking tool wherein the container end closure has been reformed; 
           [0027]      FIG. 10  is a detail view of  FIG. 9  showing the container end closure positioned within the reforming tool prior to reforming; 
           [0028]      FIG. 11  is a detail view of  FIG. 9  showing the container end closure just prior to reforming; 
           [0029]      FIG. 12  is a detail view of  FIG. 9  showing the container end closure after reforming, and depicting the alteration of the countersink inner and outer panel walls; and 
           [0030]      FIG. 13  is a cross sectional front elevation view of the container end closure of one embodiment of the present invention interconnected to a neck of a container body. 
       
    
    
       [0031]    To assist in the understanding of one embodiment of the present invention the following list of components and associated numbering found in the drawings is provided herein: 
         [0000]    
       
         
               
               
             
               
               
             
           
               
                   
               
               
                 No. 
                 Components 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 2 
                 Container end closure 
               
               
                 4 
                 Container body 
               
               
                 6 
                 Peripheral curl 
               
               
                 10 
                 Chuck wall 
               
               
                 14 
                 Lower end 
               
               
                 18 
                 Upper end 
               
               
                 22 
                 Outer panel wall 
               
               
                 26 
                 Inner panel wall 
               
               
                 30 
                 Countersink 
               
               
                 34 
                 Central panel 
               
               
                 38 
                 Normal axis 
               
               
                 42 
                 Countersink forming tool 
               
               
                 46 
                 Upper cap 
               
               
                 50 
                 Lower cap 
               
               
                 54 
                 Lower key ring 
               
               
                 58 
                 Clamp ring 
               
               
                 62 
                 Upper surface 
               
               
                 66 
                 Underside 
               
               
                 70 
                 Lower insert 
               
               
                 74 
                 Lower retainer 
               
               
                 78 
                 Springs 
               
               
                 82 
                 Outer surface 
               
               
                 90 
                 Angled surface 
               
               
                 94 
                 Inner profile 
               
               
                   
               
             
          
         
       
     
         [0032]    It should be understood that the drawings are not necessarily to scale, and various dimensions may be altered. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein. 
       DETAILED DESCRIPTION 
       [0033]    Referring now to  FIGS. 1 and 2 , a prior art container end closure  2  is shown. Container end closures  2  are typically comprised of a peripheral curl  6  that is adapted for interconnection to an upper edge of a neck of a container body  4  (See  FIG. 13 ) in a double seaming process. The peripheral curl  6  is interconnected to a chuck wall  10  that is angled downward and inwardly toward a central longitudinal axis of the container body. Often, the chuck wall will have more than one angle as disclosed in U.S. Pat. No. 6,460,723. A lower end  14  of the chuck wall  10  is interconnected to an upper end  18  of an outer panel wall  22  that is interconnected to an inner panel wall  26  via a countersink  30 . The inner panel wall  26  is also interconnected to a central panel  34  that includes an opening member, for example such as a pull tab or other stay on tab or SOT. 
         [0034]    Referring now to  FIGS. 3-5 , the container end closure  2  of one embodiment of the present invention is shown. Here, a peripheral curl  6  is interconnected to a chuck wall  10  that is interconnected on a lower end to an outer panel wall. Again, it is contemplated that the chuck wall be made of two or any number of separate chuck walls, as disclosed generally in U.S. Pat. No. 6,460,723, and which may include any number of linear, or non-linear arcuate shaped segments. The lower end  64  of the chuck wall  10  is associated with the inner panel wall  26  by the countersink  30 . Although the inner panel wall  26  and the outer panel wall  22  are shown to be generally continuous, one skilled in the art will appreciate, however, that the inner panel wall  26  and the outer panel wall  22  may possess dimples or other radii integrated therein as taught by U.S. Pat. No. 7,506,779. 
         [0035]    As shown in  FIGS. 4 and 5 , the outer panel wall  22  in certain embodiments of the present invention is angled outwardly with respect to a normal axis  38  of the central panel (See  FIG. 3 ). The chuck wall  10  is also angled in a different direction with respect to the normal axis  38 . Here, the chuck wall  10  is angled inwardly at least about 13 degrees from the normal axis  38  of the central panel  34  and the outer panel wall  22  is angled outwardly from the central panel wall  34  at an angle of at least about 8 degrees. This configuration creates a countersink  30  with an outward orientation. In addition, the inner panel wall  26  is angled (α) outwardly in one embodiment of the present invention at least about 25 degrees. 
         [0036]    The outward orientation of the countersink as provided herein has the advantage of increasing buckle strength of the container end closure. The table below provides buckle strength test data. Here, “Control Ends” describe prior art or conventional container end closures and are compared to “reformed” container end closures of embodiments of the present invention. On average, buckle strength is increased by about 0.8 psi. 
         [0000]    
       
         
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                   
                   
               
               
                   
                   
                 Control Ends 
                 Reformed Ends 
                 Δ 
               
               
                   
                 Test 
                 (psi) 
                 (psi) 
                 (psi) 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 1 
                 96.6 
                 99.0 
                 2.4 
               
               
                   
                 2 
                 97.7 
                 98.4 
                 0.7 
               
               
                   
                 3 
                 97.1 
                 100.4 
                 3.3 
               
               
                   
                 4 
                 98.6 
                 98.9 
                 0.3 
               
               
                   
                 5 
                 97.3 
                 101.0 
                 3.7 
               
               
                   
                 6 
                 97.3 
                 100.0 
                 2.7 
               
               
                   
                 7 
                 98.2 
                 99.8 
                 1.6 
               
               
                   
                 8 
                 98.6 
                 100.5 
                 1.9 
               
               
                   
                 9 
                 97.4 
                 100.2 
                 2.8 
               
               
                   
                 10 
                 97.2 
                 99.7 
                 2.5 
               
               
                   
                 11 
                 97.7 
                 98.7 
                 1 
               
               
                   
                 12 
                 96.8 
                 99.5 
                 2.7 
               
               
                   
                 13 
                 97.9 
                 98.6 
                 0.7 
               
               
                   
                 14 
                 98.6 
                 95.1 
                 −3.5 
               
               
                   
                 15 
                 97.2 
                 96.6 
                 −0.6 
               
               
                   
                 16 
                 97.8 
                 96.9 
                 −0.9 
               
               
                   
                 17 
                 97.6 
                 98.4 
                 0.8 
               
               
                   
                 18 
                 96.5 
                 96.9 
                 0.4 
               
               
                   
                 19 
                 97.8 
                 99.4 
                 1.6 
               
               
                   
                 20 
                 97.0 
                 96.5 
                 −0.5 
               
               
                   
                 21 
                 98.0 
                 97.2 
                 −0.8 
               
               
                   
                 22 
                 97.2 
                 97.8 
                 0.6 
               
               
                   
                 23 
                 99.0 
                 97.2 
                 −1.8 
               
               
                   
                 24 
                 96.6 
                 100.3 
                 3.7 
               
               
                   
                 25 
                 98.1 
                 96.0 
                 −2.1 
               
               
                   
                 26 
                 96.6 
                 97.7 
                 1.1 
               
               
                   
                 27 
                 96.8 
                 99.0 
                 2.2 
               
               
                   
                 28 
                 98.0 
                 97.9 
                 −0.1 
               
               
                   
                 29 
                 97.4 
                 97.2 
                 −0.2 
               
               
                   
                 30 
                 98.1 
                 96.4 
                 −1.7 
               
               
                   
                 Avg. 
                 97.6 
                 98.4 
                 0.8 
               
               
                   
                 Dev. 
                 0.672 
                 1.542 
               
               
                   
                 High 
                 99.0 
                 101.0 
               
               
                   
                 Low 
                 96.5 
                 95.1 
               
               
                   
                   
               
             
          
         
       
     
         [0037]    Referring now to  FIGS. 6-12 , a countersink reforming tool  42  of one embodiment of the present invention is shown that is comprised of an upper cap  46  and a lower cap  50  that provides pressure to deform the container end  2 . The countersink  30  of the container end  2  is held in place by lower key rings  54  that are held in place by a clamp ring  58 . The upper surface  62  of the central panel  34  is contacted by the upper cap  46  and the underside  66  of the central panel  34  contacts a lower insert  70 . The lower insert  70  interacts with a lower retainer  74  via a plurality of springs  78 . The lower retainer  74  abuts the lower cap  50 . 
         [0038]    During reforming operations, the end closure  2  is placed upon the lower insert  70  and the upper cap  46  is brought in contact with an upper surface  62  of the central panel  34 . An outer surface  82  of the upper cap  46  contacts the chuck wall  10  and the outer panel wall  22  of the countersink  30  is contacted by at least one lower key  54 , which is held in place by a clamp ring  58 . The lower insert  70  rests upon the plurality of springs  78  that are associated with the lower retainer  74 . The lower retainer  74  includes an angled surface  90 , which will contact an inward facing portion of the inner panel wall  26 . 
         [0039]    During reforming, with particular reference to  FIGS. 11 and 12 , the upper cap  46  is brought down upon the lower insert  70 . As the force acting on the upper cap  46  is increased, the lower insert  70  along with the container end closure  2  is brought to bear onto the outer surface  82  of the lower retainer  74 . This abutting relationship deflects the inner panel wall  26  outwardly as shown. The upper cap  46  will also help maintain 1) the radius between the central panel  34  and the inner panel wall  26  (about 0.015 inches in  FIG. 5 ); 2) the angle of the outer panel wall  22  (about 13° in  FIG. 5 ); and 3) the curl height (about 0.186 inches in  FIG. 5 ). Furthermore, the lower key ring  54  includes an inner profile  94  that creates the distinct transition between the countersink and the outer panel wall as shown. As the inner panel wall  26  and associated countersink  30  is forced outwardly, the outer panel wall  22  is brought to bear against the profile  94  of the lower key ring  54  to create the outwardly deflected outer panel wall  22 . Deflecting the countersink  30  outwardly also reduces the countersink radius. In one embodiment the countersink radius is reduced from 0.015 inches to about 0.010 inches. 
         [0040]    The lower key ring  54  defines a pivot point that deflects the countersink outwardly. In one trial the pivot point was set about 0.0216 inches below the central panel  34  and a 0.0500 inch improvement to “tab to chime” distance was achieved. Again, as used herein “tab to chime” refers to the distance from the central panel to the top of the peripheral curl. This pivot point position also increased the buckle strength of the container end closure by about 0.8 psi. 
         [0041]      FIG. 13  is a cross-sectional view showing the container end closure  2  interconnected to the container body  4  after a double seaming operation has been conducted to interconnect the end closure with the neck of the container. For comparison, the outline of a standard container end closure is shown as well. The container end closure  2  of the present invention is shown with an inner panel wall of the countersink angled at least about 30 degrees outwardly from the normal axis of the central panel  38 , which is clearly distinct from the about 5 degree angulation of the inner panel wall of the prior art. 
         [0042]    While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. Further, the invention(s) described herein is capable of other embodiments and of being practiced or of being carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.