System and method for a single press for manufacturing a finished can end

Abstract

A method of manufacturing a can end is provided. The method includes feeding a coil stock to a press and forming at least one pierce in the coil stock. The method also includes lancing the coil stock to form at least two lances in the coil stock. The at least two lances define the can end and at least one carrier attached to the can end and the coil stock. The method further includes transporting the can end between stations within the press by feeding the coil stock to each station. The at least one carrier attaches the can end to the coil stock and the coil stock transports the can end through the press. The method also includes separating the can end from the coil stock.

Description

ATTORNEY DOCKET No. 124589.0007SYSTEM AND METHOD FOR A SINGLE PRESS FOR MANUFACTURING A FINISHED CAN ENDCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a U.S. Non-Provisional Patent Application which claims priority to and the benefit of Applicant’s U.S. Provisional Patent Application No. 63 / 756,714 filed February 10, 2025, and entitled SYSTEM AND METHOD FOR A SINGLE PRESS FOR MANUFACTURING A FINISHED CAN END, which prior application is hereby incorporated by reference in its entirety. It is to be understood, however, that in the event of any inconsistency between this specification and any information incorporated by reference in this specification, this specification shall govern.TECHNICAL FIELD

[0002] The present disclosure relates generally to finished can ends and specifically to a system and method for a single press for manufacturing finished can ends.BACKGROUND OF CERTAIN ASPECTS OF THE DISCLOSURE

[0003] Beverages, such as soft drinks, alcoholic drinks, energy drinks, and / or other beverages, may be served in beverage cans (also known as aluminum cans, drink cans, or simply cans). These beverage cans include a can end including a tab, a mouth panel, and a mouth defined by a score aperture around the mouth panel. A user opens the beverage can by pivoting the tab such that a portion of the tab presses down on the mouth panel until the score aperture around the mouth panel partially releases the mouth panel to fold under the top of the can, allowing the beverage to be poured out of the can through the mouth.

[0004] Can ends are manufactured using several different presses to form the can end before the can end is attached to the rest of the can. For example, can ends are manufactured using a separate press that is aluminum sheet fed to produce shells. The shells then get transferred to a separate conversion press and are converted to finished product. The shells are transferred through the conversion press utilizing a belt that will wear and need to be replaced over time. Having multiple pieces of equipment that form the can ends increases capital costs, increases theATTORNEY DOCKET No. 124589.0007likelihood of down time due to a problem with one of the presses, and increases the maintenance costs of a facility.

[0005] Accordingly, there is a need for system and method for manufacturing can ends in a single press.BRIEF SUMMARY OF SOME ASPECTS OF THE DISCLOSURE

[0006] One aspect of the present disclosure relates to a method of manufacturing a can end. The method includes feeding a coil stock to a press and forming at least one pierce in the coil stock. The method also includes lancing the coil stock to form at least two lances in the coil stock. The at least two lances define the can end and at least one carrier attached to the can end and the coil stock. The method further includes transporting the can end between stations within the press by feeding the coil stock to each station. The at least one carrier attaches the can end to the coil stock and the coil stock transports the can end through the press. The method also includes separating the can end from the coil stock.

[0007] Another aspect of the present disclosure relates to a method of manufacturing a can end. The method includes feeding a coil stock to a single press and forming at least one pierce in the coil stock in a first station of the single press. The method also includes lancing the coil stock to form at least two lances in the coil stock in a second station of the single press. The at least two lances define the can end and at least one earner attached to the can end and the coil stock. The method further includes transporting the can end between stations within the single press by feeding the coil stock to each station. The at least one carrier attaches the can end to the coil stock and the coil stock transports the can end through the single press. The method also includes separating the can end from the coil stock in a final station of the single press.

[0008] Another aspect of the present disclosure relates to a method of manufacturing a can end. The method includes feeding a coil stock to a single press and forming three pierces in the coil stock in a first station of the single press. The method also includes lancing the coil stock to form six lances in the coil stock in a second station of the single press. The six lances define a can end and three carriers attached to the can end and the coil stock. The method further includes transporting the can end between stations within the single press by feeding the coil stock to each station. The three carriers attach the can end to the coil stock and the coil stock transports the canATTORNEY DOCKET No. 124589.0007end through the single press. The method also includes separating the can end from the coil stock in a final station of the single press by detaching the can end from the three carriers.

[0009] Another aspect of the present disclosure relates to a single press for manufacturing a can end. The single press may include a feed path configured to receive and advance coil stock through the single press, a first station of the single press configured to form at least one pierce in the coil stock, a second station of the single press configured to lance the coil stock to form at least two lances in the coil stock, wherein the at least two lances define the can end and at least one carrier attached to the can end and the coil stock, and a final station of the single press configured to separate the can end from the coil stock. The single press may be configured to transport the can end between stations by feeding the coil stock to each station while the at least one carrier attaches the can end to the coil stock until separation in the final station.

[0010] Yet another aspect of the present disclosure relates to a system of manufacturing a can end comprising a single press configured to receive a coil stock and transport a can end between stations within the single press by feeding the coil stock to each station, wherein at least one carrier attaches the can end to the coil stock and the coil stock transports the can end through the single press. The single press may include a first station of the single press configured to form at least one pierce in the coil stock, a second station of the single press configured to lance the coil stock to form at least two lances in the coil stock, wherein the at least two lances define the can end and the at least one carrier attached to the can end and the coil stock, and a final station of the single press configured to separate the can end from the coil stock.

[0011] There are other novel aspects and features of this disclosure. They will become apparent as this specification proceeds. Accordingly, this brief summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. The summary and the background are not intended to identify key concepts or essential aspects of the disclosed subject matter, nor should they be used to constrict or limit the scope of the claims. For example, the scope of the claims should not be limited based on whether the recited subject matter includes any or all aspects noted in the summary and / or addresses any of the issues noted in the background.ATTORNEY DOCKET No. 124589.0007BRIEF DESCRIPTION OF THE DRAWINGS

[0012] A further understanding of the nature and advantages of the embodiments may be realized by reference to the following drawings. In the appended figures, similar components or features may have the same reference label.

[0013] FIG. 1 illustrates a flowchart of operations of forming a finished can end using a single press in accordance with aspects of the present disclosure.

[0014] FIG. 2 illustrates a top schematic view of a coil stock as the coil stock is processed using the method illustrated in FIG. 1 in accordance with aspects of the present disclosure.

[0015] FIG. 3 illustrates a top schematic view of the coil stock as the coil stock is processed using the method illustrated in FIG. 1 in accordance with aspects of the present disclosure.

[0016] FIG. 4 illustrates a cross-sectional schematic view of a portion of a press used in the method illustrated in FIG. 1 in accordance with aspects of the present disclosure.

[0017] FIG. 5 illustrates a perspective view of a pressure pad of an upper shell form illustrated in FIG. 4 in accordance with aspects of the present disclosure.

[0018] FIG. 6 illustrates a perspective view of the shell form punch illustrated in FIG. 4 in accordance with aspects of the present disclosure.

[0019] FIG. 7 illustrates a perspective view of the lower die shell form illustrated in FIG. 4 in accordance with aspects of the present disclosure.

[0020] FIG. 8 illustrates a flowchart of operations of forming a finished can end using a single press in accordance with aspects of the present disclosure.

[0021] FIG. 9 illustrates a top schematic view of a coil stock as the coil stock is processed through stations of a single press using a method in accordance with aspects of the present disclosure.

[0022] FIG. 10 illustrates a sectional view of a pierce station and an example product configured in accordance with aspects of the present disclosure.

[0023] FIG. 11 illustrates a sectional view of an outer lance station and an example product in accordance with aspects of the present disclosure.ATTORNEY DOCKET No. 124589.0007

[0024] FTG. 12 illustrates a perspective view of an example punch of the outer lance station illustrated in FIG. 11 in accordance with aspects of the present disclosure.

[0025] FIG. 13 illustrates a sectional view of an inner lance station and an example product in accordance with aspects of the present disclosure.

[0026] FIG. 14 illustrates a perspective view of an example punch of the inner lance station illustrated in FIG. 13 in accordance with aspects of the present disclosure.

[0027] FIG. 15 illustrates a sectional view of a shell panel form station and an example product in accordance with aspects of the present disclosure.

[0028] FIG. 16 illustrates a sectional view of a shell countersink form Station and an example product in accordance with aspects of the present disclosure.

[0029] FIG. 17 illustrates a sectional view of a blank and pre-curl station and an example product in accordance with aspects of the present disclosure.

[0030] FIG. 18 illustrates a system diagram of the application of an embodiment of a single press in accordance with aspects of the present disclosure.

[0031] While the embodiments described herein are susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, the exemplary embodiments described herein are not intended to be limited to the particular forms disclosed. Rather, the instant disclosure covers all modifications, equivalents, and alternatives falling within the scope of the appended claims.DETAILED DESCRIPTION

[0032] The systems and methods disclosed herein relate to, among other things, a method of manufacturing a can end using a single press. As discussed above, can ends are manufactured using several different presses to form the can end before the can end is attached to the rest of the can. Having multiple pieces of equipment that form the can ends increases capital costs, increases the likelihood of downtime due to a problem with one of the presses, and increases the maintenance costs of a facility. The single press described herein enables the can end to be manufactured in a single press with multiple stations within the press. To address how toATTORNEY DOCKET No. 124589.0007transport the can ends between stations within the single press, the single press described herein transports the can ends between stations by maintaining an attachment between the can ends and the coil stock and feeding the coil stock between the stations. Specifically, the first station of the single press forms pierces within the coil stock that define where the attachment points will be positioned within the coil stock. The second station within the single press lances the coil stock to form the can end and carriers that attach the can end to the coil stock. The carriers enable the can ends to remain attached to the coils stock as the coil stock is transported through the single press. Thus, the carriers described herein enable can ends to be manufactured in a single press, reducing capital and maintenance costs.

[0033] For purposes of illustration, the examples provided below include single press systems including multiple stations for manufacturing a beverage can end. In some embodiments, the single press systems may be used for manufacturing any type of can ends. In some embodiments, the single press systems may be used for high-precision, high-volume metal forming operations, and may be used for any application requiring similar manufacturing characteristics. For example, the single press systems may be adapted for several other manufacturing applications including similar metal forming (e.g., bottle caps and closures, jar lids, small metal containers, automotive components), electronics manufacturing (e.g., heat sinks, electrical enclosures, connector housings (metal shells for electrical connections)), and consumer products (e.g., decorative metal items, small appliance parts, and hardware items, such as metal washers, flanges, or mounting plates). As such, the single press systems may have tooling changes (e.g., different dies and punches) as required per desired application.

[0034] FIG. 1 illustrates a flowchart of operations 100 of forming a finished can end using a single press. FIG. 2 illustrates a top schematic view of a coil stock 200 as the coil stock 200 is processed using method 100. FIG. 2 includes station numbers marked on the coil stock 200 to illustrate the progression of the can end through the stations of the press. FIG. 3 illustrates a top schematic view of the coil stock 200 as the coil stock 200 is processed using method 100. As discussed above, the operations 100 uses a single press to manufacture a finished can end 202 and the coil stock 200 is used as the transportation medium through the press. The unfinished can ends remain attached to the coil stock 200 throughout the manufacturing process so that the coil stock 200 can transport the unfinished can ends through the press during the manufacturing process. In the illustrated embodiment, carriers 204 are formed around each of the unfinished canATTORNEY DOCKET No. 124589.0007ends that attach the unfinished can ends to the coil stock 200 during the manufacturing process. The carriers 204 are precisely engineered to withstand several presses before the finished can end 202 is removed from the earners 204 and the coil stock 200.

[0035] The press includes a first station configured to pierce and notch the coil stock 200, a second station configured to lance the coil stock 200 to form the carriers 204, a third station configured to form the panel of the unfinished can end, a fourth station configured to score the unfinished can end, a fifth station configured to establish any forms on the unfinished can end, and a sixth station configured to remove the unfinished can end from the coil stock 200 and establish a finished curl on the finished can end 202. Each station is located within a single press and the coil stock 200 transports the unfinished can ends through the single press to each station.

[0036] The operations 100 includes feeding 102 the coil stock 200 into the single press. Coil stock 200 is generally delivered to a manufacturing facility in a wound configuration and the coil stock 200 is unwound and fed into the single press. The single press may include a coil reel to hold the coil stock 200, a straightener to remove any curvature from the coil stock 200, and a feed mechanism that grips and precisely advances the coil stock 200 into the single press.

[0037] The operations 100 also includes feeding 104 the coil stock 200 into the first station and forming 106 pierces 206 (pierces or notches) in the coil stock 200 to form a first unfinished can end 208. The pierces 206 allow for coil piloting and relief points (termination points) for subsequent lancing. The pierces 206 are formed by a first press in the first station within the single press. The coil stock 200 then transports the first unfinished can ends 208 to the second station.

[0038] The operations 100 also includes feeding 108 the coil stock 200 including the first unfinished can ends 208 into the second station and lancing 110 the first unfinished can ends 208 to form a second unfinished can end 210. In the illustrated embodiment, lancing 110 occurs in two stages and the second station includes a first lancing station and a second lancing station. As such, lancing 110 includes lancing 112 the first unfinished can ends 208 at the first lancing station and lancing 114 the first unfinished can ends 208 at the second lancing station.

[0039] Specifically, in the illustrated embodiment, the first lancing station lances from at least one pierce 206 in a counter-clockwise direction to form an outer circumference 212 of the carrier 204. As discussed above, the carriers 204 are precisely engineered to withstand severalATTORNEY DOCKET No. 124589.0007presses before the finished can end 202 is removed from the carriers 204 and the coil stock 200. As such, the dimensions of the carrier 204 are precisely controlled to ensure the carrier 204 can withstand several presses. In the illustrated embodiment, the pierces 206 that are proximate an edge 214 of the coil stock 200 are positioned approximately 0.034 inches from the edge 214 of the coil stock 200 (notch-edge length 216) such that the outer circumference 212 of the carrier 204 is positioned approximately 0.033 inches from the edge 214 of the coil stock 200 (outer diameter-edge length 218). Additionally, a length 234 of the first lance 220 is approximately 0.1-4 inches and establishes a length 222 of the carrier 204.

[0040] In the illustrated embodiment, the first station forms three pierces 206 positioned in a circle around the first unfinished can ends 208. As such, the first lancing station begins to form three carriers 204 that attach the first unfinished can ends 208 to the coil stock 200. In alternative embodiments, the first lancing station may lance from any number of pierces 206 and may form any number of carriers 204 that enable the system and methods to operate as described herein.

[0041] The second lancing station lances from the same pierce 206 from an opposite side of the pierce 206 and in a clockwise direction (the opposite direction of the first lance) to form an outer circumference 224 of the second unfinished can end 210 and an inner circumference 226 of the carrier 204. Thus, a lance from the first lancing station from a pierce 206 forms the outer circumference 212 of a carrier 204 and a lance from the second lancing station from a different pierce 206 forms the outer circumference 224 of the second unfinished can end 210 and the inner circumference 226 of the carrier 204. In some embodiments, a length 236 of the second lance 228 is approximately 0.1-4 inches. As discussed above, the carriers 204 are precisely engineered to withstand several presses before the finished can end 202 is removed from the carriers 204 and the coil stock 200. As such, the thickness 230 of the carrier 204 is precisely controlled to ensure the carrier 204 can withstand several presses. In the illustrated embodiment, the thickness 230 of the carrier 204 is approximately 0.08 inches from the first lance 220 to the second lance 228. Other thicknesses are contemplated including up to approximately 1 / 8 inches. The coil stock 200 then transports the second unfinished can end 210 to the third station.

[0042] The first and second lances 220 and 228 formed by the first and second lancing stations define the outer circumference 224 of the circular second unfinished can end 210 and the geometry of the earners 204. Specifically, a diameter 232 of the second unfinished can end 210ATTORNEY DOCKET No. 124589.0007and of the finished can end 202 is determined by the second lance 228. The length 234 of the first lance 220 established the length 222 of the carrier 204. The length 236 of the second lance 228 defines a carrier attachment point 238 and a length 240 of the earner attachment point 238. The length 240 of the carrier attachment point 238 determines the strength of the carrier attachment point 238 and how many presses the carrier 204 can withstand during the manufacturing process. In the illustrated embodiment, the length 240 of the carrier attachment point 238 is approximately 0.001-0.5 inches. In alternative embodiments, the length 240 of the carrier attachment point 238 may be any length that enables the carrier 204 to operate as described herein.

[0043] Additionally, because the first and second lances 220 and 228 extend from opposite sides of the pierces 206, a diameter 242 of the pierces 206 establishes the thickness 230 of the earner 204. As such, forming large pierces 206 in the first station of the single press will form thicker carriers 204 in the second station of the single press. Furthermore, the length 236 of the second lance 228 defines the length 240 of the carrier attachment point 238. A longer second lance 228 forms a shorter carrier attachment point 238 and a shorter second lance 228 forms a longer carrier attachment point 238. Finally, the length 234 of the first lance 220 defines the length 222 of the carrier 204. A longer first lance 220 forms a longer carrier 204 and a shorter first lance 220 forms a shorter earner 204. Thus, the sizes of the pierces 206 and the first and second lances 220 and 228 can be tuned to develop a carrier 204 and a carrier attachment point 238 that is capable of withstanding several presses in the manufacturing process. Additionally, the size of the finished can end 202 may determine the size of the carrier 204 and the carrier attachment point 238 and the sizes of the pierces 206 and the first and second lances 220 and 228.

[0044] The operations 100 also includes feeding 116 the coil stock 200 including the second unfinished can end 210 into the third station and pressing 118 the second unfinished can end 210 to form a third unfinished can end 244. The third station presses the second unfinished can end 210 to establish the geometry of the finished can end 202. More specifically, in the illustrated embodiment, the third station establishes 90% of the geometry of the shell profile of the finished can end 202.ATTORNEY DOCKET No. 124589.0007

[0045] The third station includes a press 400 illustrated in FIG. 4. FIG. 4 illustrates a cross-sectional schematic view of a portion of the press 400. The press 400 presses the second unfinished can end 210 to form the third unfinished can end 244 and forms the geometry of the shell profile of the finished can end 202. The press 400 includes a pressure pad of an upper shell form 402, a shell form punch 404, and a lower die shell form 406 among other parts.

[0046] In the illustrated embodiment, the pressure pad of an upper shell form 402 circumscribes the shell form punch 404. The pressure pad of an upper shell form 402 and the shell form punch 404 are positioned above the lower die shell form 406 and the second unfinished can end 210 is positioned between the pressure pad of an upper shell form 402 / the shell form punch 404 and the lower die shell form 406 during the pressing process.

[0047] FIG. 5 illustrates a perspective view of the pressure pad of an upper shell form 402. FIG. 6 illustrates a perspective view of the shell form punch 404. FIG. 7 illustrates a perspective view of the lower die shell form 406.

[0048] The operations 100 further include feeding 120 the coil stock 200 including the third unfinished can end 244 into the fourth station and scoring 122 the third unfinished can end 244 to form a fourth unfinished can end 246. The fourth station scores the third unfinished can end 244 to form in elements that may require a score to break away from the finished can end 202 during use.

[0049] The operations 100 also include feeding 124 the coil stock 200 including the fourth unfinished can end 246 into the fifth station and forming 126 at least one form in the panel to form a fifth unfinished can end 248. The fifth station forms any forms necessary on the panel of the finished can end 202.

[0050] The operations 100 also include feeding 128 the coil stock 200 including the fifth unfinished can end 248 into the sixth station and removing 130 the fifth unfinished can end 248 from the coil stock 200 to form the finished can end 202. In the illustrated embodiment, the sixth station cuts the carriers 204 to remove the fifth unfinished can end 248 from the coil stock 200.

[0051] In addition to the embodiments described above with reference to FIGS. 1-7, the following figures illustrate an alternative progression utilizing downstream forming and conversion stations configured to manufacture finished can ends while maintaining attachment ofATTORNEY DOCKET No. 124589.0007the ends to the coil stock via integral carriers. In some embodiments, the operations shown in FIGS. 8-17 may be performed in different orders, combined within a single station, or split across multiple stations, and the number of stations is not intended to be limiting.

[0052] FIG. 8 illustrates a flowchart of operations 800 of forming a finished can end using a single press according to a non-limiting embodiment of this disclosure. In the illustrated embodiment, the operations 800 include feeding 802 the coil stock into the single press. The operations 800 include feeding 804 the coil stock into a first station.

[0053] The operations 800 include piercing 806 the coil stock in the first station to create holes for alignment and future lancing stations. Specifically, the first station pierces a set of holes within and / or immediately adjacent the footprint of each end and forms progression (e.g., pilot) holes along the strip edge(s). These holes support piloting at downstream stations and also codefine carrier geometry, as described below.

[0054] The operations 800 include feeding 808 the coil stock from the first station to a second station.

[0055] The operations 800 include lancing 810 the coil stock in the second station from the pierce locations to begin forming a web. Outer lances are cut from the pierced locations to establish a first set of arcs defining an outer circumference of each carrier web.

[0056] The operations 800 include feeding 812 the coil stock from the second station to a third station.

[0057] The operations 800 include lancing 814 the coil stock in the third station from the pierce locations to finish forming the web. Inner lances are cut from the pierced locations to establish a second set of arcs defining the inner circumference of the carrier and the outer circumference of the end blank. The outer and inner lances terminate at the pierces and do not fully sever the end from the strip. The resulting arcuate web around each end acts as a compliant spring that provides range of motion during vertical forming while maintaining positive attachment for transport.

[0058] The operations 800 include feeding 816 the coil stock from the third station to a fourth station.ATTORNEY DOCKET No. 124589.0007

[0059] The operations 800 include forming 818 a shell panel surface in the fourth station. The coil indexes into a shell panel formation station where the central panel and a substantial portion of the shell profile are formed. As the first vertical forming load is applied, the previously lanced arcs elastically separate along their slit faces (e.g., the slit faces open in the thickness direction), which allows the carrier web to flex like a spring during draw and panel formation.

[0060] The operations 800 include feeding 820 the coil stock from the fourth station to a fifth station. The operations 800 include forming 822 a countersink and a vertical wall of the shell in the fifth station.

[0061] The coil may be indexed into a shell countersink formation station. The countersink and vertical wall are formed while the carriers maintain in-plane position through the pilots. Additional conversion operations (e.g., such as bubble formation, button and rivet formation and restrike, scoring, panel depress, and staking) may then be performed at subsequent stations while the end remains attached to the coil via the carriers.

[0062] The operations 800 include 824 feeding the coil stock from the fifth station through subsequent rivet, scoring, and panel forming stations.

[0063] The operations 800 include feeding 826 the coil stock from the end conversion stations to a final blank and pre curl station and removing and pre curling 828 the converted end in the final station by severing the end from the web of coil stock and pre curling the outer edge of the end.

[0064] The coil indexes to a final blank and pre-curl station. The end is severed from the carrier attachment points and pre-curled. In one embodiment, the finished end is pushed downward through the lower die into a part chute while the scrap web remains in the press line and is advanced to a scrap handling unit (e.g., a chopper or rewinder). Throughout the progression, piloting may occur at every station and spring-loaded lifters raise and support the strip between strokes to facilitate index, while vacuum ports are used at selected stations for operations such as, e.g., slug evacuation, strip hold-down, and part control.

[0065] As with the embodiments of FIGs. 1-7, the end remains attached to the coil stock via integral carriers throughout forming and conversion until the final station. A pilot-basedATTORNEY DOCKET No. 124589.0007progression is used at each station to maintain registration while eliminating a rubber or stainless transfer belt; the coil itself functions as the transport medium.

[0066] FIG. 9 illustrates a top view and cross-sectional view of a coil stock 900 (e.g., coil, sock, stock of coil, etc.) processed using a single press described herein. The coil stock 900 enters a piercing station 902 where holes (e.g., pierce) 904 and holes (pierce, pilot pierce) 938 are formed. In some embodiments, the holes 904 may be located on a concentric (e.g., bolt circle) with a planned end diameter. The holes 938 may be positioned near a strip edge for a feed mechanism and can also be used for auxiliary piloting. The pierce diameters and locations are selected to (i) provide repeatable, low-clearance piloting at every station and (ii) set the radial thickness of the carrier web formed by the lancing stations by establishing the tangent points for the arcuate lances.

[0067] The coil stock then enters an outer lance station 906 where outer lances 908 are made. In this embodiment, this station cuts three lances (e.g., arcuate slits, arcs) per end, each lance lying tangent to the outer edge of a corresponding hole 904. These lances define the outer boundary of each carrier and initiate the compliant web that will transport the end. The lances may be oriented such that small uncut tie regions remain near the pierces. The slit edges may be smooth to minimize stress concentration during subsequent forming.

[0068] Next, the coil stock enters an inner lance station 910 where inner lances 912 are made. This station cuts three corresponding lances (e.g., arcuate slits) per end tangent to the inside edge of the holes 904 but on the opposite side of each pierce relative to the outer lances. The inner lances define the outer circumference of the end blank and the inner boundary of the carrier. Together, the outer lances 908 and inner lances 912 define three carriers per end, each with a controlled thickness (radial web width between the lances) and a controlled attachment length (tie length between a lance end and the adjacent pierce). The coil stock then enters a shell panel formation station 914.

[0069] As seen in the cross-sectional, horizontal schematic view of the coil stock 900 at the shell panel formation station 914, the forming occurs primarily in the vertical direction while the coil remains planar outside the end area. A shell panel surface is formed at 916. The compliant carrier web allows the end area to displace vertically 940 relative to the surrounding strip with reduced in-plane strain, thereby decoupling forming loads from the transport strip. In someATTORNEY DOCKET No. 124589.0007embodiments, the first application of vertical forming force causes the lanced arcs to open slightly along their thickness, separating the slit faces to provide spring compliance.

[0070] The coil stock 900 then enters a shell countersink form station 920 that forms the countersink 922 and the vertical wall 942 of the shell. The web compliance and pilot control maintain coaxiality and depth control while the countersink is coined or formed.

[0071] In some embodiments, the single press may include a variety of stations for providing additional features or alterations to the coil. For example, downstream stations 924-936 may include: a primary bubble station 924 to raise a panel feature, a secondary bubble station 926 to refine the geometry, a button station 928 to form a rivet precursor, a button restrike station 930 to calibrate height and diameter, a score station 932 to create a controlled fracture path around a mouth panel, a depress panel station 934 to set panel height, and a stake station 936 to mechanically lock features such as a tab to a formed rivet. The exact sequence and presence of these stations may vary depending on the desired end design of the can end.

[0072] Finally, while not shown in FIG. 9, at a final station, a finished can end 944 is separated from the web of stock material in a blank and pre-curl operation. The can end is urged downward from the strip while the scrap web is retained and advanced for discard. The final curl is imparted after separation in the same station in one embodiment.

[0073] FIGS. 10-17 illustrate representative stations, punches, and the products that may be produced at those stations and with those punches. The particular arrangements, geometries, sequences, and counts of stations shown are exemplary only. Unless expressly stated otherwise, operations may be performed in different orders, combined into a single station, split across multiple stations, omitted, or supplemented, and tooling dimensions, profiles, and materials may be varied. Features described with respect to one figure may be used in combination with features shown in other figures. Accordingly, the embodiments associated with FIGS. 10-17 are non-limiting and encompass modifications, equivalents, and alternatives that would be apparent to a person of ordinary skill in the art.

[0074] FIG. 10 illustrates a sectional view of a pierce station 1002 configured to produce a pierced coil stock, shown as example product 1004. The station may include a stripper or binder that clamps the coil stock prior to punch entry to prevent sheet lift and to improve pierce quality. A set of precision punches forms the pierces 1006 on a circle concentric with the future endATTORNEY DOCKET No. 124589.0007diameter, and one or more pierce punches forms pierces 1008 near a strip edge 1010. The diameters of the pierces 1004 may be selected relative to the lance geometry so that the outer and inner lances can terminate tangentially at the pierces; the pierce diameters may also indirectly set the maximum web thickness by establishing the available land between tangent points. Pilots at every station may subsequently engage the same pilot holes (e.g., 1008) for repeatable registration.

[0075] FIG. 11 illustrates a sectional view of an outer lance station 1102 and an example product 1104 in accordance with aspects of the present disclosure. This station may create a number (e.g.. three) outer lances 1108. Each lance 1108 is located tangent to the outside edge of a pierce 1106 and may be cut in a first angular sense around the pierce 1106 (e.g., counterclockwise) to a defined end point. In some embodiments, the lancing creates slits rather than holes, such that scrap removal is minimal. In some embodiments, scrap removal is evacuated by localized vacuum or air. The outer lances 1108 define the outer boundary of each carrier web and begin to establish the compliant, spring-like ring that will accommodate out-of-plane forming loads downstream.

[0076] FIG. 12 illustrates a perspective view of an embodiment of a punch 1200 of an outer lance station. The punch 1200 of FIG. 12 includes a cutting edge 1202 with an arcuate profile. In one embodiment, the cutting edge 1202 is formed on a replaceable insert coupled to a punch body to facilitate maintenance and geometry changes for different end sizes. The arc length and chord geometry of the cutting edge 1202 are chosen to set the carrier web length and the location of the attachment (tie) relative to the pierce. The punch 1200 face may include a slight shear angle along the arc to reduce peak cutting force and to promote a progressive slit. Relief features behind the cutting edge may reduce rubbing on the slit faces. The relationship between the cutting edge 1202 and the diameter of the pierces ensures the arc is tangent to the outer edge of the pierce, thereby fixing the web thickness in cooperation with the inner lancing operation.

[0077] FIG. 13 illustrates a sectional view of an inner lance station 1302 configured to produce an inner-lanced coil stock, shown as example product 1304. This station complements the outer lancing by cutting a number (e.g., three) inner lances 1308, each lance arc located tangent to the inside edge of the pierces 1306 and cut in the opposite angular sense around the pilot (e.g., clockwise) to a defined end point that leaves an uncut tie. The inner lances 1308ATTORNEY DOCKET No. 124589.0007define the outer circumference of the end blank 1310 and the inner boundary of the carrier web 1312. The combination of outer and inner arcs tied at the pierces yields three discrete carriers with a controlled radial width and attachment length. In some embodiments, as with the outer lancing, the operation may be a slit rather than a through-blanking, so no slugs are produced.

[0078] FIG. 14 illustrates a perspective view of an embodiment of an inner lance punch 1400 of an inner lance station. The inner lance punch 1400 includes a cutting edge 1402 with an arcuate profile that mirrors the desired inner lance geometry. In some embodiments, the inner lance punch 1400 employs a slightly different edge radius or clearance than an outer lance punch to set the desired web thickness (radial distance between inner and outer arcs) and to tune compliance. The inner cutting edge 1402 is located to be tangent to the inner edge of the corresponding pierce so that the pierce diameter, together with the arc offset, establishes the web thickness. The inner lance punch may include micro-relief flats near the arc ends to control tie length (attachment length), which can be used to tailor how many downstream forming operations the carriers can withstand without failure.

[0079] FIG. 15 illustrates a sectional view of a shell panel form station 1502 configured to produce a shell panel formed coil stock, shown as example product 1504. This station may include a pressure pad or binder that clamps the stock around the end footprint and a panel punch that forms the central panel 1506 and a majority of the shell profile 1508 in a vertical direction. The carriers / web 1510 surrounding each end provide a compliant, spring-like ring that accommodates the vertical displacement of the end relative to the surrounding strip 1512. As the first significant forming load is applied, the previously cut outer and inner lances may elastically open along their slit faces. Pilots at this station may engage before forming to maintain concentricity and to resist any tendency for the end to rotate relative to the strip during forming.

[0080] FIG. 16 illustrates a sectional view of a shell countersink form station 1602 configured to produce a shell countersink formed coil stock, shown as example product 1604. This station may coin or form the countersink and vertical wall 1606 while the end 1608 remains attached to the strip via the carriers 1610. Because the carriers provide radial and torsional compliance, they permit the shell circle to flex like a spring during countersink formation, which helps maintain dimensional accuracy without overloading the carrier attachments. The countersink depth and wall angle may be set by the relative stroke of the punch and die faces.ATTORNEY DOCKET No. 124589.0007

[0081] FIG. 17 illustrates a section view of a blank and pre-curl Station 1702 configured to produce a finished end, shown as product 1704 separated from the web of stock material with pre-curls along the outer edge. In this station, a blanking punch may shear the end from the carriers at the designed carrier attachment points. The end may then be immediately engaged by a pre-curl ring and / or rollers that impart a pre-curl 1706 to the outer edge suitable for downstream seaming operations. In one embodiment, the finished end 1706 is ejected downward through an aperture in the lower die into a part chute under vacuum assist or air blow-off, while the scrap web remains supported by the strip and is advanced by the feed mechanism to a scrap chopper or rewind. In some embodiments, the pre-curl operation may be performed at this last step to avoid interference with upstream piloting and to maintain a flat transport surface.

[0082] Across FIGs. 9-17, embodiments are shown piloting into the same set of pierces at every station ensures that each operation is performed in fixed registration relative to the end centerline and to the carrier geometry established at the lancing stations. Spring-loaded lifters may support the coil between strokes to facilitate reliable indexing. Vacuum may be applied where beneficial for slug removal, strip hold-down, and part control, reducing debris-induced defects. The combination of pierces, paired arcuate lances, and three carriers per end allows the end to remain integrally attached to and transported by the coil stock through all forming and conversion stations, replacing the conventional transfer belt. The arcuate web acts as a compliant spring ring that provides the range of motion necessary for vertical forming while preserving transport integrity, and the final separation and curl are performed in the last station to complete the finished end.

[0083] FIG. 18 illustrates a system diagram 1800 of the application of an embodiment of a single press 1802 in accordance with aspects of the present disclosure. In the illustrated embodiment, coil stock 1804 is fed into the single press 1802. The single press 1802 may process the coil stock 1804 through multiple stations, such as a piercing station 1806, an outer lancing station 1808, an inner lancing station 1810, a shell panel formation station 1812, a shell countersink formation station 1814, subsequent can formation stations 1816, and a blank and pre-curl station 1818 as described through the present specification. The output / result of the single press 1802 may be a finished can end 1820. It is to be appreciated that all the stations described herein are incorporated into a single press, such that coil stock 1804 enters the single press 1802 and a finished can end 1820 exits the single press 1802.ATTORNEY DOCKET No. 124589.0007

[0084] An aspect of the present disclosure relates to a single press for manufacturing a can end. The single press may include a feed path configured to receive and advance coil stock through the single press, a first station of the single press configured to form at least one pierce in the coil stock, a second station of the single press configured to lance the coil stock to form at least two lances in the coil stock, wherein the at least two lances define the can end and at least one carrier attached to the can end and the coil stock, and a final station of the single press configured to separate the can end from the coil stock. The single press may be configured to transport the can end between stations by feeding the coil stock to each station while the at least one carrier attaches the can end to the coil stock until separation in the final station.

[0085] Another aspect of the present disclosure relates to a system of manufacturing a can end comprising a single press configured to receive a coil stock and transport a can end between stations within the single press by feeding the coil stock to each station, wherein at least one carrier attaches the can end to the coil stock and the coil stock transports the can end through the single press. The single press may include a first station of the single press configured to form at least one pierce in the coil stock, a second station of the single press configured to lance the coil stock to form at least two lances in the coil stock, wherein the at least two lances define the can end and the at least one carrier attached to the can end and the coil stock, and a final station of the single press configured to separate the can end from the coil stock.

[0086] The description set forth herein, in connection with the appended drawings, describes example configurations and does not represent all the examples that may be implemented or that are within the scope of the claims. The term “exemplary” used herein means “serving as an example, instance, or illustration,” and not “preferred” or “advantageous over other examples.” The detailed description includes specific details for the purpose of providing an understanding of the described techniques. These techniques, however, may be practiced without these specific details. In some instances, well-known structures and devices are shown in block diagram form in order to avoid obscuring the concepts of the described examples.

[0087] In the appended figures, similar components or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If just the first reference label is used in the specification, the description is applicable to any one ofATTORNEY DOCKET No. 124589.0007the similar components having the same first reference label irrespective of the second reference label.

[0088] The description herein is provided to enable a person skilled in the art to make or use the disclosure. Various modifications to the disclosure will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other variations without departing from the scope of the disclosure. Thus, the disclosure is not limited to the examples and designs described herein, but is to be accorded the broadest scope consistent with the principles and novel features disclosed herein.

[0089] Terminology and Interpretative Conventions

[0090] The following terms are provided to facilitate understanding of some embodiments and are intended to be illustrative and non-limiting. These terms should be construed broadly in view of the disclosure and the knowledge of a person of ordinary skill in the art.

[0091] Press: A “press” refers to a manufacturing machine used to form and shape metal components through mechanical force. In some embodiments, the press is used to manufacture can ends (the tops of cans (e.g„ beverage cans)).

[0092] Carrier: A “carrier” generally refers to a portion of the stock material that remains connected to an end during processing and permits the end to be transported by the stock between stations. In some embodiments, a carrier is an integral web bounded by non-intersecting cuts or lances; in other embodiments, carriers may include ties, tabs, bridges, or other connective regions, which may be continuous or intermittent, of any suitable geometry or thickness, configured to temporarily attach the end to the surrounding strip and provide compliant support during forming.

[0093] Lance: A “lance” generally refers to a localized separation along a non-closed path that at least partially delineates a boundary of the end and / or a carrier. A lance may be implemented as a cut, slit, score, or other material removal formed by punching, shearing, slitting, laser cutting, or similar techniques. A lance may terminate at, originate from, or be tangent to a pierce, notch, relief, or other feature, and need not fully sever the end from the sheet.

[0094] Pierce: A “pierce” generally refers to an opening, hole, notch, slot, or recess formed in the stock for any useful purpose, including piloting, progression, defining carrier geometryATTORNEY DOCKET No. 124589.0007and lance termination, slug evacuation, or tool clearance. Pierce shapes, sizes, and locations may vary (e.g., circular or non-circular, closed or partially open to an edge), and a given embodiment may employ one or more different pierce types.

[0095] Any methods described in the claims or specification may be performed in any order, adding and omitting as desired, unless explicitly claimed otherwise or a specific order is inherently necessitated by the claim language. Also, the methods should be interpreted to provide support to perform the recited steps in any order unless stated otherwise.

[0096] Spatial or directional terms, such as “left,” “right,” “front,” “back,” and the like, relate to the subject matter as it is shown in the drawings. However, it is to be understood that the described subject matter may assume various alternative orientations and, accordingly, such terms are not to be considered as limiting.

[0097] Articles such as “the,” “a,” and “an” can connote the singular or plural. Also, the word “or” when used without a preceding “either” (or other similar language indicating that “or” is unequivocally meant to be exclusive - e.g., only one of x or y, etc.) shall be interpreted to be inclusive (e.g., “x or y” means one or both x or y).

[0098] The term “and / or” shall also be interpreted to be inclusive (e.g., “x and / or y” means one or both x or y). In situations where “and / or” or “or” are used as a conjunction for a group of three or more items, the group should be interpreted to include one item alone, all the items together, or any combination or number of the items.

[0099] The terms have, having, include, and including should be interpreted to be synonymous with the terms comprise and comprising. The use of these terms should also be understood as disclosing and providing support for narrower alternative embodiments where these terms are replaced by “consisting” or “consisting essentially of.”

[0100] Unless otherwise indicated, all numbers or expressions, such as those expressing dimensions, physical characteristics, and the like, used in the specification (other than the claims) are understood to be modified in all instances by the term “approximately.” At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the claims, each numerical parameter recited in the specification or claims which is modified by the termATTORNEY DOCKET No. 124589.0007“approximately” should be construed in light of the number of recited significant digits and by applying ordinary rounding techniques.

[0101] All disclosed ranges are to be understood to encompass and provide support for claims that recite any and all subranges or any and all individual values subsumed by each range. For example, a stated range of 1 to 10 should be considered to include and provide support for claims that recite any and all subranges or individual values that are between and / or inclusive of the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less (e.g., 5.5 to 10, 2.34 to 3.56, and so forth) or any values from 1 to 10 (e.g., 3, 5.8, 9.9994, and so forth).

[0102] All disclosed numerical values are to be understood as being variable from 0-100% in either direction and thus provide support for claims that recite such values or any and all ranges or subranges that can be formed by such values. For example, a stated numerical value of 8 should be understood to vary from 0 to 16 (100% in either direction) and provide support for claims that recite the range itself (e.g., 0 to 16), any subrange within the range (e.g., 2 to 12.5) or any individual value within that range (e.g., 15.2).

[0103] The terms recited in the claims should be given their ordinary and customary meaning as determined by reference to relevant entries in widely used general dictionaries and / or relevant technical dictionaries, commonly understood meanings by those in the art, etc., with the understanding that the broadest meaning imparted by any one or combination of these sources should be given to the claim terms (e.g., two or more relevant dictionary entries should be combined to provide the broadest meaning of the combination of entries, etc.) subject only to the following exceptions: (a) if a term is used in a manner that is more expansive than its ordinary and customary meaning, the term should be given its ordinary and customary meaning plus the additional expansive meaning, or (b) if a term has been explicitly defined to have a different meaning by reciting the term followed by the phrase “as used in this document shall mean” or similar language (e.g., “this term means,” “this term is defined as,” “for the purposes of this disclosure this term shall mean,” etc.). References to specific examples, use of “i.e.,” use of the word “invention,” etc., are not meant to invoke exception (b) or otherwise restrict the scope of the recited claim terms. Other than situations where exception (b) applies, nothing contained in this document should be considered a disclaimer or disavowal of claim scope.ATTORNEY DOCKET No. 124589.0007

[0104] The subject matter recited in the claims is not coextensive with and should not be interpreted to be coextensive with any embodiment, feature, or combination of features described or illustrated in this document. This is true even if only a single embodiment of the feature or combination of features is illustrated and described in this document.

Claims

ATTORNEY DOCKET No. 124589.0007CLAIMSWhat is claimed:

1. A method of manufacturing a can end, the method comprising:feeding a coil stock to a press;forming at least one pierce in the coil stock;lancing the coil stock to form at least two lances in the coil stock, wherein the at least two lances define the can end and at least one carrier attached to the can end and the coil stock;transporting the can end between stations within the press by feeding the coil stock to each station, wherein the at least one carrier attaches the can end to the coil stock and the coil stock transports the can end through the press; andseparating the can end from the coil stock.

2. The method of claim 1, wherein the press comprises a single press comprising a plurality of stations.

3. The method of claim 1, wherein the at least one carrier comprises three carriers attached to the coil stock and the can end.

4. The method of claim 1, wherein at least one pierce comprises three pierces.

5. The method of claim 1, wherein lancing the coil stock to form at least two lances in the coil stock comprises lancing a first lance in the coil stock at a first lancing station.

6. The method of claim 5, wherein the first lance in the coil stock extends from a first pierce in a clockwise direction.

7. The method of claim 6, wherein lancing the coil stock to form at least two lances in the coil stock further comprises lancing a second lance in the coil stock at a second lancing station.

8. The method of claim 7, wherein the second lance in the coil stock extends from a second pierce in a counter-clockwise direction.ATTORNEY DOCKET No. 124589.00079. The method of claim 8, wherein the first lance at least partially defines an outer circumference of the at least one carrier and the second lance at least partially defines an inner circumference of the at least one carrier.

10. The method of claim 8, wherein a distance between an end of the second lance and the first pierce defines a earner attachment point configured to attach the at least one carrier to the can end as the can end is transported through the press by the coil stock.

11. The method of claim 10, wherein separating the can end from the coil stock comprises separating the can end from the coil stock at the carrier attachment point.

12. The method of claim 1, further comprising pressing the can end.

13. The method of claim 1, further comprising scoring the can end.

14. The method of claim 1, further comprising forming at least one form on the can end.

15. A single press for manufacturing a can end, comprising:a feed path configured to receive and advance coil stock through the single press; a first station of the single press configured to form at least one pierce in the coil stock;a second station of the single press configured to lance the coil stock to form at least two lances in the coil stock, wherein the at least two lances define the can end and at least one carrier attached to the can end and the coil stock; anda final station of the single press configured to separate the can end from the coil stock;the single press configured to transport the can end between stations by feeding the coil stock to each station with the feed path while the at least one carrier attaches the can end to the coil stock until separation at the final station.

16. The single press of claim 15. further comprising a third station of the single press configured to press the can end.ATTORNEY DOCKET No. 124589.000717. The single press of claim 15, further comprising a fourth station of the single press configured to score the can end.

18. The single press of claim 15, further comprising a fifth station of the single press configured to form at least one form on the can end.

19. The single press of claim 15, wherein the second station of the single press comprises a first lancing station and a second lancing station.

20. A method of manufacturing a can end, the method comprising: feeding a coil stock to a single press;forming three pierces in the coil stock in a first station of the single press; lancing the coil stock to form six lances in the coil stock in a second station of the single press, wherein the six lances define the can end and three earners attached to the can end and the coil stock;transporting the can end between stations within the single press by feeding the coil stock to each station, wherein the three carriers attach the can end to the coil stock and the coil stock transports the can end through the single press; andseparating the can end from the coil stock in a final station of the single press by detaching the can end from the three earners.

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