Forging for High-Strength Metal Packaging

Method for manufacturing thin-walled aluminum bottle-shaped cans with small diameter and height, that prevents deformation and variation in shape during production. The key features are: 1) curved corner, inclined, and bent portions at the bottom end of the body to disperse vertical loads and prevent deformation. 2) Angle between common tangent and ground contact plane is 50-70 degrees, with included angles difference of 20-40 degrees. 3) Limiting height of lower end where common tangent intersects body surface. 4) Contacting lower end with retaining surface during processing to disperse loads. This allows thinning the can walls without buckling or deformation.

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A method for forming a curled portion at the open end of a metal bottle-shaped can with a cap, that maintains rigidity and strength even when the can wall is thin or the opening diameter is small. The curling process involves expanding the can wall outward and curving it downward, then curling the tip edge inward and abutting it against the curved wall. The angle between the curled portion and can axis is 20-30 degrees, and the tip edge abuts at 90 degrees. This prevents deformation under vertical loads. The curling process is done by expanding outward and pressing inward.

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A bottle-shaped can made of metal that can be resealed by screwing on a cap. The can has a unique nose shape that improves buckling resistance and allows thinning without deformation. The nose has a male screw portion, a bulge below it, and a straight portion. The bulge has a larger diameter than the straight portion. The straight portion has a recessed section with a symmetrical shape. The length of the nose between the shoulder and bulge is 1-7 mm. The outer diameter of the straight portion is 26-40 mm and thickness is 0.28-0.34 mm. The outer diameter of the bulge is smaller than the straight portion and larger than the concave section. The height of the S-shaped bead is 0.7-1.5 mm. This nose shape prevents buckling during capping due to the compressive loads.

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Apparatus and methods for forming container end closures that provide improved sealing. The methods involve using forming anvils with oblique inwardly angled edges to create bends in the container material at the corners. This allows the material to more easily fold over during sealing. The anvils are inserted into the container opening to form the end closure. Another method involves rotating a pressing device to contact the sub-panels at lower regions first, increasing the contact area as the rotation continues. This helps the material fold over during sealing. The container blanks have specific layouts of straight boundary lines and internal lines of weakness between them. This allows the container to be formed with improved sealing properties.

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Method for manufacturing thin-walled beverage cans that prevents deformation and damage when filled with contents. The method involves reshaping the bottom of the can body to improve strength and resistance to internal pressure, impact, and stacking forces. The bottom is reformed by reducing the inclination angle of the annular convex portion and forming a concave portion in the inner and outer peripheral regions. This remodeling improves strength against internal pressure and compression forces compared to the original bottom shape. The reforming is done after steps that soften the can body like inner coating and drying.

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One-piece tin can body that can withstand high pressures generated during sterilization of food products without deforming or leaking. The can body is formed by stamping and drawing metal to create a flat bottom section that doesn't return to its original position after pressure is released. This prevents projected contents when opening the can. The can is closed with a separate lid. The flat bottom allows sterilization at high pressures without deformation.

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Tool pack design for forming tall, thin-walled metal bottles with reduced defects and higher production speeds compared to conventional tool packs. The tool pack has a redraw die and two ironing dies in a 30 inch stroke bodymaker. The distances between the dies are optimized to consistently produce tall, thin-walled bottles at high speeds. This allows controlling the work done on the cup and avoiding excessive deformation. It reduces defects like tearing and splitting of the metal. The tool pack can make bottles with heights of 8.83-9.76 inches and wall thicknesses of 0.0083-0.0096 inches at 200-230 bottles/min.

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Bottle can design and manufacturing method to reduce weight and improve efficiency while preventing deformation and failure in can body, neck, and cap attachment steps. The can is formed by reducing the wall thickness near the bottom and gradually increasing to the cap. The wall thickness range is 0.115-0.135mm near the bottom and 0.215-0.220mm at the flange. The step between flange and wall is 0.110mm or less. This allows thinning the wall and bottom without buckling or failure. The reduced diameter cap area has a thickness of 0.325-0.355mm. This prevents deformation when attaching the cap. The thinner walls and flange allow efficient DI pressing and bottleneck forming without buckling or failure.

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Aluminum alloy plate for bottle caps that has high axial tension strength and prevents curl cracks during manufacturing. The plate composition is optimized with elements like Si, Fe, Cu, Mn, Mg to improve rigidity and reduce wrinkling during necking and curling operations. The plate is manufactured by cold rolling without intermediate annealing to further enhance strength. Controlling parameters like rolling temperatures and pressures during cold rolling also helps.

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Preforming tool and rewinding tool for producing metal sheet packaging, like aluminum cans, that improves the efficiency and quality of the preforming and rewinding steps in can manufacturing. The preforming tool has a matrix, clamp, and punch with specific shaped surfaces that provide controlled resistance during preforming to prevent material wrinkling and deformation. The rewinding tool has matrix and clamp surfaces with features that create resistance during scrolling to prevent material wrinkling and deformation. The devices for producing preforms and rewinding extrudates are mounted in machines for integrated preforming and rewinding operations.

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A method to improve the strength and prevent deformation of the bottom of thin-walled metal beverage cans. The method involves reshaping the bottom by remolding steps at various points during the manufacturing process. The remolding involves deforming the inner and outer peripheral regions of the annular convex portion at the bottom to reduce the inclination angle with respect to the can axis. This improves the strength against internal pressure and compressive forces. The remolding can be done between steps like coating, drying, and necking to take advantage of the softened metal from heating.

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A tool pack configuration for manufacturing long aluminum bottles with thin walls at high production rates. The tool pack consists of a redraw die, two ironing dies, and a body maker with a specific stroke length. The redraw die reduces the cup height and wall thickness. The first ironing die further thins the walls. The second ironing die reduces the walls further. The die positions are optimized to consistently mold long aluminum cups with thin walls for bottle-shaped containers. The specific die locations, stroke length, and reduction percentages are provided. This tool pack setup allows high-speed production of long aluminum bottles with thin walls for containers like tall metal cans or bottles.

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Tool pack design for forming tall, thin-walled metal bottles with reduced defects and consistent quality at high speeds. The tool pack has a redraw die and two ironing dies in a 30-inch stroke bodymaker. The redraw die forms the initial cup shape. The first ironing die reduces the sidewall thickness by 10-40%. The second ironing die further thins the sidewalls. Placing the dies at specific distances allows consistent tall, thin cups without overworking the material.

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Improved sealing and forming devices for metal container manufacturing that enhance container sealing and reduce weak lines in the container structure. The devices address issues with traditional container manufacturing processes that result in weak sealing areas and excessive line breaks. The improvements include: 1. Bumper forming device for forming end closures of partially formed containers that reinforces and curves the nib areas around the closure boundary. 2. Attachment forming device for forming attachments around boundary areas of partially formed containers that reinforces and curves the attachment areas. 3. Pressure device with angled surfaces for compressing sub-panels during container closure to prevent wrinkling and improve sealing. 4. Container segments and enclosures with optimized weakness line layouts to balance sealing performance and container integrity.

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A toolset for forming tall, narrow-necked metal bottles at high speeds using a 30 inch stroke body former. The toolset includes a re-embossing die followed by two ironing dies arranged with specific spacing. This configuration allows consistently forming thin-walled tall bottles with necks and heights exceeding conventional sets. The toolset enables thinner walls and taller bottles compared to standard tooling on 30 inch stroke machines, reducing deformation issues.

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A tool pack design for forming tall, thin-walled bottle-shaped metal containers at high speed with reduced defects compared to conventional tool packs. The tool pack has a redraw die followed by two ironing dies with specific stroke lengths and thickness reductions. The first ironing die reduces the sidewall thickness by 10-40% and the second ironing die reduces it by 38-44%. This controlled processing allows tall, thin-walled cups to be formed consistently and consistently for molding tall bottles. The tool pack is used in a 30-inch stroke body former to form cups with specific dimensions and thicknesses.

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Low-spread metal elongated bottles with reduced rejection rates during manufacturing. The bottles have a narrow neck and elongated body shape formed from sheet metal with a low spread between yield and ultimate tensile strengths. This allows higher plastic deformation during forming without defects compared to traditional wider spread metal. The low-spread metal provides better formability for the complex geometry of elongated bottles.

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A tool set and method for manufacturing tall, thin-walled metal bottle-shaped containers using high production speeds. The tool set has a body former with three matrices: a re-inlay matrix, a first stretching matrix, and a second stretching matrix. The method involves forcing the blank through these matrices in sequence to form the tall, thin-walled bottle shape. This set and method allow consistently forming tall, narrow containers with high production speeds without defects like tearing and excision due to overworking the material.

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Method to make aluminum bottles with integrated threads strong enough for screw closures using recycled aluminum alloy. The alloy composition is a mix of scrap aluminum alloys like 3104, 3004, 3003, 3103, 3013, and 3105 with pure aluminum like 1070. The scrap alloys are melted, cast, and formed into slabs which are cooled, punched, and impact extruded into bottles. Annealing and finishing steps are performed. The threads are formed by compressing inner and outer core pieces against the neck.

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Impact extrusion process to produce metal bottles with threaded necks using recycled aluminum alloys. The method involves molding recycled aluminum chips into metal bottle shapes using impact extrusion. The recycled aluminum alloy composition is specifically designed to have enough strength to form threaded necks during extrusion. The alloy contains a mix of recycled 3105 or 3104 aluminum and virgin 1070 aluminum. This allows forming threaded necks on the bottles without needing external threads or separate caps.

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