Aerosol Can Neck Forming With Shoulder Support for Material Savings
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Solution Overview
Problem
Current methods for producing aerosol containers are inefficient in material usage, leading to higher costs due to thicker wall thicknesses and lack of flexibility in wall thickness variations, which restricts the production of cost-effective and pressure-resistant aerosol parts.
Innovation Solution
A procedure involving fluid pressing and a supporting device allows for the production of aerosol containers with varying wall thicknesses, enabling material savings by defining and supporting the can shoulder and neck independently, allowing for thinner walls and efficient material usage, and enabling the production of aerosol parts that can withstand nominal pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional extrusion methods are used to produce aerosol can bodies, then the can body can be manufactured with uniform wall thickness, but material usage is inefficient and costs increase due to thicker walls than necessary
Solution Approach 1:
The patent applies local quality by implementing variable wall thickness distribution in the can body through a multi-stage extrusion process. The first extrusion creates a preliminary can body with uniform wall thickness, while the second extrusion selectively thins specific regions (such as the upper and lower portions) to achieve optimal material distribution. This allows thinner walls where structural demands are lower, reducing material consumption while maintaining strength where needed.
Solution Approach 2:
The manufacturing process is segmented into multiple extrusion stages. The first extrusion produces a can body with uniform wall thickness, and the second extrusion selectively removes material from specific regions. This segmentation of the forming process enables precise control over wall thickness distribution, allowing material savings in non-critical areas while preserving uniform thickness in load-bearing regions.
2Ease of manufacture
If uniform wall thickness is maintained throughout the can body, then manufacturing is simpler, but material savings are lost and cost-effectiveness decreases
Solution Approach 1:
The first extrusion stage creates a preliminary can body with uniform wall thickness, establishing a solid foundation structure. This preliminary form ensures adequate material distribution in all regions before the second extrusion stage selectively thins specific areas. By preparing the uniform-walled preliminary structure first, the process ensures that material is strategically removed only where needed, rather than attempting complex variable thickness formation in a single step.
3Loss of substance
If wall thickness is reduced to save material, then material costs decrease, but pressure resistance and structural strength may be compromised
Solution Approach 1:
The variable wall thickness design applies local quality by strategically thinning only those regions of the can body that are not primary load-bearing areas. The shoulder region and connection areas maintain sufficient thickness to handle pressure loads, while upper and lower portions can be thinner. This localized optimization achieves material savings without compromising the structural integrity or pressure resistance of critical regions.
Solution Approach 2:
The can body incorporates curved transitions and rounded corners in the variable thickness regions, avoiding sharp angles that would create stress concentration points. The smooth curvature transitions between thick and thin sections distribute stress more evenly, maintaining pressure resistance even with reduced wall thickness in certain areas.
4Manufacturing precision
If the can shoulder is supported during forming, then the can neck can be formed into a spray valve seat with precise geometry, but the process complexity increases
Solution Approach 1:
The can shoulder is pre-formed during the first extrusion stage with sufficient structural integrity to serve as a support element. This preliminary formation of the shoulder region provides a stable foundation during the second extrusion stage, enabling precise formation of the can neck and spray valve seat geometry without requiring additional complex support structures or multi-step operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in cost-effective aerosol containers with optimized wall thicknesses, allowing for material savings and enhanced pressure resistance, while enabling flexible production of aerosol parts with different geometries and shapes.
Implementation Method 1
a) extrusion, in particular automatic extrusion, or extrusion, in particular only, of a slug (2) to form a can main body blank (3)
Implementation Method 2
b) supporting, in particular automatically supporting, the can shoulder (5) on an inner side (7) of the can shoulder (5) by means of a supporting device (110)
Implementation Method 3
forming, in particular automatically forming, at least a portion of the can neck, in particular the complete can neck, into a spray valve seat
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
The invention relates to a method for manufacturing an aerosol can main part (1), the method comprising the steps of: - a) extrusion of a slug (2) into a can main part blank (3) comprising a can body (4), a can shoulder (5) and a can neck (6), and - b) supporting the can shoulder (5) on an inner side (7) of the can shoulder (5) by means of a support device (110) and forming at least one section of the can neck (6) into a spray valve seat (8) during the supporting process. The invention also relates to a device for manufacturing an aerosol can main part and an aerosol can main part.