Abstract:
An easy open safety end having a central portion and a rim portion separated by a score line. A tab applies a force to the end adjacent the score line so as to shear the score line at opening. A circumferentially extending fold is formed in either the central portion or the rim portion, or both, to protect the user from being cut by the sharp edge the results upon shearing the score line. A first circumferential portion of the fold is tight, whereas a second portion, which is preferably proximate the tab is loose. The fold is displaced below a portion of the end adjacent the score line by a circumferentially extending gap. In the tight portion of the fold, the width of the gap is less than the thickness of the end, and preferably less than one half the thickness, whereas in the loose portion of the fold, the width of the gap is greater than the thickness of the end, and is preferably at least twice the thickness of the end.

Description:
FIELD OF THE INVENTION  
         [0001]    The current invention is directed to a safe ended type end for a container. More specifically, the current invention is directed to an end for a container having improved opening characteristics.  
         BACKGROUND OF THE INVENTION  
         [0002]    Many products, such as food stuffs, including potato chips, as well as other articles, such as tennis balls, are packaged in containers having an easy open end  2 , such as that shown in FIGS.  1 - 3 . Conventionally, such ends are formed from metal plate, such as aluminum, having a thickness t of about 0.0095 inch (0.24 mm). Such ends have a circular score line formed between the central panel  8  and the rim  10 . The rim  10  has a curl  17  formed thereon for attachment to the side wall of the container. A tab  4 , attached by a rivet  5  to the central panel  8 , is employed to effect opening. By pulling up on the end  7  of the tab  4 , the nose  6  of the tab presses against the rim and causes the score line  12  to shear, thereby separating the central panel  8 , which is discarded, from the rim  10 . The minimum pulling force exerted on end of the tab  4  that is required to cause the initial shearing of the score line  12  is referred to as the “pop value.” After initial shearing, continued manipulation of the tab allows the user to completely sever the central panel from the rim portion by shearing the score line along its entire circumference. The force necessary to continue the shearing of the score line after the initial severing is referred to as the tear force. The lower the pop value and the tear force, the easier it is for the user to open the container.  
           [0003]    The opening operation described above can result in a sharp edge being formed on the rim  8 , which can result in a cutting hazard to the user. This rim edge can be made safe by folding under a portion of the rim  10  adjacent the score line  12  inwardly and then outwardly so as to form an upper fold  16  and a lower fold  14 , with the bend  18  of the lower fold projecting radially inward beyond the score line  12  so as to protect the user from the sharp edge formed on the rim when it is severed along the score line, as shown in FIGS.  1 - 3 .  
           [0004]    The opening process also results in a sharp edge on the central panel. This central panel edge can be made safe by folding under a portion of the cental panel adjacent the score line  112  outwardly and then inwardly so as to form an upper fold  121  and a lower fold  117 , with the bend of the lower fold projecting radially outward beyond the score line  112  so as to protect the user from the sharp edge formed on the central panel when it is severed along the score line, as shown in FIG. 4. In this type of can end, folds  115  and  123  are also formed in the rim portion  110 , as discussed above. However, in this case, the rim folds are located above the score line, rather than below it. A can end having a folds in both the rim and the central panel is more fully disclosed in U.S. Pat. No. 3,986,632 (Morrison et al.), hereby incorporated by reference in its entirety.  
           [0005]    Conventionally, the folds are tightly formed. For example, an easy open end made by the assignee of the current invention is made from metal plate having a thickness t of about 0.0095 inch (0.24 mm). As shown in FIG. 3, the vertical gap G 1 , by which the upper surface of the bend  18  of the lower fold  14  is displaced below the lower surface of the rim  10 , has a width W 1  in the vicinity of the score line  12  that is typically less than the thickness t of the plate and may often be less than one-half the thickness t of the plate and is sometimes even zero, so that the upper surface of the bend  18  contacts the lower surface of the rim portion  20 . The width W 2  of the vertical gap G 2 , by which the lower surface of the bend  19  in the upper fold  16  is displaced above the upper surface of the lower portion of the rim  10 , is typically approximately equal to one or two times the thickness t of the plate. The overall height H of the folds  14  and  16  is typically no more than about six times the thickness t of the plate.  
           [0006]    Unfortunately, the tightness of the folds can undesirably increase the difficulty of initially shearing the score line  12 —that is, increase the pop value. As shown in FIG. 3 the width W 1  of the gap G 1  is minimal. Consequently, in order for the nose  6  of the tab  4  to create sufficient downward deflection in the upper portion  20  of the rim  10  to shear the score line  12 , it must apply sufficient force F to also downwardly deflect the underlying bend  18  in the lower fold  14 . This situation, which is sometimes referred to as “lockout”, increases the pop value.  
           [0007]    The tightness of the folds can also increase the tear force, especially in ends that have folds on both the central panel and the rim panel. In such ends, further manipulation of the tab  5  and tearing of the score around its circumference after the initial pop causes the central panel  8  to bend along line A-A shown in FIG. 1. As shown in FIG. 4, this deformation causes the periphery of the central panel to locally bow at locations B, which are typically at approximately the 10:30 o&#39;clock and 1:30 o&#39;clock locations. This bowing causes the severed edge  109  of the central panel  108  to contact the bend in the rim fold  115  above it so that additional force must be applied to the tab  104  in order to effect continued shearing of the score line  112 , thereby increasing the required tearing force.  
           [0008]    Although easy open ends can be made, and have been made, with uniformly large gaps around the entire circumference of the fold, such as that disclosed in U.S. Pat. No. 5,105,977 (Taniuchi), such an arrangement can compromise the safety afforded by the fold if the upper portion  20  of the rim  10  does not spring completely down against the underlying fold after the central panel  8  has been removed.  
           [0009]    Consequently, it would be desirable to create a easy open container end that is safe and yet is also easy to open.  
         SUMMARY OF THE INVENTION  
         [0010]    It is an object of the current invention to provide an easy open safety container end with improved opening characteristics. This and other objects is accomplished in an easy open safety container end comprising (i) a central portion, (ii) a rim portion surrounding the central portion, the rim and central portions having a thickness and separated by a score line, (iii) means for applying a force to a portion of the end proximate the score line, and (iv) first and second circumferentially extending folds formed in the end adjacent the score line. The first fold is displaced from a portion of the end proximate the score line by a circumferentially extending gap, with a first circumferentially extending portion of the gap being less than the thickness and a second circumferentially extending portion of the gap being greater than the thickness. In a preferred embodiment of the invention, the second portion of the gap is greater than twice the thickness and encompasses an angle between about 2° and 45°. The first portion of the gap is less than one half the thickness.  
           [0011]    The current invention also encompasses an apparatus for forming an easy open container end, comprising upper and lower forming tools having opposing forming surfaces for forming a circumferentially extending fold in the container end, a first recess formed in at least one of the opposing forming surfaces, at least one of the forming tools movable toward the other of the forming tools whereby the recessed portion of the forming surface forms a first circumferentially extending portion of the fold and the remaining portion of the forming surface forms a second circumferentially extending portion of the fold, the first portion of the fold being looser than the second portion of the fold. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    [0012]FIG. 1 is a plan view of an easy open container end according to the prior art.  
         [0013]    [0013]FIG. 2 is a cross-section taken through line II-II shown in FIG. 1.  
         [0014]    [0014]FIG. 3 is an enlarged view of the fold area of the container end shown in FIG. 2.  
         [0015]    [0015]FIG. 4 is an isometric view of a portion of a prior end can end having folds on both the central and rim portion during the opening process.  
         [0016]    [0016]FIG. 5 is a plan view of an easy open container end according to the current invention.  
         [0017]    [0017]FIG. 6 is a cross-section taken through line VI-VI shown in FIG. 5.  
         [0018]    [0018]FIG. 7 is a cross-section taken through line VII-VII shown in FIG. 6.  
         [0019]    [0019]FIG. 8 is enlarged view of a portion of loose fold area of the container end shown in FIG. 6.  
         [0020]    [0020]FIGS. 9 and 10 show two positions of the tooling used to produce the container end shown in FIGS.  5 - 8 .  
         [0021]    [0021]FIG. 11 is a elevation view of the tooling shown in FIG. 10 taken along line XI-XI.  
         [0022]    [0022]FIG. 12 is a plan view of the fold ring shown in FIGS.  9 - 11 .  
         [0023]    [0023]FIG. 13 is a cross-section similar to that shown in FIG. 6 showing the invention incorporated into an end having folds on both the central portion and the rim portion.  
         [0024]    [0024]FIG. 14 is enlarged view of a portion of the loose fold area of the container end shown in FIG. 13. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0025]    A container end  2 ′ having folds on only the rim portion  10 ′ according to the current invention is shown in FIGS.  5 -  8 . As is conventional, the end  2 ′ is made from aluminum plate having a thickness t of about 0.0095 inch (0.24 mm). As shown in FIGS. 5 and 6, around a portion  3  of its circumference, the geometry of the upper fold  16  is the same as that in conventional safety ends, shown in FIGS.  1 - 3 . In particular, the upper fold  16  in circumferential portion  3  is tight, for example as shown in FIG. 3 or the left hand side of FIG. 6, so that the vertical gap G 1 , by which the upper surface of the bend  18  of the lower fold  14  is displaced below the lower surface of the rim  10 ′, has a width W 1  in the vicinity of the score line  12  that is preferably less than the thickness t of the plate (i.e., less than about 0.01 inch (0.25 mm)), more preferably less than about one-half the thickness t of the plate (i.e., less than about 0.005 inch (0.12 mm)), and most preferably is zero so that the upper surface of the bend  18  contacts the lower surface of the rim portion  20 . Moreover, as also shown in FIG. 3 and the left hand portion of FIG. 6, in the circumferential portion  3 , the lower fold  14  is also tight, so that the vertical gap G 2 , by which the lower surface of the bend  19  in the upper fold  16  is displace above the upper surface of the lower portion of the rim  10 ′, has a maximum width W 2  that is preferably no more than about two times the thickness t of the plate (i.e., no more than about 0.02 inch (0.5 mm)). In addition, the overall height H of the fold  14  is typically no more than about six times the thickness t of the plate (i.e., no more than about 0.06 inch (1.4 mm)).  
         [0026]    However, according to the current invention, a circumferential portion of the folds are locally loosened. Specifically, the upper fold  16  in the portion  3 ′ of the circumference of the container end  2 ′, which may be in the vicinity of the tab nose  6 , is loose rather than tight. As shown best in FIGS. 7 and 8, in the loose portion  16 ′ of the upper fold, the width W 1 ′ of the vertical gap G 1 ′ adjacent the score line  12  is greater than the thickness t of the plate (ie., greater than about 0.01 inch (0.25 mm)) and, more preferably, is at least twice the thickness of the plate (i.e., at least about 0.02 inch (0.5 mm)). Moreover, preferably the lower fold  14 ′ is also loose in portion  3 ′ so that, preferably, the width W 2 ′ of the vertical gap G 2 ′ is more than two times the thickness t of the plate (i.e., more than about 0.02 inch (0.5 mm)) and, more preferably, is at least three times the thickness of the plate (i.e., at last about 0.03 inch (0.75 mm)). The overall height H&#39; of the loose fold portion  3 ′ is preferably more than about six times the thickness t of the plate (i.e., more than about 0.06 inch (1.4 mm)) and, most preferably, is at least seven times the thickness of the plate (i.e., more than about 0.07 inch (1.8 mm)).  
         [0027]    As shown best in FIG. 8, as a result of the local looseness of the folds in circumferential portion  3 ′, the deflection of the portion  20  of the rim  10 ′ as a result of the force F applied by the nose  6  of the tab  4  when the tab is pulled is unimpeded by the bend  18 ′ in the lower fold  14 ′, thereby minimizing the force required to shear the score line  12 . Further, as shown in FIGS. 3 and 8, loosening the folds locally tends to reduce the distance d by which the bend  18  in the lower fold  14  projects radially inward past the score line, thereby reducing the likelihood that the bend will interfere with the opening process in the loose fold area.  
         [0028]    As shown in FIG. 5, the tight fold circumferential portion  3  of the container end  2 ′ forms a major portion of the circumference in order to provide maximum safety from sharp edges, while the loose fold circumferential portion  3 ′ forms a minor portion of the circumference. Preferably, the loose fold portion is formed in only those areas of the circumference in which tight folds interfere with the opening process, such as the lock out areas previously discussed. Most preferably, the minor, loose fold portion is located in the vicinity of the nose  6  of the tab  4 . In order to prevent lockout and minimize the pop value, yet retain as much as possible the optimal safety afforded by a tight fold, the loose fold portion  3 ′ preferably extends over an arc centered about the axis of the tab and defined by any angle A that is between about 1° and 25°, more preferably between about 2° and 10°. In one embodiment of the invention, a loose fold portion centered about the tab has a circumferential length of about ¼ inch (6 mm). However, a smaller or larger portion  3 ′ could also be utilized, if desired, in order to obtain an optimum balance of ease of opening and safety. Moreover, although as shown in FIG. 5, the container end  2 ′ has only one portion  3 ′ having loose folds, it may also be desirable in some instances to distribute several sections of loose folds around the circumference of the end  2 ′ in order to obtain optimal ease of opening.  
         [0029]    Although as shown in FIGS.  5 - 8  locally loose folds are formed in both the upper and lower rim folds, if desired, the invention could be practiced by forming locally loose areas in only one of the folds.  
         [0030]    A series of experiments were conducted on container ends made from aluminum plate having a thickness of about 0.0095 inch (0.24 mm) to determine the effect of loosening the fold  14 ′ on the pop value. Twenty six conventional container ends  2  were made having tight folds  14  and  16  and the pop value necessary to shear the score line  12  was measured, resulting in an average pop value of 4.0 lbs. The experiment was repeated with twenty six container ends  2 ′ made according to the current invention with loose folds  14 ′ and  16 ′ extending over a portion  3 ′ of the circumference defined by an angle of about 3° to 5° centered about the axis of the tab  4 . The average pop value of these ends was 2.5 lbs, a reduction of almost 40%.  
         [0031]    Container ends  2 ′ according to the current invention are preferably made on a conventional multi-station rotary press. The tooling for forming the folds in such container ends  2 ′ is shown in FIGS.  9 - 12 . The partially formed end  9 , in which pre-folds  32  have been formed in a prior station, is transferred to a folding station  41 . The upper tooling of the folding station  41  comprises a locator ring  42  that encircles a fold punch  40 . The lower tooling of the folding station  41  comprises a lower forming die  44  that encircles a fold ring  46 , which is supported on a spring (not shown). The fold ring  46  encircles a pressure pad  52 .  
         [0032]    As shown best in FIGS. 11 and 12, a relief  48  is formed in the fold ring  46  over the portion of its circumference encompassed by the angle A that is intended to form the loose folds. A similar relief  50  is formed in the fold punch  40 . Preferably, the depth of the reliefs  48  and  50  are such that when the fold punch  40  and fold ring  46  reached the closed position, shown in FIG. 10, the vertical height of the gap formed between the relieved portions is approximately equal to H&#39;, the intended height of the loose folds, whereas the vertical height of the gap formed in the remainder of the circumference is approximately equal to H, the intended height of tight folds.  
         [0033]    During manufacture, the locator ring  42  accurately locates the partially formed end  9  on the tooling. The fold punch  40  is then lowered, thereby compressing the pre-folds  32  so as to form the final folds. In the portion of the circumference of the tooling that is not relieved, the resulting folds are tight, as shown in FIG. 3. However, the portion formed by the relieved portions  48  and  50 , the folds are loose, as shown in FIG. 8.  
         [0034]    The invention can also be practiced on an easy open end having folds on both the rim portion and the central panel. FIGS. 13 and 14 show the invention as applied to a container end  102  have both safety folds formed on the central panel  108  and the rim portion  110 . In this case, the folds  117  and  121  located below the score line  112  are formed on the central panel  108 , while the folds  115  and  123  on the rim portion  110  are located above the score line. The nose  106  of the tab  104  presses on the portion of the central panel  110  proximate the score line  112  in order to effect opening.  
         [0035]    According to the current invention, the central panel folds  117  and  121  around a first portion of the circumference are tight, as shown in the left hand portion of FIG. 13. In the tight fold portion, the vertical gap G 1 , by which the upper surface of the bend  127  of the lower fold  117  is displaced below the lower surface of the upper portion of the central panel  108 , has a width in the vicinity of the score line  112  that is preferably less than the thickness t of the plate (i.e., less than about 0.01 inch (0.24 mm)), more preferably less than about one-half the thickness t of the plate (i.e., less than about 0.005 inch (0.12 mm)), and most preferably is zero. Further, in the tight fold portion, the vertical gap G 2 , by which the lower surface of the bend in the upper fold  121  is displaced above the upper surface of the lower portion of the central panel, has a maximum width W 2 ′ that is preferably no more than about two times the thickness t of the plate (i.e., no more than about 0.02 inch (0.5 mm)).  
         [0036]    The central panel folds  117 ′ and  121 ′ around another portion of the circumference are loose. Specifically, the width W 1 ′ of the vertical gap G 1 ′ adjacent the score line  12  is greater than the thickness t of the plate (i.e., greater than about 0.01 inch (0.24 mm)) and, more preferably, is at least twice the thickness of the plate (i.e., at least about 0.02 inch (0.5 mm)). Moreover, in the loose fold circumferential portion, preferably, the width W 2 ′ of the vertical gap G 2 ′ is more than two times the thickness t of the plate (i.e., more than about 0.02 inch (0.5 mm)) and, more preferably, is at least three times the thickness of the plate (ie., at least about 0.03 inch (0.75 mm)).  
         [0037]    Similarly, the rim folds  115  and  123  around the portion of the circumference in which the central panel folds are tight are also tight, as shown in the left hand portion of FIG. 13, with the vertical gap G 3 , by which the lower surface of the bend  129  of the upper rim fold  115  is displaced above the upper surface of the lower portion of the rim  110 , having a width in the vicinity of the score line  112  that is preferably less than the thickness t of the plate (i.e., less than about 0.01 inch (0.24 mm)), more preferably less than about one-half the thickness t of the plate (i.e., less than about 0.005 inch (0.12 mm)), and most preferably is zero, and the vertical gap G 4 , by which the lower surface of the upper portion of the rim is displaced above the upper surface of the bend in the lower rim fold  123 , having a maximum width that is preferably no more than about two times the thickness t of the plate (i.e., no more than about 0.02 inch (0.5 mm)).  
         [0038]    The rim folds  115 ′ and  123 ′ around the circumferential portion in which the central panel folds are loose are also loose. Specifically, the width W 3 ′ of the vertical gap G 3 ′ adjacent the score line  12  is greater than the thickness t of the plate (i.e., greater than about 0.01 inch (0.24 mm)) and, more preferably, is at least twice the thickness of the plate (i.e., at least about 0.02 inch (0.5 mm)). Moreover, in this portion, preferably, the width W 4 ′ of the vertical gap G 4 ′ is more than two times the thickness t of the plate (i.e., more than about 0.02 inch (0.5 mm)) and, more preferably, is at least three times the thickness of the plate (i.e., less than about 0.03 inch (0.75 mm)).  
         [0039]    As shown best in FIG. 14, as a result of the looseness of the portion  121 ′ of the fold in the central panel  108 , the deflection of the portion of the central panel adjacent the score line  112  as a result of the force applied by the nose  106  of the tab  104  when the tab is pulled is unimpeded by the bend  127  in the lower fold  117 ′, thereby minimizing the force required to shear the score line  112 . Further, as a result of the looseness of the portion  123 ′ of the fold in the rim portion  110 , bowing of the central panel adjacent the score line during tearing, as previously discussed, will not cause interference with the bend  129  in the upper rim fold  115 ′, thereby minimizing the force required to tear the score line  112 . Further still, loosening the folds tends to reduce the distance by which the bend  127  in the lower central panel fold  117  projects radially outward past the score line and tends to reduce the distance by which the bend  129  in the upper rim fold  115  projects radially inward past the score line, thereby reducing the likelihood that these bends will interfere with the opening process.  
         [0040]    The tight fold circumferential portion of the end shown in FIGS. 13 and 14 forms a major portion of the circumference in order to maximize protection from sharp edges, while the loose fold portion forms a minor portion of the circumference. Preferably, the minor, loose fold portion is formed in only those areas of the circumference in which tight folds interfere with the opening process, such as the lock out areas previously discussed. Most preferably, the loose fold portion is comprised of three portions. The first loose fold portion is in the vicinity of the nose  106  of the tab  104 —that is at the 12 o&#39;clock location. The second and third loose fold portions are formed on either side of the nose, preferably at about the 10:30 and 1:30 o&#39;clock positions corresponding to locations B in FIGS. 1 and 4 where the lock out situation previously discussed occurs. In order to prevent lockout and minimize the pop and tear values, yet retain as much as possible the optimal safety afforded by a tight fold, the loose fold portion at 12 o&#39;clock preferably extends over an arc centered about the axis of the tab and defined by any angle A that is between about 1° and 25°, more preferably between about 2° and 10°. The loose fold portions at 10:30 and 1:30 o&#39;clock preferably each extend over an arc centered about the axis of the tab and defined by any angle A that is between about 3° and 75°, more preferably between about 6° and 30°. Thus, in total, the loose fold portions at 10:30, 12 and 1:30 o&#39;clock encompass an arc of about 7° to 175°, more preferably about 14° to 70°. In one embodiment of the invention, the circumferential length of the loose fold portion at 12 o&#39;clock is about ¼ inch (6 mm) and the circumferential length of the loose fold portions at 10:30 and 1:30 o&#39;clock are each about ¾ inch (20 mm). However, smaller or larger loose fold portions  3 ′, or a greater number of loose fold portions, could also be utilized, if desired, in order to obtain an optimum balance of ease of opening and safety.  
         [0041]    Although as shown in FIGS. 9 and 10, locally loose folds are formed in both the rim portion and the central panel, if desired, the locally loose folds could be formed in only the rim portion or in only the central panel, leaving the entirety of the folds in the other portion of the end tight.  
         [0042]    The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.