Manufacturing tool and method for producing push button container closures - Patents.com

Abstract

A tooling assembly and associated manufacturing method is provided for producing a push button container closure 10. The tooling assembly includes only one "all-in-one" press station 120 where all of the scorelines 30, 32, 34 are cut into the blank 50 that will be formed into the container closure 10. The profile and features of the container closure 10 are generally rotationally symmetric, with the exception of the scorelines 30, 32, 34, and therefore no orientation dimples or other features need to be formed in the blank 50 or used to maintain a precise rotational position of the blank 50 as it moves between the various press stations 70, 80, 100, 120 of the tooling assembly.

Description

[Technical field]

[0001] The present invention relates to manufacturing tooling and methods for forming container closures from sheet metal, and in particular to container closures used to enclose food or beverage containers that may be pressurized and that include features for relieving a pressure differential across the closure before the closure is removed to open the container. [Background technology]

[0002] A metallic container closure is a construct configured to enclose a substantially enclosed space defined by a container body. Several types of container closures for food and beverage applications are known and are widely used in the field, as described below.

[0003] In one embodiment, the container is a food container including a food can body and a food can container closure (or food can end). That is, the container body is a food can body, such as, but not limited to, a sardine can body. After the food can body is filled with food, the food can end is bonded to the food can body. The food can end includes an end panel and a tear panel, the tear panel being separated from the end panel by a substantially continuous score line that surrounds the entire tear panel. For example, the end panel is substantially a peripheral portion of the food can end and the tear panel is a large central portion thereof. A pull tab is bonded to the tear panel adjacent the score line. The pull tab is lifted to create an initial break at the score line and then the pull tab is pulled to separate the tear panel from the end panel.

[0004] In another embodiment, the container is a beverage container including a beverage can body and a beverage can container closure (or beverage can end). That is, the container body is a beverage can body, such as, but not limited to, a can body for carbonated beverages. The can end includes an end panel and a tear panel separated from a portion of the end panel by a score line. In such applications, a lift tab is coupled to the end panel adjacent the tear panel. When the lift tab is actuated, i.e., lifted, a portion of the lift tab engages the tear panel and moves the tear panel relative to the end panel. When the tear panel moves relative to the end panel, the tear panel and the end panel separate at the score line. The tear panel does not fall into the beverage can body, but rather bends toward the beverage can body such that a consumer can drink liquid through a container opening that appears as a result of moving the tear panel.

[0005] In a further aspect, the container may be a glass jar. The glass jar includes a base and an upwardly depending sidewall. A distal portion of the sidewall includes male threads. In this embodiment, the container closure is a twist lug, or "lid" as used herein. That is, by "lid" it is meant a closure configured to be removably coupled to a jar, the closure including a generally flat top and a depending sidewall having female threads. As is well known, food products stored in glass jars typically require some process retort (heating / cooling) to sterilize / cook the contents. In this process, the product is exposed to a vacuum during the cooling process. This vacuum exposes the underside of the closure of the lid to a negative pressure, which tends to make the closure difficult to open or twist off the jar. One solution to this problem is to provide a push button on the lid. That is, the push button is a type of tear panel that is lifted for access. Similar to the can end described above, the lid defines an end panel and a tear panel. The tear panel includes a raised portion that is a push button. Arcuate score lines further define the tear panel. When a user opens the bottle, the user engages the button and tears the tear panel at least along the score lines, allowing some ambient atmosphere to enter the enclosed space, thereby equalizing pressure across the closure and thus facilitating removal of the lid from the container.

[0006] In each of the container closures described above, the tear panel, and therefore the container opening, is at least partially defined by a scoreline. The scoreline is typically formed by a blade that engages the blank. The blade thins the metal at the scoreline. That is, in a tooling assembly, the upper tooling includes the blade and the lower tooling includes an anvil that opposes the blade. The metal blank is disposed between the upper and lower tooling. As the upper and lower toolings come together, the blade engages the top surface of the blank and deforms the metal. That is, the metal under the blade flows to either side of the blade in a cutting-like action, thereby forming a thin remainder (a cross-section through the thickness through the blank / closure, which is the scoreline).

[0007] In particular, in the design of container closures and / or lids having push button type tear panels, a relatively complex pattern of profile elements and score lines having different depths of cut into the material of the container closure may be collectively formed on the container closure to assist the push button in precisely and reliably applying force to the area of ​​the score line that is to be broken when opening of the lid is desired. For example, a main score line may be provided in one area, and one or more anti-fracture score lines may be provided to ensure that fracture of the container closure caused by application of force at the push button is limited to occurring at the main score line. The shape and profile of the push button itself may also be specifically configured to contribute to this function. Thus, forming this type of container closure from a sheet metal "blank" involved a multi-step process with multiple die sets and presses used to form all of these features into the container closure. For example, one press station may cut the ancillary scores into the container closure, and then another press station may cut the main scores into the container closure. As can be readily appreciated, the orientation and positioning of the container closure is important to maintain between these different press stations, as misalignment can result in push buttons and / or score lines that do not function as intended (and in some cases cannot hold the pressure differential necessary to seal and store the food or beverage product in a bottle-type container), adding significant cost and complexity to the container closure manufacturing process and equipment. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] US Patent Application Publication No. 2016 / 0376070 [Patent Document 2] US Patent Application Publication No. 2019 / 0256247 [Patent Document 3] US Patent Application Publication No. 2018 / 0339814 [Patent Document 4] US Patent Application Publication No. 2018 / 0071810 [Patent Document 5] US Patent Application Publication No. 2009 / 0293572 Summary of the Invention [Problem to be solved by the invention]

[0009] It would therefore be desirable to improve manufacturing tools and methods for container closures of this type, and more specifically, to provide tools and methods that can more efficiently create the various profile shapes, features, and scorelines desired in container closures as compared to conventional manufacturing processes. [Means for solving the problem]

[0010] These and other technical advantages are achieved by embodiments of the manufacturing methods and tools of the present invention. To this end, the manufacturing methods and tools of the present invention allow for the elimination of one or more manufacturing stations, thereby making the process of manufacturing container closures faster and more efficient. Similarly, the critical need to maintain shell alignment between press stations can be eliminated, thereby improving process reliability.

[0011] In a first set of embodiments, a method of manufacturing a push button container closure from a sheet of material is provided. The method includes providing a container closure blank including a generally planar central panel and sidewalls extending from a periphery of the central panel at a corner joint for processing in a series of press stations. A first press station deforms the central panel of the container closure to include a bubble that protrudes upwardly from a remainder of the central panel. A second press station further deforms the central panel at the bubble to form a central button and a recessed annular region surrounding the central button. The central button is positioned at a relative height below the corner joint of the container closure after the deformation step. A third press station deforms an outer region of the central panel located between the recessed annular region and the sidewall to reshape the central panel at the outer region, thereby moving the central button upwardly toward the height of the corner joint. The fourth press station cuts into a recessed annular area surrounding the central button to provide primary and secondary scores on the top surface of the container closure. All scores cut into the container closure are formed solely at the fourth press station in a single compression motion. A selected one of the primary scores cuts deeper into the material of the container closure than all the other scores, so that the central button can be pressed to sever the central panel at the selected one of the primary scores and release the pressure differential across the container closure.

[0012] In one embodiment, the fourth press station includes a second die tool having a plurality of cutting projections and a first die tool opposing the second die tool. The step of scoring using the fourth press station further includes simultaneously cutting a primary score and a secondary score into the top surface of the container closure by inserting the plurality of cutting projections into the container closure at the fourth press station as the first and second die tools move toward one another.

[0013] In another embodiment, the fourth press station includes a second die tool having a plurality of cutting projections and a first die tool opposing the second die tool, the first die tool having a raised anvil extending over an adjacent portion of the first die tool. The raised anvil is also aligned with a selected cutting projection on the second die tool configured to form a main score. The step of making a cut using the fourth press station further includes supporting an underside of the container closure with the raised anvil of the first die tool as the selected cutting projection of the second die tool is inserted into an upper surface of the container closure opposite the raised anvil, thereby generating a main score.

[0014] In a related embodiment, the first die tool of the fourth press station includes a flat support surface at all portions except adjacent the raised anvil. The step of cutting using the fourth press station then includes supporting the bottom surface of the container closure against the flat support surface of the first die tool as the cutting prongs of the second die tool are inserted into the top surface of the container closure to create the auxiliary score. The flat support surface of the first die tool is positioned 0.001 inches (about 25.4 μm) below the top of the raised anvil to define additional spacing between the first and second die tools when pressed together and to reduce the force applied to the container closure by the fourth press station at the location where the auxiliary score is cut into the top surface of the container closure.

[0015] In yet another embodiment, the step of making cuts using the fourth press station also includes cutting the top surface of the container closure with the major scores so that each of the major scores defines a curve including a concave nose portion including an apex extending toward the central button and a convex line portion extending from each end of the concave nose portion and each having an apex extending away from the central button.

[0016] In a further embodiment, the step of cutting using the fourth press station includes creating a primary score and a secondary score as the only main score on the container closure. The primary score is deeper into the top surface of the container closure than the secondary score and is also located between the center button and the secondary score. The secondary score thus functions as an anti-vandal score, with the primary score configured to cut to release a pressure differential across the container closure. The step of creating the primary score and the secondary score may further include cutting the top surface of the container closure such that about 0.001 inches (about 25.4 μm) of material thickness remains on the container closure below the primary score, and cutting the top surface of the container closure such that about 0.002 inches (about 50.8 μm) of material thickness remains on the container closure below the secondary score.

[0017] In one embodiment, the step of making the cut using the fourth press station includes cutting the top surface of the container closure with the auxiliary scores such that each of the auxiliary scores is defined by one or more of a circular line arc portion generally concentric with the central portion and a radial line portion extending toward and away from the center of the central button. In a related embodiment, the step of cutting the top surface of the container closure with the auxiliary scores further includes cutting at least three of the auxiliary scores to include both a circular line arc portion and a radial line portion to collectively define a circular trapezoid shape for the auxiliary scores. The circular trapezoid shape is continuous except where interrupted by the area of ​​the main score. The auxiliary scores generally surround the periphery of the central button and the main scores on the container closure such that a force applied to the central button is directed to be focused in a direction to cut the container closure with the main scores.

[0018] In another embodiment, the step of making cuts using the fourth press station further includes cutting the top surface of the container closure such that about 0.0045 inches (about 114.3 μm) of material thickness remains on the container closure below each auxiliary score.

[0019] In a further embodiment, the method also includes moving the container closure from the first press station to a second press station and then to a third press station and a fourth press station so that the steps of deforming and scoring the container closure can be performed sequentially. No orientation dimples or features are formed in the container closure to guide movement of the container closure between press stations because the angular orientation of the container closure does not need to be maintained because all of the primary and secondary scores are formed by the same fourth press station and all other press stations produce circumferentially symmetric deformations in the container closure.

[0020] In a second set of embodiments, a tooling assembly is provided for producing a push button container closure from a blank, the blank including a generally planar central panel and sidewalls extending from a periphery of the central panel at a corner juncture. The tooling assembly includes first, second, third, and fourth press stations. The first press station includes first and second die tools that press together to deform the central panel of the container closure to include a bubble that protrudes upwardly from a remainder of the central panel. The second press station includes first and second die tools that press together to further deform the central panel at the bubble to form a central button and a recessed annular region surrounding the central button. The central button is disposed at a relative height below the corner juncture after deformation by the second press station. The third press station includes first and second die tools that press together to deform an outer region of the central panel located between the recessed annular region and the sidewall, reshaping the central panel at the outer region, thereby moving the central button upwardly to approximate the height of the corner joint of the container closure. The fourth press station includes first and second die tools that press together to cut into the recessed annular region surrounding the central button to provide the primary and secondary scores on the top surface of the container closure. The second die tool includes a plurality of cutting protrusions that cut into the top surface to form the primary and secondary scores when the first and second die tools are pressed together. One of the cutting protrusions is larger in size than the remainder of the cutting protrusions to form a selected one of the primary scores that cuts deeper into the material of the container closure than all of the other scores. Thus, the central button can be pressed to cut the central panel at the selected one of the primary scores and release the pressure differential across the container closure. The fourth press station is advantageously configured to cut all of the scores into the container closure by using a single compression action only at the fourth press station, and to this end, the container closure is scored at only one of the press stations in the tooling assembly.

[0021] In one embodiment, the first and second die tools of the fourth press station are each hollow cylindrical dies defining annular surfaces that engage only the recessed annular region when the first and second die tools are pressed together to cut the container closure.

[0022] In another embodiment, the first die tool of the fourth press station further includes raised anvils extending over adjacent portions of the first die tool that are aligned with selected cutting protrusions on a second die tool of the fourth press station configured to form the main score. The raised anvils are positioned to support an underside of the container closure as selected cutting protrusions of the second die tool are inserted into an upper surface of the container closure opposite the raised anvils to create the main score.

[0023] In a related embodiment, the raised anvil includes a flat upper surface extending between curved sides that taper away from the flat upper surface. The flat upper surface is perfectly aligned with and follows a path defined by the cutting edges of selected cutting protrusions on the second die tool. In this regard, each flat upper surface of the raised anvil defines a width between the curved sides of about 0.005 inches (about 127 μm).

[0024] In another embodiment, each of the raised anvils and each of the selected cutting projections configured to form the primary scores follow a curvilinear path in plan view, the curvilinear path including a concave nose portion having an apex extending toward an axial center of the first and second die tools, and convex line portions extending from opposite ends of the concave nose portion, each having an apex extending away from the axial center of the first and second die tools.

[0025] In yet another embodiment, the second die tool of the fourth press station includes only two selected cutting protrusions and the first die tool of the fourth press station includes only two raised anvils. One of the selected cutting protrusions closer to the axial center of the second die tool is larger in size than the other of the selected cutting protrusions. In this manner, the larger selected cutting protrusion cuts a primary score having a greater depth than the secondary score cut into the top surface of the container closure by the other selected cutting protrusion (the smaller cutting protrusion). For example, when the first and second die tools of the fourth press station are pressed together, the larger of the selected cutting protrusions is spaced about 0.001 inches (about 25.4 μm) from one of the raised anvils, thereby leaving about 0.001 inches (about 25.4 μm) of material thickness in the container closure below the primary score. When the first and second die tools are pressed together, the other of the selected cutting projections is spaced about 0.002 inches (about 50.8 μm) from the other of the raised anvils, thereby leaving about 0.002 inches (about 50.8 μm) of material thickness in the container closure below the secondary scores, whereby the secondary scores are configured to function as anti-puncture scores and the primary scores are configured to be cut to release the pressure differential.

[0026] In a further embodiment, the first die tool of the fourth press station further includes a flat support surface at all portions except adjacent the raised anvil. The flat support surface is positioned to support the underside of the container closure when the cutting prongs of the second die tool are inserted into the upper surface of the container closure to create the auxiliary score. The flat support surface of the first die tool is positioned 0.001 inches (about 25.4 μm) below the flat upper surface of the raised anvil, thereby defining additional spacing between the first die tool and the second die tool when pressed together about the location where the auxiliary score will be formed in the container closure.

[0027] In one embodiment, each of the cutting projections configured to form the auxiliary scores follows a path defined in plan by one or more arcuate portions generally concentric with the axial center of the second die tool and radial portions extending toward and away from the axial center of the second die tool. At least three of the cutting projections forming the auxiliary scores have both circular line portions and radial portions, defining a circular trapezoid shape for these auxiliary scores. The circular trapezoid shape is continuous except where interrupted by the region of the cutting projections configured to form the main score. The first die tool of the fourth press station further includes a flat support surface spaced from the raised anvil, and when the first and second die tools are pressed together at the fourth press station, each of the cutting projections configured to form the auxiliary scores is spaced from the flat support surface by about 0.0045 inches (about 114.3 μm). This leaves about 0.0045 inches (about 114.3 μm) of material thickness in the container closure below each auxiliary score.

[0028] In these embodiments, none of the first, second, third, or fourth press stations form orientation features in the container closure because the angular orientation of the container closure can be changed (e.g., without adversely affecting the formation of desired features on the container closure) when moving between each press station.

[0029] It will be appreciated that the described embodiments of the manufacturing methods and tooling assemblies may be combined in any combination or sub-combination without departing from the scope of the invention. [Brief description of the drawings]

[0030] [Figure 1] FIG. 2 is a top front perspective view of one embodiment of a push button container closure produced using the manufacturing tool and method of the present invention. [Diagram 2] FIG. 2 is a top rear perspective view of the container closure of FIG. 1. [Figure 3A] A cross-sectional view of a container closure (specifically, a "blank" used to form the container closure) having a central panel in a generally flat initial configuration prior to processing at a first station of a manufacturing tool. [Figure 3B] FIG. 3B is a cross-sectional view of the container closure of FIG. 3A, showing a central bubble formed in the central panel after processing at the first station. [Figure 3C] FIG. 3C is a cross-sectional view of the container closure of FIG. 3B with a button formed where the central bubble was formed after processing at a second station of the production tool. [Figure 3D] FIG. 3D is a cross-sectional view of the container closure of FIG. 3C with an additional annular feature following processing at a third station of the manufacturing tool. [Figure 3E] FIG. 3E is a cross-sectional view of the container closure of FIG. 3D with several score lines added to the closure following processing at a fourth station of the production tool, where the container closure is in a finished state. [Figure 4] FIG. 3F is a top view of the container closure of FIG. 3E showing the various scorelines in further detail. [Figure 4A] 5 is a detailed top view of a scoreline formed on the container closure of FIG. 4. FIG. [Figure 5A] 3B (in progress) is a side cross-sectional view of a first station of a manufacturing apparatus operating on the container closure of FIG. 3A to produce the container closure of FIG. 3B (in progress). [Figure 5B] 3C is a cross-sectional side view of a second station of a manufacturing apparatus operating on the container closure of FIG. 3B to produce the (in-progress) container closure of FIG. 3C. [Figure 5C] 3C to produce the (in-progress) container closure of FIG. 3D. FIG. 3D is a cross-sectional side view of a third station of the manufacturing apparatus operating on the container closure of FIG. 3C to produce the (in-progress) container closure of FIG. 3D. [Figure 5D] 3E is a side cross-sectional view of a fourth station of the manufacturing apparatus operating on the container closure of FIG. 3D to produce the final shape of the container closure of FIG. 3E. [Figure 6]FIG. 5E is a detailed side view of a portion of the fourth station of the manufacturing tool of FIG. 5D illustrating additional features along this portion of the fourth station during manipulation of the container closure. [Figure 7] 5E is a detailed side view of another portion of the fourth station of the production tool of FIG. 5D, thereby illustrating additional features along this portion of the fourth station when manipulating the container closure. FIG. [Figure 8] FIG. 13 is a perspective view of upper and lower dies defining a fourth station production tool; [Figure 9] 1 is a schematic flow chart illustrating a method of forming a container closure from a blank using various press stations in a production tool in accordance with an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the general description of the invention given above and the detailed description given below, serve to explain the invention.

[0032] As summarized above, a tooling assembly and associated manufacturing method for producing push button container closures is provided to address several deficiencies in the art. Advantageously, the tooling assembly includes only one "all in one" press station where all score lines are cut into the blank to be formed into the container closure. Furthermore, the profile and features of the container closure are generally rotationally symmetric, except for the score lines, and thus no orientation dimples or other features need to be formed into the blank or used to maintain a precise rotational position of the blank as it moves between the various press stations of the tooling assembly. As a result, the manufacturing tool itself is easier to use and more efficient, since at least one press / cut station and orientation device of conventional tooling designs are no longer necessary in the process. Further technical advantages will become apparent from the further detailed description of the tooling assembly and method provided below.

[0033] Before describing the tooling assembly and its operation in detail, reference is made to Figures 1, 2, 4 and 4A. Each of these figures shows a different view of one embodiment of a push button container closure (also referred to in the art as a "lid") that can be formed using the tooling assembly and method of the present invention. It is understood that design variations are possible from this container closure shown, as this is only one exemplary embodiment to illustrate the functionality achieved. The container closure 10 shown in these figures includes a generally flat body or central panel 12 having a product side 14 facing downward in these figures and a customer side 16 (as referenced when the container closure 10 is used) facing upward in these figures. The container closure 10 is configured to be removably coupled to a container (not shown), such as a bottle. The container closure 10 further includes a sidewall 18 extending in one direction from a periphery 20 of the central panel 12, which typically includes an internal thread (not shown). The container closure 10 thereby defines a corner joint 22 connecting the annular side wall 18 to the central panel 12 .

[0034] A bottle for engaging such a container closure 10 includes a top opening having an exterior thread. The interior thread thus engages with the exterior thread of the bottle to couple the container closure 10 to the container / bottle in use, thereby forming a sealed space within the bottle. As is well known, and as first described in the Background section above, a product placed in an enclosed space may be heated, for example, for sterilization. As the bottle cools, a vacuum or partial vacuum is created within the bottle. The vacuum or partial vacuum further pulls the container closure 10 into engagement with the top of the bottle. In order to loosen the container closure 10 for removal, the user must overcome this bias, or remove or reduce the bias. It is therefore desirable to configure the container closure 10 to selectively admit ambient atmosphere into the bottle to release the vacuum and facilitate removal of the container closure 10. In this embodiment, the container closure 10 includes one or more scores (also known as score lines) cut into its top surface (customer side 16) to provide such functionality.

[0035] The scorelines may be defined by shifted material scorelines and / or conventional scorelines, in either case being areas of the container closure 10 where the body has been thinned by cutting into at least one surface of the container closure 10. It is understood that when sufficient force or pressure is applied to the scorelines, the body will separate at the scorelines, thereby forming an opening. Thus, the container closure 10 includes "end panels" and "tear panels" that separate along the openings, consistent with the previously described known types of container closures. The openings formed in this exemplary embodiment are merely limited openings that allow atmospheric pressure to remove the vacuum or pressure differential defined across the two sides 14, 16 of the container closure 10; e.g., large openings are not created by cutting along the scorelines.

[0036] In this exemplary embodiment of the container closure 10, a plurality of scorelines are disposed about a central button 24 located at the axial center of the central panel 12. The central button 24 is surrounded by a recessed annular area 26 formed in the central panel 12, and the scorelines are all located in this recessed annular area 26 to collectively define a force concentrating structure that assists in direct forces applied to the central button 24 being specifically applied to assist in shearing open the container closure 10 along the primary main scores 30. In addition to the primary main scores 30, the container closure 10 includes secondary main scores 32 that serve the purpose of anti-puncture scoring, as further described below. The plurality of scorelines also includes a plurality of secondary scores 34 disposed about the primary scores 30, 32. Details of the scores 30, 32, 34 are most clearly shown in FIG. 4A and will now be described.

[0037] Many of the auxiliary scores 34 are defined by arcuate portions 34a and radial portions 34b that collectively combine to form one or more circular trapezoidal shapes around the circumference of the central button 24. In the illustrated embodiment, each circular trapezoidal shape extends over an arc of slightly less than 120 degrees as a result of the circular trapezoidal shapes being spaced apart from one another along the radial portions 34b. One of the circular trapezoidal shapes defines a completely continuous perimeter, while the other two circular trapezoidal shapes are broken perimeters as a result of interruptions by the areas where the primary scores 30, 32 are located. The small size of the gap between the circular trapezoidal shapes of the auxiliary scores 34 and the nearly complete perimeter coverage around the central button 24, excluding the primary scores 30, 32, collectively contribute to directing or concentrating the application of forces to the button 24 that are primarily applied to the areas where the primary scores 30, 32 are located (and the remaining unbroken material "links" between the circular trapezoidal shapes). Although this example includes three circular trapezoidal shapes, in other embodiments of the container closure 10, four, five, or more circular trapezoidal shapes may be defined by the auxiliary scores 34, and such force concentrating functionality is similar in these alternative embodiments. Each of the circular trapezoidal shapes further includes an inner scoreline 36 formed within a perimeter defined by the arcuate portion 34a and the radial portion 34b, which are specifically arcuate portions in the illustrated embodiment.

[0038] Returning to the primary scores 30, 32, each of them defines a generally linear curve. To this end, the primary primary score 30 is shown in these figures to include a first convex line portion 40, a generally arcuate or concave nose portion 42, and a second convex line portion 44 at an opposite end of the nose portion 42 from the first. The nose portion 42 thus extends between and is continuous with the first and second convex line portions 40, 44. The concave nose portion 42 defines an apex that points directly toward the central button 24, thereby allowing the primary primary score 30 to focus forces applied from the central button 24 to the nose portion 42, and particularly to the apex. The force focusing design advantageously allows the primary primary score 30 to shear or break with a lower application of force than any alternative score that does not have force focusing shapes and features. It will be appreciated that breakage generally occurs first along the apex of nose portion 42, and thus this is also the location where atmosphere escapes through container closure 10 upon actuation. Each of first and second convex line portions 40, 44 also includes an apex that extends generally away from central button 24. Primary main score 30 traverses the two interrupted circular trapezoid shaped paths of secondary score 34 generally along first and second convex line portions 40, 44, which are each disposed within corresponding perimeters of the at least partially circular trapezoid shapes.

[0039] In the exemplary embodiment, the secondary major scores 32 define a similar shape of a generally linear curve that follows a parallel path along the primary major scores 30. As discussed above, the secondary major scores 32 function as puncture prevention scores as a result of being located adjacent to the primary major scores 30 and as a result of the primary major scores 30 cutting deeper into the material of the container closure 10. The provision of the secondary major scores 32 ensures that forces applied in this area and transmitted from the central button 24 remain primarily applied to the primary major scores 30 until the shear opening occurs, e.g., by preventing the forces from being transmitted beyond the primary major scores 30 and causing unpredictable breakage or damage elsewhere in the container closure 10. Thus, without detailed description or numbering, the secondary major scores 32 are understood to include the same features of the first and second convex line portions and the concave nose portion therebetween. It will also be understood that more than one puncture prevention score may be provided in other embodiments without departing from the scope of the present invention.

[0040] Each of the scores 30, 32, 34 depicted in this pattern on the container closure 10 has a residual. As is known, as used herein, a "residual" is the thickness of material remaining under a score after a scoring / cutting operation. The primary main scores 30 always have the smallest residual so that an opening or shear occurs, the secondary main scores 32 have a larger residual, and each of the secondary scores 34 have an even larger residual than the secondary main scores 32. In the exemplary embodiment shown here, the top surface 16 of the container closure 10 is cut so that the residual under the primary main scores 30 is about 0.001 inches (about 25.4 μm) of material, the residual under the secondary main scores 32 is about 0.002 inches (about 50.8 μm) of material, and the residual under each secondary score 34 is about 0.0045 inches (about 114.3 μm) of material. It will be understood that the remaining remnants of material may vary, such as ±0.0002 inches (about 5.1 μm) for the major scores 30, 32 and ±0.001 inches (about 25.4 μm) for each of the auxiliary scores 34, and that the sizes of the remnants may vary so long as the size relationships therebetween remain similar to those in this exemplary embodiment. In summary, the set of scores and profile features on the container closure 10 constitute the same for use on a bottle-like container capable of holding vacuum pressure as described above.

[0041] 3A-3E, a series of cross-sectional views taken from the side of the container closure 10 are shown in detail, specifically illustrating the progression from a blank 50 partially defined by a sheet of material at the start of the manufacturing process in FIG. 3A to the final container closure 10 as detailed in the exemplary embodiment above. FIG. 3A shows the blank 50 as initially provided, prior to modification by a series of press stations, further described below. In this state, the blank 50 already has formed thereon a sidewall 18 that projects downwardly from a corner joint 22 defined along the periphery 20 of the generally planar central panel 12. Although not shown in detail, the sidewall 18 may also already include any internal threads (not shown) that engage with external threads on the bottle / container, as well as a terminal edge curl 54 to avoid a sharp leading edge on the container closure 10, and further, a sealing gasket material 52 may also already be disposed along the underside or product side 14 of the central panel 12 adjacent the corner joint 22 (e.g., where the product side 14 of the container closure 10 engages the top or rim of a bottle). It will be understood that such features may alternatively be provided in a different order in other embodiments, and that such manufacturing process steps are not the focus of the present invention. Instead, the manufacturing methods and steps of interest are those that act on the central panel 12 to create the central button 24 and the plurality of scores 30, 32, 34 that enable the container closure 10 to function to hold and then release a pressure differential across the sides of the container closure 10 when in use on a bottle / container.

[0042] In a first process step, the first press station deforms the blank 50 along the central panel 12, which is generally flat prior to deformation, as shown in FIG. 3A. More specifically, the central panel 12 is deformed along its center (e.g., about an axial center indicated in these figures by axis 56) to produce a rounded bubble 58 that protrudes upwardly from the remaining portion of the central panel 12, which is annular in shape and remains generally flat, as shown in FIG. 3B. The bubble 58 protrudes at a height or relative height above the corner joints 22, even though the majority of the central panel 12 on the blank 50 was initially disposed below the relative heights of the perimeter 20 and corner joints 22. Thus, in the first process step, the material of the central panel 12 is generally deformed or pressed upwardly toward the top or customer side 16.

[0043] In a second process step, the second press station further deforms the blank 50 of FIG. 3B to form the central button 24. In this regard, further deformation occurs in and around the region of the bubble 58, which produces the central button 24 surrounded by the recessed annular region 26, as shown most clearly in FIG. 3C. The central button 24, as shown in FIG. 3C and the above detailed view of the container closure 10, is circular and generally flat in shape, with the vertical relative height of the central button 24 being less than the height of the corner joints 22 along the periphery 20 and generally matching the relative height of the remainder of the central panel 12 located radially outward or outboard of the recessed annular region 26. Thus, in this second process step, the material of the central panel 12 is generally deformed and pressed downwardly toward the underside or product side 14. The recessed annular region 26 is further reduced in relative height compared to the central button 24 so that the central button 24 extends upwardly to be pressed by a consumer or user when the container closure 10 is completed and placed on a bottle or similar container. The recessed annular region 26 is also generally flat along its annular shape following this further deformation. As also shown in FIG. 3C, this deformation step results in a sloped profile or step 62 formed connecting the central button 24 to the inside of the recessed annular region 26 and connecting the outside of the recessed annular region 26 to the remainder of the central panel 12, hereafter referred to as the outer region 60 of the central panel 12. Both steps 62 at this point in the manufacturing process define a relatively gradual slope transitioning between the connected elements, meaning that the transition is not provided as a vertical or near-vertical wall portion within the container closure 10.

[0044] In a third process step, a third press station deforms the outer region 60 of the central panel 12 to reshape it so that it includes an inclined profile rather than simply being a flat sheet of material. To this end, the material of the central panel 12 is again deformed or pressed upwards in this third process step towards the upper or customer side 16, whereby a portion of the outer region 60 and the central button 24 move upwards in relative height to a point that is substantially flush with the corner joint 22 at the top of the sidewall 18, as shown most clearly in FIG. 3D. Thus, the step 62 located between the outer region 60 and the recessed annular region 26 becomes somewhat sharper, e.g., steeper, as a result of this deformation, although the step 62 is still not substantially close to vertical. Similarly, a V-shaped dip profile 64 is formed along an outer portion of the outer region 60 adjacent the periphery 20 connected to the corner joint 22. Nonetheless, recessed annular region 26 is now offset from the peripheral portion of center panel 12 to help concentrate the force applied to center button 24 at the score line as previously described when container closure 10 is in use. Up to this point in the manufacturing process, all of the features added to blank 50 have been circumferentially symmetric, which means that precise rotational orientation and alignment of blank 50 does not need to be maintained as it moves between press stations.

[0045] In a fourth process step, a fourth press station scores the recessed annular region 26 of the blank 50 to complete the formation of the final container closure 10, as seen in FIG. 3E. The cross-sectional view of FIG. 3E illustrates the apexes of the primary main scores 30 and secondary main scores 32 along one side of the central button 24, and several auxiliary scores 34 along the opposite side of the central button 24. The shape and profile of the central panel 12 is not significantly altered by the fourth press station, as this "all-in-one" station is specifically configured to function in a single compression motion primarily with respect to providing all of the scores that are cut into the container closure 10. After the scores are scored, the container closure 10 is in its final form, ready to be deployed and used with a bottle-like container. Again, since there is no further press station after the cut made in the fourth process step, there is no need for orientation maintenance, which advantageously simplifies the manufacturing tooling as well as the process required to form the container closure 10 as shown from the blank 50.

[0046] 5A-5D, the various press stations described above as part of a tooling assembly for manufacturing a push button container closure 10 are shown in further detail and in operation. It will be understood that these cross-sectional views are schematic and in some places simplified from the actual apparatus used to clearly illustrate the operation and its critical portions. Beginning with FIG. 5A, a first press station 70 of the manufacturing tool is shown in this view to include a first die tool 72 on its upper side and an opposing second die tool 74 on its lower side. The blank 50 of FIG. 3A is loaded into the first press station 70 in an upside-down orientation from that previously shown, e.g., with the product side 14 facing the first die tool 72. Because this portion of the blank 50 is not actively deformed or pressed by the first press station 70, the first die tool 72 may include a recess for receiving the sidewall 18 as shown. It will be appreciated that in other embodiments, the orientation of the first and second die tools 72, 74 may be reversed.

[0047] FIG. 5A illustrates the operation of the first press station 70 to deform the central panel 12 of the blank 50. For this purpose, the first die tool 72 is moved along the direction of the arrow 76 in FIG. 5A to engage the center of the central panel 12. The central portion 78 of the first die tool 72 has a rounded shape configured to form the bubble 58, and the opposite portion of the second die tool 74 is open so that the first die tool 72 can force the material of the central panel 12 into this opening of the second die tool 74 when it is brought against the other portion of the central panel 12 clamped between the two substantially flat opposing portions of the first die tool 72 and the second die tool 72, 74. Thus, as can be seen from this view of FIG. 5A, the blank 50 changes from the first state described above with respect to FIG. 3A to the second state shown in FIG. 3B (also generally shown in FIG. 5A). The first and second die tools 72, 74 are then moved away from one another, releasing the blank 50 for movement to a second press station.

[0048] FIG. 5B shows the second press station 80 of the tooling assembly in operation. The blank 50 from the first press station 70, including the bubble 58, has been loaded into the second press station 80 between a first die tool 82 on its upper side and a second die tool 84 on its lower side. In this view, the product side 14 of the blank 50 is again facing upwards, so the first die tool 82 again includes an annular recess sized to receive the sidewall 18 that will not be deformed or otherwise acted upon at the second press station 80. Insertion of the sidewall 18 into the recess can ensure proper alignment of the blank 50, although it will be understood that the rotational direction is not critical in view of the circumferential symmetry of the blank 50 at this step in the manufacturing process.

[0049] FIG. 5B illustrates the operation of the second press station 80 to further deform the central panel 12 of the blank 50. To this end, the first and second die tools 82, 84 are moved along the direction of the arrows 86 in FIG. 5B to engage the central panel 12 located therebetween. The first and second die tools 82, 84 again clamp the outermost portion of the central panel 12 (e.g., the portion that will later define the outer region 60) between their outer portions. The central portion of the first die tool 82 has an inner die piece 88 with a generally flat end for engaging the bubble 58 to form the central button 24, and also has an outer die piece 90. The outer die piece 90 clamps against a similar outer die piece 92 of the second die tool 84 to deform the central panel 12 to form a recessed annular region 26 that is generally flat and surrounds the central button 24. An opening is provided inside the outer die piece 92 of the second die tool 84, thereby allowing the end of the inner die piece 88 of the first die tool 82 to push the material of the central panel 12 into the opening at the bubble 58 and lift the central button 24 that has been formed "above" the recessed annular region 26. Thus, as can be seen from this view of Figure 5B, the blank 50 changes from the condition described above with respect to Figure 3B to the condition shown in Figure 3C (also generally shown in Figure 5B). The first and second die tools 82, 84 are then moved away from one another to release the blank 50 for movement to the third press station.

[0050] 5C shows the third press station 100 of the tooling assembly in operation. The blank 50 from the second press station 80, including the central button 24 and recessed annular area 26, has been loaded into the third press station 100 between a first die tool 102 on its upper side and a second die tool 104 on its lower side. In this view, the product side 14 of the blank 50 again faces upward, so the first die tool 102 again includes an annular recess sized to receive the sidewall 18 that will not be deformed or otherwise acted upon at the third press station 100. Again, the direction of rotation is not important given the circumferential symmetry of the blank 50 at this step in the manufacturing process.

[0051] 5C illustrates the operation of the third press station 100 to deform the central panel 12 of the blank 50, particularly along the outer region 60 located between the previously formed recessed annular region 26 and the corner joint 22 of the periphery 20 of the central panel 12. The interior of the first die tool 102 and the interior of the second die tool 104 are essentially identical to those elements in the die tools of the second press station 80, which when the first and second die tools 102, 104 are brought together as indicated by arrow 106, effectively just clamp the central button 24 and recessed annular region 26 in place while the outer region 60 is being actively formed by deformation. For this purpose, the first die tool 102 includes outer (from annular shape) press elements 108 located just outside the location of the recessed annular region 26, and the second die tool 104 includes recesses 110 opposite these press elements 108, allowing deformation and movement of the outer region 60 relative to the recessed annular region 26 and the corner joint 22. The recesses 110 are defined on the inside by the interior of the second die tool 104 described above, and on the outside by press projections 112 configured to add a V-shaped dip profile 64 to the region adjacent the periphery 20 of the central panel 12. The action of the various press elements 108 and press projections 112 when the first and second die tools 102, 104 are brought together is to deform the outer region 60, including sharpening the angle of the step 62 between the outer region 60 and the recessed annular region 26, and raising the relative height of the outer region 60 (and also the central button 24) so ​​that it is again approximately flush with the periphery 20 and the corner joints 22. Thus, as can be seen from this view of FIG. 5C, the blank 50 changes from the condition described above with respect to FIG. 3C to the condition shown in FIG. 3D (and also generally shown in FIG. 5C). The first and second die tools 102, 104 are then moved away from each other, releasing the blank 50 for movement to the fourth press station. As noted above, no orientation dimples or other rotational orientation maintaining steps need be performed for this movement to the next station.

[0052] 5D, which illustrates the fourth press station 120 of the tooling assembly in operation. Additional views of certain portions of the fourth press station 120 and portions of the first and second die tools 122, 124 are illustrated in Figures 6-8. This "all-in-one" cutting station advantageously cuts all of the scores into the blank 50 simultaneously and in a single compression motion (indicated diagrammatically by arrow 126) to complete the production of the container closure 10. The first and second die tools 122, 124 include some similar elements and profiles as the tools in the third press station 100, for example the first die tool 122 still includes an annular recess sized to receive the sidewall 18 that will not be deformed or otherwise acted upon in the fourth press station 120, and the second die tool 124 again includes the recess 110 and press projection 112, but these elements are used only to support the outer region 60 of the blank 50 rather than to impart further deformation thereto (the corresponding press portion having been removed from the first die tool 122 in this case). The direction of rotation is not important given the circumferential symmetry of the blank 50 at the start of this step in the manufacturing process.

[0053] The primary working portions of the first and second die tools 122, 124 are configured to engage and cut the blank 50 along the recessed annular region 26 of the blank 50. To help further illustrate this cutting action and the relatively small features which give rise to it, enlarged detailed views of the primary working portions of the first and second die tools 122, 124 are provided in Figs. 6 and 7 to illustrate the cutting action performed against the recessed annular region. Additionally, a perspective view of the hollow cylindrical die which defines the primary working portions of the first and second die tools 122, 124 is shown in Fig. 8. To this end, the first die tool 122 (which is shown above in Figs. 5D-7 but below in the view of Fig. 8) includes a first hollow cylindrical die 128 including a raised anvil 130 located at the location where the primary scores 30, 32 will be generated in the container closure 10, and also includes a flat support surface 132 in all areas except the area immediately adjacent and surrounding the raised anvil 130. The second die tool 124 includes a second hollow cylindrical die 134 (shown at the top of FIG. 8) that defines a generally flat end surface 136 and has a plurality of cutting projections 138 extending outwardly therefrom. From the perspective view of the cutting projections 138 in FIG. 8, it can be readily seen that the cutting projections 138 are of the same configuration as all of the scores that are cut into the container closure 10; for example, the appearance of the second hollow cylindrical die 134 is similar to the score pattern previously shown in FIGS. 4 and 4A. The opposing flat support surface 132 and flat end surface 136 are annular as a result of the hollow cylindrical shapes of the first and second dies 128, 134. FIG. 5D also shows that the first die tool 122 can include a similar central support die 144 for engaging and supporting the blank 50 at the central button 24 during the cutting operation, which central support die 144 is located within the central opening defined by the first hollow cylindrical die 128, although it is understood that such a central support die 144 may be omitted in other embodiments.

[0054] In the exemplary embodiment shown in these figures, two of the cutting protrusions 138 are selected cutting protrusions that are larger in size than the others and are therefore configured to cut the primary scores 30, 32 into the container closure 10. These selected cutting protrusions 138 are shown in operation in a detailed view in FIG. 6. As can be seen in this figure, a first selected cutting protrusion 138a is located near the axial center of the container closure 10 and the second die tool 124 and is slightly larger in size than a second selected cutting protrusion 138b that is located radially outwardly adjacent to the first selected cutting protrusion 138a. FIG. 6 also shows that the two raised anvils 130 on the first die tool 122 are located directly opposite the tips 140 of the first and second selected cutting protrusions 138a, 138b.

[0055] In the fully compressed state at the fourth press station 120 shown in FIG. 6, the first selected cutting projection 138a is inserted into the recessed annular region 26 to a depth such that it is spaced from the corresponding raised anvil 130 by about 0.001 inches (about 25.4 μm), which is the remnant or amount of remaining material left under the primary major score 30 created by this action. In comparison, the second selected cutting projection 138b is inserted into the recessed annular region 26 to a depth such that it is spaced from the other corresponding raised anvil 130 by about 0.002 inches (about 50.8 μm), which is the remnant or amount of remaining material left under the secondary major score 32 created by this action. In this embodiment, the tip 140 of the first selected cutting projection 138a is positioned at a height of about 0.0185 inches (about 469.9 μm) beyond the flat end surface 136, and each of the tips 140 is formed with a flat surface about 0.0003 inches (about 7.62 μm) wide that is small enough in size so that it is still nearly invisible even in the detailed view of FIG. 6. Each of the raised anvils 130 defines a flat upper surface 146 that is about 0.005 inches (about 127 μm) wide and curved sides 148 on either end of this width that slope downwardly toward a recess 150 that surrounds and is adjacent both raised anvils 130. The recess 150 provides an area for material to be extruded from the path of the selected cutting projection 138a, 138b and migrate as needed during the cutting process. By positioning the raised anvil 130 directly opposite selected cutting projections 138a, 138b, this area of ​​the recessed annular region 26 can be supported during scoring, providing further confidence that the primary scores 30, 32 will be formed to the desired specifications with the dimensions discussed above.

[0056] Turning to the other side of the cross section through the fourth press station 120 shown in FIG. 7 (FIG. 5D), a series of other cutting projections 138 are shown to be inserted into the blank 50 to form the auxiliary scores 34 within the recessed annular region 26. As can be seen from the perspective views provided in FIGS. 4A and 8, the cross sections shown in FIGS. 5D-7 are taken to generally intersect the centers (AKA where the apexes of the nose portions 42 are located) of selected cutting projections 138a, 138b configured to form the primary scores 30, 32, such that each of the cutting projections 138 shown in FIG. 7 forms one of the arcuate portions 34a that define one of the circular trapezoidal shapes of the auxiliary scores 34 (and another arcuate portion that defines the interior scoreline 36 within the circular trapezoidal shape). 7 is inserted into the recessed annular region 26 to a depth such that the tip 152 of each of the cutting projections 138 is spaced from the flat support surface 132 supporting the blank 50 opposite the cutting projection 138 by about 0.0045 inches (about 114.3 μm), which is also the remnant or amount of remaining material left under each auxiliary score 34 created in this operation. In this embodiment, the tip 152 of each of these cutting projections 138 is located about 0.015 inches (about 381 μm) high above the flat end surface 136, and each of the tips 152 is formed with a flat surface about 0.001 inches (about 25.4 μm) wide, which is significantly thicker than the tips 140 on the cutting projections 138a, 138b selected to form the primary scores 30, 32. This shaping of the cutting projection 138, and the remaining remaining portions, all collectively contribute to a design that promotes shear action only along the primary major scores 30 when the container closure 10 is in use, as described herein.

[0057] Thus, the flat support surface 132 and raised anvil 130 provide support for the side of the recessed annular region 26 opposite where the cutting projections 138 are inserted, while simultaneously providing all of the scores to the container closure 10. In the illustrated embodiment, the flat support surface 132 is also positioned at a height of about 0.001 inches (about 25.4 μm) below the flat top surface 146 of the raised anvil 130, such additional spacing allowing for more variation in coating or material thickness within the recessed annular region 26 of the blank 50. Such additional spacing also reduces the force applied when scoring the auxiliary scores 34, which may be desirable in some applications. In other embodiments of the tool, the tops of the flat support surface 132 and raised anvil 130 are at the same relative height.

[0058] Some final details of the features on the first and second hollow cylindrical dies 128, 134 are best visualized in the perspective view of Fig. 8. To this end, Fig. 8 shows that each of the cutting projections 138a, 138b selected to make the main scores 30, 32 extends along a substantially straight curvilinear path so that the main scores 30, 32 follow these same paths on the surface of the recessed annular region 26. More specifically, each of the selected cutting projections 138a, 138b includes a curved nose portion 156 with an apex toward the axial center of the second hollow cylindrical die 134 and convex line portions 158 at either end of the nose portion 156 that define the apex of the curvature pointing away from the axial center. As indicated by the numbering of the elements applied to Fig. 8, each of the two raised anvils 130 also includes a nose portion 156 and a convex line portion 158. The other cutting projections 138 forming the auxiliary score 34 follow a path defined by either an arcuate portion 160, which is generally concentric with the axial center of the second hollow cylindrical die 134, or a radial portion 162, which extends directly toward and away from said axial center. These portions for the other cutting projections 138 allow for the circular trapezoidal shape formed by the auxiliary score 34, as described above.

[0059] Thus, as can be seen from FIG. 5D, the blank 50 changes from the state described above with respect to FIG. 3D to the state shown in FIG. 3E (and generally shown in FIG. 5D). This is the final configuration of the blank 50 as the container closure 10. The first and second die tools 122, 124 are then moved away from each other to release the container closure 10 so that it can be collected for transportation or installation and used on a container. Because all of the scores 30, 32, 34 are formed in the same single compression operation at this fourth press station 120, there is no need to perform any orientation dimples or other rotational orientation maintaining steps before or after this step of the manufacturing process. This further improvement by using an "all-in-one" station makes the manufacturing process faster, less expensive, and more reliable in operation.

[0060] Having now step-by-step described the manufacturing tooling and steps using the diagrams of Figures 3A-3E and 5A-5D, a summary of the manufacturing steps for producing a container closure 10 according to an embodiment of the present invention can now be provided. Referring to the operational flow chart of Figure 9, the manufacturing process begins at step 200 with providing a blank 50 having a central panel 12 and a sidewall 18 connected to the central panel 12 at a corner joint 22. Step 200 also includes moving the blank 50 to a first press station 70. Next, at step 202, the method includes compressing the blank 50 between a first die tool 72 and a second die tool 74 at the first press station 70, thereby deforming the central panel 12 to include a bubble 58 that protrudes upward from the remainder of the central panel 12. This state of the blank 50 can be seen in Figure 3B, previously discussed. Next, at step 204, the blank 50 is moved to a second press station 80. In the next step 206, the method includes compressing the blank 50 between a first die tool 82 and a second die tool 84 at a second press station 80, which further deforms the central panel 12 about the bubble 58 to form the central button 24 and the recessed annular region 26 surrounding the central button 24. This condition of the blank 50 can be seen in FIG. 3C.

[0061] Thereafter, in step 208, the blank 50 is moved to the third press station 100. Next, in step 210, the blank 50 is compressed between the first die tool 102 and the second die tool 104 of the third press station 100, deforming the outer region 60 of the central panel 12 to add further profile while moving the central button 24 upward in height. The resulting state of the blank 50 can be seen in FIG. 3D. Next, in step 212, the blank 50 is moved to the fourth press station 120. As mentioned above, because all of the deformations and features made up to this point in the manufacturing process are circumferentially symmetric on the blank 50, advantageously, there is no need to provide dimples or features to maintain orientation and associated apparatus to ensure alignment during movement between the various press stations 70, 80, 100, 120. At the fourth press station 120, in a further step 214, the blank 50 is compressed between the first die tool 122 and the second die tool 124 to score the recessed annular region 26 to include the primary scores 30, 32 and the secondary scores 34. As noted in step 216, the cutting projections 138 of the fourth press station 120 are simultaneously inserted into one surface of the blank 50 (the top surface to be used on the container) to perform the cuts, making all cuts simultaneously in one compression operation, which step also completes the blank 50 and converts it into a container closure 10. Finally, in step 218, the container closure 10 is removed from the fourth press station 120 and moved for shipping or use on a pressure holding container as described in detail throughout this specification.

[0062] By modifying the manufacturing tooling and method to use a new "all-in-one" press station to simultaneously score all score lines into the container closure 10, the efficiency and reliability of production is significantly improved. Various technical problems and potential failure points presented by the conventional method are avoided, such as by avoiding the possibility of rotational misalignment that places the scores or other profile shapes and features in an incorrect location. The container closure 10 resulting from this process is preferably more suitable for use with bottle-like containers that may contain a vacuum pressure or pressure differential that must be released before the container can be opened. Of course, the one-station scoring concept can be redesigned to work with many other types of container closures as well, and the process developed herein can be applied more broadly to the field of container closures, for example, and not just the closures of the exemplary embodiment shown by way of example here. Thus, improvements in the manufacturing process will clearly benefit both the companies that sell such products in containers and the end consumers.

[0063] The present invention has been illustrated by the description of various embodiments, and while these embodiments have been described in considerable detail, it is not the intention of the applicant to limit the scope of the appended claims to such details. Further advantages and modifications will be readily apparent to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope of the applicant's general inventive concept.

Claims

1. A method of manufacturing a push button container closure (10) from a sheet of material comprising the steps of: providing a container closure blank (50) for processing in a series of first, second, third and fourth press stations, the blank including a generally planar central panel (12) and side walls (18) extending from a periphery (20) of said central panel at corner joints (22); using the first press station (70) to deform the central panel of the container closure to include a bubble (58) that projects upwardly from a remainder of the central panel; using the second press station (80) to further deform the central panel at the bubble location to form a central button (24) and a recessed annular area (26) surrounding the central button, the central button being positioned at a relative height below the corner joint of the container closure; using the third press station (100) to deform an outer region (60) of the central panel located between the recessed annular region and the sidewall to reshape the central panel at said outer region, thereby moving the central button upwardly toward the height of the corner joint of the container closure; using the fourth press station (120) to score the recessed annular area surrounding the central button to provide primary scores (30, 32) and secondary scores (34) in the top surface (16) of the container closure; Including, all scores cut into the container closure are formed only at the fourth press station in a single compression action, and a selected one of the main scores cuts deeper into the material of the container closure than all other scores, so that the center button can be pressed to sever the central panel at the selected one of the main scores and release a pressure differential across the container closure. method.

2. the fourth press station includes a second die tool having a plurality of cutting protrusions and a first die tool opposing the second die tool, and the step of making the cut using the fourth press station further includes:

2. The method of claim 1, comprising simultaneously cutting the main scores and the auxiliary scores into the top surface of the container closure by inserting the plurality of cutting projections into the container closure at the fourth press station as the first and second die tools move toward one another.

3. the fourth press station includes a second die tool having a plurality of cutting projections and a first die tool opposing the second die tool, the first die tool including a raised anvil extending over an adjacent portion of the first die tool and aligned with selected cutting projections on the second die tool configured to form the main score; The step of making the incision using the fourth press station further includes:

2. The method of claim 1, comprising supporting an underside of the container closure with the raised anvil of the first die tool as the selected cutting protrusion of the second die tool is inserted into the upper side of the container closure opposite the raised anvil, thereby creating the main score.

4. the first die tool of the fourth press station includes a flat support surface at all portions except a portion adjacent the raised anvil, and the step of making a cut using the fourth press station further includes:

4. The method of claim 3, further comprising supporting a lower surface of the container closure against the flat support surface of the first die tool when the cutting protrusion of the second die tool is inserted into the upper surface of the container closure to create the auxiliary score.

5. 5. The method of claim 4, wherein the flat support surface of the first die tool is positioned 0.001 inches (about 25.4 μm) below the top of the raised anvil to define additional spacing between the first die tool and the second die tool when pressed together and to reduce the force applied to the container closure by the fourth press station at a location where the auxiliary score is cut into the top surface of the container closure.

6. The step of making the incision using the fourth press station further includes:

2. The method of claim 1, comprising cutting the top surface of the container closure at the major scores so that each of the major scores defines a curve including a concave nose portion having an apex extending toward the central button and a convex line portion extending from each end of the concave nose portion and having an apex extending away from the central button.

7. The step of making a cut using the fourth press station further includes:

2. The method of claim 1, comprising generating a primary score and a secondary score as the only main score on the container closure, the primary score being deeper into the top surface of the container closure than the secondary score and also being located between the central button and the secondary score, the secondary score acting as an anti-vandalism score, and the primary score being configured to break to release the pressure differential when the container closure is engaged with a container.

8. The step of generating the primary score and the secondary score further comprises: cutting the top surface of the container closure such that about 0.001 inches (about 25.4 μm) of material thickness remains on the container closure below the primary scores; and 8. The method of claim 7, comprising cutting the top surface of the container closure such that about 0.002 inches (about 50.8 μm) of material thickness remains on the container closure below the secondary scores.

9. The step of making a cut using the fourth press station further includes:

2. The method of claim 1, comprising cutting the top surface of the container closure with the auxiliary scores such that each of the auxiliary scores is defined by one or more of an arcuate portion generally concentric with the central button and a radial portion extending toward and away from the center of the central button.

10. The step of cutting the top surface of the container closure with the auxiliary score further comprises:

10. The method of claim 9, wherein at least three of the auxiliary scores are cut to include both arcuate and radial portions thereby defining a circular trapezoid shape for the auxiliary scores, the circular trapezoid shape being continuous except where interrupted by an area of ​​the major scores, and the auxiliary scores substantially circumscribing the central button and the major scores on the container closure such that a force applied to the central button is directed to be focused in a direction to cut the container closure at the major scores.

11. The step of making a cut using the fourth press station further includes:

10. The method of claim 1, comprising cutting the top surface of the container closure such that about 0.0045 inches (about 114.3 μm) of material thickness remains on the container closure below each of the auxiliary scores.

12. moving the container closure from the first press station to the second press station, then to the third press station, and then to the fourth press station to sequentially perform the steps of deforming and scoring the container closure; 2. The method of claim 1, wherein all of the primary and secondary scores are formed by the same fourth press station, all other press stations impart circumferentially symmetric deformations to the container closure so that the angular orientation of the container closure is not required to be maintained, and no orientation dimples or features are formed in the container closure to guide movement of the container closure between press stations.

13. 1. A tooling assembly for manufacturing a push button container closure (10) from a container closure blank (50), the blank including a generally planar central panel (12) and sidewalls (18) extending from a periphery (20) of the central panel at corner joints (22), the tooling assembly comprising: a first press station (70) including first and second die tools (72, 74) that press together to deform a central panel of the container closure to include a bubble (58) that protrudes upwardly from a remainder of the central panel; a second press station (80) including first and second die tools (82, 84) that press together to further deform the central panel at the bubble to form a central button (24) and a recessed annular area (26) surrounding the central button, the central button being positioned at a relative height below the corner joint of the container closure; a third press station (100) including first and second die tools (102, 104) that press together to deform an outer region (60) of the central panel located between the recessed annular region and the sidewall to reshape the central panel at said outer region, thereby moving the central button upwardly toward the height of the corner joint of the container closure; a fourth press station (120) including first and second die tools (122, 124) that, when pressed together, cut into the recessed annular area surrounding the central button to provide major scores (30, 32) and minor scores (34) in the top surface (16) of the container closure, the second die tool including a plurality of cutting protrusions (138) for cutting into the top surface of the container closure to form the major scores and the minor scores when the first and second die tools are pressed together, one of the cutting protrusions being larger in size than the remaining cutting protrusions to form a selected one of the major scores that cuts deeper into the material of the container closure than all of the other scores, whereby the central button can be pressed to cut the central panel at the selected one of the major scores and release a pressure differential across the container closure; Including, a tooling assembly, the fourth press station configured to cut all of the scores into the container closure in a single compression operation only at the fourth press station, whereby the container closure is scored at only one of the press stations in the tooling assembly.

14. 14. The tooling assembly of claim 13, wherein the first die tool and the second die tool of the fourth press station are each hollow cylindrical dies defining an annular surface that engages the recessed annular region when the first die tool and the second die tool are pressed together to score the container closure.

15. The first die tool of the fourth press station further comprises:

14. The tooling assembly of claim 13, including a raised anvil extending over an adjacent portion of the first die tool and aligned with a selected cutting protrusion on the second die tool of the fourth press station configured to form the main score, the raised anvil positioned to support a lower surface of the container closure when the selected cutting protrusion of the second die tool is inserted into the upper surface of the container closure opposite the raised anvil, thereby creating the main score.

16. 16. The tooling assembly of claim 15, wherein the raised anvil includes a flat upper surface extending between curved sides that taper away from the flat upper surface, the flat upper surface perfectly aligned with and following a path defined by cutting edges of the selected cutting projections on the second die tool.

17. 17. The tooling assembly of claim 16, wherein the flat upper surface of each of the raised anvils defines a width between the curved sides of about 0.005 inches (about 127 μm).

18. 16. The tooling assembly of claim 15, wherein each of the raised anvils and each of the selected cutting projections configured to form the major scores follow a curvilinear path in a plan view, the curvilinear path including a concave nose portion having an apex extending toward an axial center of the first and second die tools, and convex line portions extending from opposite ends of the concave nose portion, each having an apex extending away from the axial centers of the first and second die tools.

19. 16. The tooling assembly of claim 15, wherein the second die tool of the fourth press station includes only two selected cutting protrusions, and the first die tool of the fourth press station includes only two raised anvils, and one of the selected cutting protrusions closer to an axial center of the second die tool is sized larger than the other of the selected cutting protrusions such that one of the selected cutting protrusions cuts a primary score having a greater depth than a secondary score cut into the top surface of the container closure by the other of the selected cutting protrusions.

20. 20. The tooling assembly of claim 19, wherein when the first and second die tools of the fourth press station are pressed together, one of the selected cutting protrusions is spaced about 0.001 inches from one of the raised anvils, thereby leaving about 0.001 inches of material thickness in the container closure below the primary score, and when the first and second die tools of the fourth press station are pressed together, the other of the selected cutting protrusions is spaced about 0.002 inches from the other of the raised anvils, thereby leaving about 0.002 inches of material thickness in the container closure below the secondary score, whereby the secondary score is configured to function as an anti-breakage score and the primary score is configured to be cut to release the pressure differential.

21. The first die tool of the fourth press station further comprises:

16. The tooling assembly of claim 15, including a flat support surface at all portions except adjacent the raised anvil, the flat support surface positioned to support the lower surface of the container closure when cutting prongs of the second die tool are inserted into the upper surface of the container closure to create the auxiliary score.

22. 22. The tooling assembly of claim 21, wherein the flat support surface of the first die tool is positioned 0.001 inches (about 25.4 μm) below the flat upper surface of the raised anvil, defining additional spacing between the first die tool and the second die tool when pressed together about the location where the auxiliary score will be formed in the container closure.

23. 16. The tooling assembly of claim 15, wherein each of the cutting projections configured to form the auxiliary scores follows, in a plan view, a path defined by one or more of a circular arc portion generally concentric with an axial center of the first die tool and a radial portion extending toward and away from the axial center of the first die tool, and further wherein at least three of the cutting projections forming the auxiliary scores have both circular line portions and radial portions, thereby defining a circular trapezoidal shape for the auxiliary scores that is continuous except where interrupted by regions of the cutting projections configured to form the main scores.

24. 24. The tooling assembly of claim 23, wherein the second die tool of the fourth press station further includes a flat support surface spaced from the raised anvil, and when the first die tool and the second die tool of the fourth press station are pressed together, each of the cutting projections configured to form the auxiliary scores is spaced about 0.0045 inches from the flat support surface, thereby leaving about 0.0045 inches of material thickness in the container closure below each of the auxiliary scores.

25. 14. The tooling assembly of claim 13, wherein none of the first, second, third or fourth press stations forms an orientation feature in the container closure such that an angular orientation of the container closure may vary between each of the press stations.

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