Patent Abstract:
An apparatus and method of forming a metallic cup that is subsequently reformed into a container body is provided. More specifically, the present invention relates to an apparatus and methods used to form a metallic cup with a reformed bottom having an inwardly oriented projection. The inwardly oriented projection reduces a height of the metallic cup but utilizes the same amount of metallic stock material as a taller cup with substantially the same diameter that does not have an inward projection. The inwardly oriented projection thus allows the use of a conventional bodymaker and other can manufacturing tools to convert the cup into a container body of a preferred size and shape.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 62/069,623 filed Oct. 28, 2014, which is incorporated herein in its entirety by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to the manufacturing of metallic cups from flat sheet material to form container bodies. More specifically, the present invention relates to methods and apparatus for forming metallic cups with reduced height and reformed bottoms having an inwardly oriented projection. The cups are subsequently formed into metallic container bodies, such as aerosol containers. 
       BACKGROUND 
       [0003]    Metallic containers offer distributors and consumers many benefits by providing optimal protection properties for products. For example, metallic containers prevent CO 2  migration and block UV radiation which can have a damaging effect on personal care, pharmaceutical, and food products and on other UV-sensitive formulations, negatively influencing the effectiveness of ingredients, as well as the fragrance, appearance, flavor, or color of the product. Metallic containers also offer an impermeable barrier to light, water vapor, oils and fats, oxygen and micro-organisms and keep the contents of the container fresh and protected from external influences, thereby guaranteeing a long shelf-life. 
         [0004]    The increased durability of metallic containers compared to glass containers reduces the number of containers damaged during processing and shipping, resulting in further savings. Additionally, metallic containers are lighter than glass containers of comparable size, resulting in energy savings during shipment. Further, metallic containers can be manufactured with high burst pressures which make them ideal and safe for use as containers holding products under pressure, such as aerosol containers. Finally, recycling metallic containers is generally easier than recycling glass and plastic containers because labels and other indicia are printed directly onto the metallic body of the container while glass and plastic containers typically have labels that must be separated during the recycling process. 
         [0005]    Metallic containers may include a container body that is formed in a draw and wall ironing (DWI) process separately from a can end. The manufacture of the DWI container body starts by forming a cup from a metallic stock material which is typically shipped and stored in large rolls. Referring to  FIG. 1 , which depicts the prior art process, a sheet  4  of metallic stock material is fed into a draw-redraw apparatus  2 . As shown in  FIG. 1A , a blank and draw die  6  cuts a blank  8  from the sheet  4 . The blank  8  can have any desired shape. The cut blank  8  is illustrated in  FIG. 1A  separate from apparatus  2  for clarity. The blank and draw die  6  then draws the blank  8  into a cup  9  with sidewalls  10  and a closed endwall  11  with a first diameter, as illustrated in  FIG. 1B . Referring now to  FIGS. 1C-1D , optionally a redraw die  12  redraws the cup  9  into a formed cup  13  with a closed endwall  14 . As will be appreciated by one of skill in the art, during a redraw operation, the direction of the sidewalls  15  of the cup  14  are reversed. Thus, the open end of the cup  13  faces a direction substantially opposite of the direction of the open end of cup  9 . The redraw operation also generally lengthens the sidewalls  15  compared to sidewalls  10  of cup  9 , reducing the diameter of the closed endwall  14 . Thus, the endwall  14  of the formed cup  13  has a second diameter that is less than the first diameter. The formed cup  13  is then ejected from the apparatus  2  and another portion of the sheet  4  is fed into the apparatus  2 , as illustrated in  FIG. 1E . In the prior art apparatus  2  illustrated in  FIG. 1 , the formed cup  13  has a cross-section with generally linear sidewalls  15 , as shown in  FIG. 1D . The closed endwall  14  is also generally linear. After forming the cup  13 , the apparatus  2  ejects the cup in a direction substantially perpendicular to the sheet  4  of stock material. The formed cup  13  is subsequently formed into a container body by a bodymaker by methods known to those of skill in the art. Generally, the size of the container body is directly related to the size of the blank  8  used to form the formed cup  13 , i.e., the larger the blank, the more material that is present to form the formed cup  13  and, subsequently, the container body. 
         [0006]    To form a taller or wider container body, such as an aerosol container, current manufacturing methods require a blank of a larger size resulting in a formed cup  13  with an increased height. For example, to form a taller or wider container body using the method and apparatus of  FIGS. 1A-1E , the height of the sidewall  15  of the formed cup  13  is increased. However, as the height of the formed cup increases, the bodymaker must use a longer punch stroke and longer stroke redraw carriage to form the formed cup  13  into the container body, reducing the speed and efficiency of the bodymaker. 
         [0007]    Accordingly, there is an unmet need for a method and apparatus of forming a cup from a blank with a larger size without increasing the height of the cup so that the cup can be reformed into a larger container body without reducing the speed and efficiency of a conventional bodymaker. Further, by utilizing conventional bodymaker tools, equipment costs can be reduced because new tooling is not required in the manufacturing plant. The present invention is particularly useful to manufacture metallic cups which can be utilized in a bodymaker to form aerosol containers. 
       SUMMARY OF THE INVENTION 
       [0008]    The present invention provides novel methods and apparatus for forming a cup with a reformed closed endwall having an inwardly oriented projection for the purpose of reducing the overall height of the cup. After the cup with the reformed closed endwall is formed, the cup may be formed into a container body of any size, shape, or type for any product. One aspect of the present invention is to provide a cup with a reformed closed endwall. The cup generally comprises, but is not limited to, an open end, a sidewall, a closed endwall, and an inwardly oriented protrusion formed in a portion of the closed endwall. In one embodiment of the present invention, the cup has a reduced height compared to a cup of a similar diameter formed from a blank of substantially the same size. 
         [0009]    Another aspect of the present invention is to provide a die center punch with a cavity. The die center punch is adapted to support a portion of an interior surface of a cup endwall as an inward projection is formed in the cup. 
         [0010]    Still another aspect of the present invention is a reform punch with an extension. The extension is adapted to apply pressure to a portion of an exterior surface of a cup endwall to form an inward projection in the cup. 
         [0011]    Another aspect of the present invention is a draw-redraw apparatus operable to form a cup with a reformed closed endwall and a reduced cup height. In one embodiment, the draw-redraw apparatus includes a die center punch, a reform punch, and a reform draw pad. The reform draw pad has a cavity therethrough that aligns with an extension of the reform punch. At least a portion of the extension passes at least partially through the cavity of the reform draw pad and applies a force to a predetermined portion of a bottom surface of the cup. A portion of the bottom of the cup is deformed into a cavity formed at the end of the die center punch, forming an inwardly oriented projection in the bottom of the cup. 
         [0012]    In accordance with one aspect of the present invention, a novel method of forming a metallic cup having a sidewall and a reformed bottom is provided. This includes, but is not limited to, a method generally comprising: (1) providing a sheet of stock metal material; (2) shearing the sheet of stock metal material with a tool to form a substantially circular blank with a predetermined size; (3) drawing the blank into a cup with a first diameter by pushing a peripheral edge of the blank downward with a first tool while supporting a center portion of the blank with a second tool, the cup including a closed endwall; (4) reforming the cup by applying pressure to a portion of the closed endwall of the cup to form an inwardly oriented protrusion, the protrusion reducing the interior volume of the cup; and (5) ejecting the metallic cup. In one embodiment, the method may further comprise redrawing the cup with a first diameter to form a cup with a second diameter that is less than the first diameter. 
         [0013]    In one embodiment, reforming the cup to form an inwardly oriented protrusion comprises utilizing a die center punch with a cavity formed therein. The inwardly oriented protrusion is formed at least partially within the cavity of the die center punch by applying pressure to an exterior surface of the cup endwall with a reform punch. In one embodiment, the reform punch includes an extension with a generally cylindrical shape. In another embodiment, the extension has a horizontal cross-sectional shape that substantially conforms to a horizontal cross-sectional shape of the cavity of the die center punch. 
         [0014]    In one embodiment, the inwardly oriented projection in the bottom portion of the cup formed by the extension of the reform punch has a generally cylindrical shape. In another embodiment, the inwardly oriented projection in the bottom portion of the cup has a shape that is not cylindrical. For example, in one embodiment, the reform punch is generally conically shaped. In yet another embodiment, the reform punch generally has the shape of a frustum. 
         [0015]    In one embodiment, reforming the cup to form the inwardly oriented protrusion decreases a height of the cup. A diameter of the cup with the inwardly oriented protrusion is substantially the same as the first diameter of the cup. In another embodiment, the diameter of the metallic cup with the protrusion is at least about 5% less than a diameter of cup of approximately the same height and formed from a blank of approximately the same diameter that does not have an inwardly oriented projection. In still another embodiment, the protrusion reduces the internal volume of the cup by at least about 10%. It will be appreciated that varying the dimensions of the protrusion change internal volume of a cup with a protrusion. Accordingly, in still another embodiment, a cup with a protrusion has an internal volume that is reduced by from about 15% to about 22% compared to the same cup without the protrusion. 
         [0016]    In another embodiment, reforming the cup comprises extending an unsupported portion of the closed endwall of the cup. In one embodiment, the second tool that supports the center portion of the blank comprises a reform draw pad with a cavity formed there-through. The reform draw pad is positioned between the reform punch and the die center punch. In one embodiment, the cavity is substantially centered on the reform draw pad. In another embodiment, the cavity of the reform draw pad has a generally circular shape. 
         [0017]    In one embodiment, the blank has a generally circular shape, but in another embodiment, the blank has a non-circular shape. In another embodiment, the blank has a shape resembling one of an oval, a square, a rectangle, a triangle, a circle, or any combination thereof. 
         [0018]    In one embodiment, the metallic cup has a generally cylindrical shape. In another embodiment, the metallic cup is not cylindrical. 
         [0019]    It is another aspect of the present invention to provide a method of forming a metallic cup with an inwardly oriented protrusion. The method generally comprises, but is not limited to: (1) drawing a substantially circular metallic blank into a cup with a first diameter by pushing a peripheral edge of the blank with a first tool while supporting a portion of the blank with a second tool, the cup including a closed endwall and a sidewall; (2) redrawing the cup to form a cup with a second diameter that is less than the first diameter; and (3) reforming the cup by applying pressure to a portion of the closed endwall to form a protrusion within an interior of the cup, the protrusion reducing a length of the cup sidewall. 
         [0020]    In one embodiment, reforming the cup to form the protrusion does not substantially change the second diameter of the cup. In another embodiment, reforming the cup comprises extending an unsupported portion of the closed endwall of the cup into a cavity of a die center punch positioned within the interior of the cup. In still another embodiment, a reform punch applies pressure to an unsupported bottom surface portion of the closed endwall of the cup during the reforming. In one embodiment, a reform draw pad is positioned between the reform punch and the closed endwall of the cup during the reforming. The reform draw pad includes a cavity to receive at least a portion of the punch. 
         [0021]    In accordance with another aspect of the present invention, an improved apparatus for forming a metallic cup having a conical shaped bottom portion with an inwardly extending projection from a cup with a substantially flat bottom portion is disclosed. The improvement generally comprises, but is not limited to: (1) providing a metallic cup with a substantially flat bottom portion and a sidewall; (2) a first tool to support an interior surface of the bottom portion of the metallic cup proximate to at least the sidewall; and (3) a second opposing tool to apply pressure to an exterior surface of the bottom portion of the metallic cup opposite of the first tool, the second tool comprising a projection which travels at least partially into a cavity formed in the first tool to form an inwardly oriented projection in the cup bottom portion. 
         [0022]    In one embodiment, the first tool comprises a die center punch with the cavity formed therein. In another embodiment, the second tool comprises a reform punch with an upwardly extending projection. 
         [0023]    In one embodiment, a reform draw pad with a substantially centered cavity is positioned between the first tool and the second tool as the inwardly oriented projection is formed. In another embodiment, the sidewall of the metallic cup is supported by a third tool as the inwardly oriented projection is formed. 
         [0024]    In one embodiment, the cavity of the reform draw pad has a shape that is generally round, oval, square, rectangular, triangular, or any combination thereof. In one embodiment, the extension of the reform punch has a shape that is generally spherical, conical, cylindrical, rectangular, triangular, a frustum, or any combination thereof. 
         [0025]    The above-described embodiments, objectives, and configurations are neither complete nor exhaustive. As will be appreciated, other embodiments of the invention are possible using, alone or in combination, one or more of the features set forth above or described in detail below. 
         [0026]    As will be appreciated by one of skill in the art, the method and apparatus of the current invention may be used to form cups of any material used to form metallic containers, including without limitation aluminum, tin, steel, and combinations thereof. Further, the method and apparatus of the current invention may be used to form cups that are subsequently formed into container bodies or vessels of any size and shape and for storing any type of product for any industry. Accordingly, cups formed by the method and apparatus of the present invention may be formed into containers or vessels used to store or contain liquids and gases of all types, including consumer products and beverages as well as industrial chemicals and products. 
         [0027]    The phrases “at least one,” “one or more,” and “and/or,” as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C,” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together. 
         [0028]    Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.” 
         [0029]    The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. 
         [0030]    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. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein. 
         [0031]    It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112(f). Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts and the equivalents thereof shall include all those described in the Summary of the Invention, Brief Description of the Drawings, Detailed Description, Abstract, and Claims themselves. 
         [0032]    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 and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements or components. 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 DRAWINGS 
         [0033]    The accompanying drawings, which are incorporated herein and constitute a part of the specification, illustrate embodiments of the invention and together with the Summary of the Invention given above and the Detailed Description of the drawings given below serve to explain the principles of these embodiments. In certain instances, details that are not necessary for an understanding of the disclosure 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. Additionally, it should be understood that the drawings are not necessarily to scale. 
           [0034]      FIGS. 1A-1E  depict a prior art method and apparatus used to form a metallic cup; 
           [0035]      FIGS. 2A-2F  depict a method and apparatus for forming a cup with an inwardly oriented projection in a closed endwall portion with a draw-redraw apparatus according to one embodiment of the present invention as well as a cup with an inward projected formed by the apparatus; and 
           [0036]      FIGS. 3A-3F  depict a method and apparatus for forming a cup with an inwardly oriented projection in a closed endwall portion with a draw-redraw apparatus according to another embodiment of the present invention as well as a cup with an inward projected formed by the apparatus. 
       
    
    
       [0037]    Similar components and/or features may have the same reference number. Components of the same type may be distinguished by a letter following the reference number. If only the reference number is used, the description is applicable to any one of the similar components having the same reference number. 
         [0038]    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]    
       
         
               
               
             
               
               
             
           
               
                   
               
               
                 Number 
                 Component 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 2 
                 Draw-redraw apparatus; 
               
               
                 4 
                 Sheet of metallic stock material 
               
               
                 6 
                 Blank and draw die 
               
               
                 8 
                 Blank 
               
               
                 9 
                 Cup 
               
               
                 10 
                 Sidewalls 
               
               
                 11 
                 Closed endwall 
               
               
                 12 
                 Redraw die 
               
               
                 13 
                 Formed cup 
               
               
                 14 
                 Closed endwall 
               
               
                 15 
                 Sidewall 
               
               
                 16 
                 Draw-redraw apparatus 
               
               
                 18 
                 Blanking die 
               
               
                 20 
                 Cut edge 
               
               
                 22 
                 Blank and draw die 
               
               
                 24 
                 Draw pressure pad 
               
               
                 26 
                 Redraw pressure pad 
               
               
                 28 
                 Redraw die 
               
               
                 29 
                 Void between blank and draw die and redraw die 
               
               
                 30 
                 Die center punch 
               
               
                 31 
                 Cavity of die center punch 
               
               
                 32 
                 Reform draw pad 
               
               
                 33 
                 Cavity of reform draw pad 
               
               
                 34 
                 Reform punch 
               
               
                 35 
                 Extension of reform punch 
               
               
                 36 
                 Leading surface of blank and draw die 
               
               
                 37 
                 Leading edge 
               
               
                 38 
                 Blank 
               
               
                 40 
                 Cup 
               
               
                 41 
                 Closed endwall 
               
               
                 42 
                 Redrawn cup 
               
               
                 43 
                 Sidewalls 
               
               
                 44 
                 Projection 
               
               
                 45 
                 Open end 
               
               
                 46 
                 Finished cup with reformed closed endwall 
               
               
                 48 
                 Diameter of blank 
               
               
                 50 
                 First sidewall height 
               
               
                 52 
                 First diameter of endwall 
               
               
                 54 
                 Second sidewall height 
               
               
                 56 
                 Second diameter of endwall 
               
               
                 58 
                 Third sidewall height 
               
               
                 60 
                 Third diameter of endwall 
               
               
                 62 
                 Projection height 
               
               
                 64 
                 Projection diameter 
               
               
                   
               
             
          
         
       
     
       DETAILED DESCRIPTION 
       [0039]    The present invention has significant benefits across a broad spectrum of endeavors. It is the Applicant&#39;s intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed. To acquaint persons skilled in the pertinent arts most closely related to the present invention, a preferred embodiment that illustrates the best mode now contemplated for putting the invention into practice is described herein by, and with reference to, the annexed drawings that form a part of the specification. The exemplary embodiment is described in detail without attempting to describe all of the various forms and modifications in which the invention might be embodied. As such, the embodiments described herein are illustrative, and as will become apparent to those skilled in the arts, may be modified in numerous ways within the scope and spirit of the invention. 
         [0040]    Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term by limited, by implication or otherwise, to that single meaning. 
         [0041]    Referring now to  FIGS. 2A-2F , a draw-redraw apparatus  16  with a novel die set of one embodiment of the present invention is provided. The apparatus  16  generally comprises a blank die  18  with a cut edge  20 , a blank and draw die  22 , a draw pressure pad  24 , a redraw pressure pad  26 , a redraw die  28 , a die center punch  30 , a reform draw pad  32 , and a reform punch  34 . The apparatus  16  is operable to form a plurality of cups from a sheet  4  of metallic stock material through a draw and wall ironing (DWI) process. Optionally, the apparatus  16  may redraw the cups. The finished cups  46  are formed from a blank  38  with an increased diameter  48  and have an inwardly oriented projection  44  in a closed endwall portion that reduces a height of the cup compared to cups formed from a similar sized blank using the prior art process illustrated in  FIG. 1 . Other forming operations may subsequently be used to form the cups into container bodies of any shape for any variety of products, including aerosol cans. 
         [0042]    As illustrated in  FIG. 2A , a sheet  4  of metallic stock material is fed into the apparatus  16 . The blank and draw die  22  is then moved in a first direction toward the blanking die  18  and the draw pressure pad  24  until a leading surface  36  of the blank and draw die  22  contacts and applies pressure to an upper surface of the sheet  4 . The sheet  4  is forced against the cut edge  20  of the blanking die  18 , as illustrated in  FIG. 2B . The sheet  4  is sheared to form a blank  38  of a predetermined size and shape. The blank  38  is also illustrated in  FIG. 2B  separated from the apparatus  16  for clarity. In one embodiment, the blank  38  has a generally circular shape with a predetermined diameter  48  of between about 5 inches and about 10 inches, and in some embodiments the diameter is more preferably between about 7 inches and about 8 inches. In other embodiments the blank diameter is between about 6.75 inches and about 8.25 inches to form smaller sized cups. However, it will be appreciated by those of skill in the art that the blank  38  can have any desired diameter depending upon the desired size of the finished container. Further, the blank may have any shape, including oval, square, rectangular, triangular, circular, and/or combinations thereof. 
         [0043]    In conjunction with the movement of the blank and draw die  22  and the draw pressure pad  24 , the redraw pressure pad  26  and the die center punch  30  are moved towards the redraw die  28 . The bottom surface of the blank  38  is then contacted with the redraw die  28 . The peripheral edge of the blank  38  is pushed in the first direction while a center portion of the blank is supported. The blank  38  is deformed, or drawn, under pressure and conforms to an interior surface of a hollow interior of the blank and draw die  22  forming a cup  40  with a predetermined, generally cylindrical shape. In an alternative embodiment a projection  44  may be formed in the cup at this stage or later as described below. The cup  40  generally includes an open end  45 , sidewalls  43  with a first height  50  and a closed endwall  41  with a first diameter  52 , as illustrated in  FIG. 2C . In one embodiment, the cup  40  has a generally cylindrical shape, although as will be appreciated by those of skill in the art, the cup  40  can have any desired shape, including a non-cylindrical shape. An exterior surface of the redraw die  28 , which comprises a smaller outer diameter than the internal diameter of the hollow interior of the blank and draw die  22 , is nested within the hollow interior of the blank and draw die  22 . As the blank  38  is deformed, the blank  38  transitions out of a space between the blank and draw die  22  and the draw pressure pad  24 . 
         [0044]    Referring now to  FIG. 2D , a portion of an upper surface of the cup  40  is contacted with the die center punch  30 . Optionally, the cup  40  may be reformed (or partially redrawn) to form a redrawn cup  42  as the die center punch  30  continues to move in the first direction, conforming a portion of the cup  40  to the interior shape of the redraw die  28  under pressure. As illustrated in  FIG. 2D , the material of the cup  40  is translated out from a space  29  between the blank and draw die  22  and the redraw die  28 . While the cup is redrawn, the cup  40  also transitions out of a space between the redraw pressure pad  26  and the redraw die  28 . The redrawn cup  42  in  FIG. 2D  has a closed endwall  41  with a second diameter  56  that is less than the endwall diameter  52  of the cup  40  shown in  FIG. 2C . In one embodiment, the redrawn cup  42  has a diameter of between about 2.5 inches and about 5.0 inches and in another embodiment between about 3.5 inches and about 4.25 inches. For smaller cups, the diameter of the redrawn cup is between about 2.75 inches and 3.50 inches. The redrawn cup  42  illustrated in  FIG. 2D  has sidewalls  43  with a height  54  that may be the same as, or different from, the height  50  of the sidewalls  43  of cup  40 . As will be appreciated by one of skill in the art, the cup  40  may be reformed any number of times, including zero times. Each time the cup is reformed, the diameter of the closed endwall is decrease by a predetermined amount. 
         [0045]    A closed endwall portion of the reformed redrawn cup  42  contacts the reform draw pad  32  and moves the reform draw pad  32  in the first direction toward the reform punch  34  as the die center punch  30  continues moving in the first direction forming the optional redrawn cup  42 . An extension  35  of the reform punch  34  aligns substantially concentrically with a cavity  33  formed through the reform draw pad  32 . In one embodiment, the extension  35  has a generally cylindrical shape with a tapered or rounded upper edge  37 . However, it will be appreciated by those of skill in the art that the extension  35  can have any desired shape. In one embodiment, the extension has a cross-section with a round shape, an oval shape, a square shape, a rectangular shape, a triangular shape, a frustum, and/or combinations thereof. The cavity  33  of the reform draw pad  32  has a shape adapted to at least partially receive the extension  35  of the reform punch  34 . In one embodiment, the cavity  33  has a generally circular shape with an interior diameter of between about 2.0 inches and about 2.75 inches, and more preferably between about 1.5 inches and about 3.0 inches, which is greater than an exterior diameter of the extension  35 . Thus, the interior diameter of the cavity  33  is between about 40% and about 75% of the diameter of the draw pad  32 , and in other embodiments between about 50% and about 65% of the diameter of the cavity  33 . As will be appreciated by those of skill in the art, the cavity  33  can have any desired shape adapted to at least partially receive the extension  35 . In one embodiment, the cavity  33  is substantially centered on the reform draw pad  32 . In another embodiment, the cavity has a shape that is different than the cross-sectional shape of the extension. 
         [0046]    Referring now to  FIG. 2E , as the die center punch  30  continues to move in the first direction to form the redrawn cup  42 , the reform draw pad  32  also continues to move in the first direction. The extension  35  of the reform punch  34  projects at least partially through the cavity  33  and contacts the closed endwall portion  41  of the redrawn cup  42 . The extension  35  applies force to the closed endwall  41  and reforms the closed endwall, displacing the closed endwall at least partially into a cavity  31  of the die center punch  30 . The cavity  31  is adapted to at least partially receive the extension  35  and a portion of the closed endwall of the redrawn cup  42 . In one embodiment, the cavity  31  has a generally cylindrical shape and is substantially concentrically aligned with the cavity  33  of the reform draw pad  32 . The cavity  31  has a diameter that is at least equal to the exterior diameter of the punch extension  35 . Thus, the extension  35  pushes against an unsupported portion of the closed endwall  41  of the cup  42 . As the extension  35  pushes against an exterior surface of the endwall, a portion of the interior surface of the closed endwall is supported. 
         [0047]    In one embodiment, the cavity  31  has an interior diameter that is at least equal to the interior diameter of the cavity  33  of the reform draw pad  32 . In one embodiment the cavity  31  has a diameter of between about 1.5 inches and about 3.0 inches, and alternatively between about 2.0 inches and about 2.75 inches. As the extension  35  applies force to the closed endwall portion of the redrawn cup  42 , the closed endwall portion of the redrawn cup  42  is reformed and an inwardly oriented projection  44  is formed in a portion of the closed endwall  41  of the finished cup  46 . Although the inwardly oriented projection  44  is illustrated being formed on a redrawn cup  42 , it will be appreciated that an inwardly oriented projection  44  can also be formed in a cup  40  that has not been reformed using the method and apparatus of the present invention. 
         [0048]    The finished cup  46  illustrated in  FIG. 2E  has a closed endwall  41  with a predetermined diameter  60  of between about 2.5 inches and about 5.0 inches and preferably between about 3.5 inches and about 4.25 inches. In one embodiment, the diameter  60  is substantially the same as the redrawn cup  42  diameter  56  illustrated in  FIG. 2D . The cup  46  has sidewalls  43  with a predetermined height  58  of between about 2.0 inches and about 5.0 inches and more preferably between about 2.5 inches and about 4.5 inches. The projection  44  has a predetermined height  62  of between about 0.25 inches and about 1.5 inches and more preferably between about 0.5 inches and about 1.25 inches. A diameter  64  of the projection  44  is between about 1.5 inches and about 3.0 inches. In a more preferred embodiment, the diameter is between about 2.0 inches and about 2.75 inches. The inwardly oriented projection  44  can have any desired size or shape. In one embodiment, the projection  44  has a cross-section of a truncated cone, or frustum, with a first diameter  64  proximate to the closed endwall surface  41  of the finished cup  46  that is greater than a second diameter at a top of the projection  44 . In another embodiment, the projection has a generally cylindrical shape with a substantially constant diameter. Thus, the volume of the cup  40  shown in  FIG. 2C  when compared to the cup  46  shown in  FIG. 2E  is reduced by between about 15% and about 50%. More preferably, the internal volume is reduced by between about 20% and about 45%. Of course, as will be appreciated, the size (or volume) of the projection  44  may be altered. Accordingly, the internal volume of the cup  46  may change. In one embodiment, the internal volume of cup  40  is reduced by between about 5% and about 15% when the projection  44  is formed to create cup  46 . In a more preferred embodiment, the internal volume of cup  46  is about 10% less than cup  40 . In another embodiment, the internal volume of cup  46  is at least 7% less than cup  40 . 
         [0049]    After forming the projection  44 , the tooling is separated and/or extracted, and the finished cup  46  with the reformed bottom is ejected as illustrated in  FIG. 2F . In one embodiment, the die center punch  30 , reform draw pad  32 , and the redraw pressure pad  26  each move in the second direction toward their starting positions illustrated in  FIG. 2A . As the reform draw pad  32  moves in the second direction, the finished cup  46  moves out of the redraw die  28  until the bottom surface of the finished cup  46  is substantially level with the upper surface of the blanking die  18 . The finished cup  46  is then ejected from the apparatus  16  and another portion of the sheet  4  of metallic stock material is fed into the apparatus  16 , as illustrated in  FIG. 2A . In one embodiment, the finished cup  46  is ejected laterally from the apparatus  16 . 
         [0050]    Referring now to  FIGS. 3A-3F , a draw-redraw apparatus  16 A according to another embodiment of the present invention is provided herein. Apparatus  16 A is used to form a finished cup  46  with an inwardly oriented projection  44  in a number of sequential steps in a manner similar to the method illustrated in  FIGS. 2A-2F . In apparatus  16 A, a reform punch  34 A is positioned further from the sheet  4  of metallic stock material with respect to the redraw die  28  compared to the position of the reform punch  34  of the embodiment of the present invention described in conjunction with  FIG. 2 . Thus, the optional redraw of the cup  40  to form the redrawn cup  42 , illustrated in  FIG. 3D , is substantially completed before the reform punch  34 A reforms the closed endwall portion of the redrawn cup  42 , illustrated in  FIG. 3E . In one embodiment, the reform punch  34 A has substantially the same size and shape as reform punch  34 A. 
         [0051]    Referring now to  FIG. 3A , a sheet  4  of metallic stock material is fed into the apparatus  16 A. A blank  38  with diameter  48  is sheared from the sheet  4  as illustrated in  FIG. 3B . The blank  38  illustrated in  FIG. 3B  may be the same as, or similar to, blank  38  illustrated in  FIG. 2B . Similarly, the diameter  48  may have the same, or similar, dimensions as discussed above in conjunction with  FIG. 2B . 
         [0052]    Referring now to  FIG. 3C , the apparatus  16 A forms the blank  38  into a cup  40  with a predetermined shape. The cup  40  may have the same shape, endwall diameter  52 , and sidewall height  50  as the cup  40  illustrated in  FIG. 2C . Optionally, the cup  40  is redrawn to form a redrawn cup  42 , as illustrated in  FIG. 3D . The redrawn cup  42  illustrated in  FIG. 3D  may have the same endwall diameter  56  as the redrawn cup  42  illustrated in  FIG. 2D . However, in this embodiment of the present invention, the sidewalls  43  are substantially completely re-drawn before the closed endwall  41  is reformed. Accordingly, the redrawn cup  42  illustrated in  FIG. 3D  has sidewalls with a generally linear cross-sectional height  54  which is distinct from the shape and size of the sidewalls of the cup  42  of the embodiment illustrated in  FIG. 2D . In one embodiment, the height  54  of cup  42  illustrated in  FIG. 3D  is between about 2.0 inches and about 4.5 inches. More preferably, the height  54  is between about 2.5 inches and about 3.75 inches. As will be appreciated by one of skill in the art, in one embodiment, the cup  42  shown in  FIG. 3D  may be ejected from the apparatus  16 A and used to form a container. Thus, in one embodiment, the cup  42  shown in  FIG. 3D  may be used to form a container with a predetermined shape and size without forming a projection in the closed end-wall of the cup. 
         [0053]    The closed endwall  41  of the redrawn cup  42  is reformed by the reform punch  34 A to form a finished cup  46  with a reformed closed endwall comprising an inwardly oriented projection  44 , as illustrated in  FIG. 3E . The height  58  of the cup  46  is less than the height  54  of cup  42  illustrated in  FIG. 3D  after forming the inwardly oriented projection  44 . Thus, the total internal volume, or the overflow volume, of cup  42  is reduced. More specifically, the volume of the cup  46  shown in  FIG. 3E  is reduced with respect to the volume of the cup  42  shown in  FIG. 3D  by between about 5% to about 40%. In a more preferred embodiment, the volume of cup  46  is between about 10% and about 30% less than the internal volume of cup  42  illustrated in  FIG. 3D . In another embodiment, the volume of cup  46  is between about 15% and about 21% less than the internal volume of cup  42  shown in  FIG. 3D . In a still more preferred embodiment, the cup  46  has a volume that is about 18% less than the volume of cup  42  of  FIG. 3D . As will be appreciated by one of skill in the art, changing the size or shape of the projection  44  changes the relative volumes of cups  42  and  46 . Thus, in still another embodiment of the present invention, the volume of cup  42  of  FIG. 3D  is reduced by at least 10% when the projection  44  is formed to make cup  46 . The cup  46  and projection  44  illustrated in  FIG. 3E  may generally have the same shape and dimensions as the cup  46  projection  44  illustrated and described in conjunction with  FIG. 2E , above. Thus, in one embodiment, the cup  46  has the same endwall diameter  60 , sidewall height  58 , projection diameter  64 , and projection height  62  as the cup  46  of the embodiment of the present invention illustrated in  FIG. 2E . 
         [0054]    Referring now to  FIG. 3F , the finished cup  46  is ejected from the apparatus  16 A. In one embodiment, the finished cup  46  is ejected laterally from the apparatus  16 . The finished cup  46  is subsequently formed into a container body by a bodymaker by any method known to those of skill in the art. 
         [0055]    In various embodiments, pneumatic compressed air or other means provides force to one or more of the tooling components of the draw-redraw apparatus  16  described herein. For example, in one embodiment, a tooling component, such as the redraw pressure pad  26  is provided with an “inner” air pressure which applies a clamping force as shown in  FIGS. 2B-2D and 3B-3D  and another tooling component, such as the draw pressure pad  24 , is supplied with an “outer” air pressure, which is illustrated as a clamp force in  FIGS. 2B and 3B . 
         [0056]    By reforming the closed endwall portion  41  of the finished cup  46  with the projection  44 , the height  58  of the finished cup  46  is decreased compared to the height of the cup  13  formed by the prior art method. Accordingly, existing tooling and bodymakers can be used to form cups  46  into container bodies that are larger. In this manner, container bodies with an increased height and/or an increased diameter can be formed. The finished cup  46  has a height  58  that is less than the height of the formed cup  13  formed using the prior art method and apparatus, although the diameter  48  of the blanks  8 ,  38  used to form cups  13 ,  46  are substantially equal. 
         [0057]    Further, reforming the closed endwall portion of the finished cup  46  enables a shorter bodymaker ram stroke and a shorter stroke redraw carriage to be used when forming the container body. Thus, the bodymaker can operate at a higher speed than is possible when forming a container body from a cup  13  without the reformed closed endwall having the inwardly oriented projection. As will be appreciated by one of skill in the art, the maximum amount that the diameter of a cup can be reduced by a bodymaker in a subsequent redraw step is known as a “draw ratio.” By forming an inwardly oriented projection  44  on a closed endwall portion of a finished cup  46  with a diameter corresponding to the draw ratio of a bodymaker, the amount of the material in the finished cup  46  can be increased while the height  58  of the finished cup  46  is shortened. Thus, the finished cup  46  can be formed into a container body by a conventional bodymaker. 
         [0058]    A further advantage of reforming the closed endwall portion  41  of the finished cup  46  is that the finished cup  46  of a predetermined blank size and maximum height may be formed with a smaller transverse dimension of a longitudinal cross section than would otherwise be possible. For example, a cylindrical cup with reformed closed endwall and specified maximum height may have a smaller diameter than a cylindrical cup of the same height made from a blank of the same size. In one embodiment of the present invention, the diameter  60  of a finished cup  46  with a cylindrical shape having a reformed closed endwall is approximately 5% less than that of a cylindrical cup  13  of the same height without an inwardly oriented projection  44 , although both cups  13 ,  46  are formed from substantially the same size blank  8 ,  38 . This reduction in the transverse dimension of the finished cup  46  facilitates the redraw operation in the bodymaker. The redraw operation in the bodymaker must reduce the internal diameter of the cylindrical cup to the diameter of the finished container body. Reduction of the cup diameter to the finished container body diameter is most reliably accomplished when the reduction in the diameter of the cup is small. If the attempted diameter reduction is too large, the redraw operation will fail by any of several means, including wrinkling or rupture of the cup material. In one embodiment, the reduction in diameter from cup diameter to container body diameter, as compared to the cup diameter, is limited to not more than 40%. In another embodiment, the reduction is limited to not more than 35%. 
         [0059]    The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limiting of the invention to the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments described and shown in the figures were chosen and described in order to best explain the principles of the invention, the practical application, and to enable those of ordinary skill in the art to understand the invention. 
         [0060]    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. 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. 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.

Technology Classification (CPC): 1