Can Shoulder Roll Forming for 3D Decoration Without Buckling

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Solution Overview

Problem

Existing methods for decorating the shoulder of thin-walled cans often result in abnormal deformation due to the use of molds that press onto the can, leading to damage and buckling, especially when trying to apply uneven patterns.

Innovation Solution

A method and apparatus involving inner and outer rolls with concave and convex portions that clamp and rotate the shoulder of the can, allowing for the formation of three-dimensionally shaped portions without causing abnormal deformation, by supporting the shoulder from the inside and pressing it from the outside, maintaining a suitable diameter ratio and wall thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a mold is pressed onto the shoulder of a thin-walled can to form uneven patterns, then decoration is applied to the shoulder, but the shoulder becomes buckled and abnormally deformed

Engineering Contradiction:

Improvedecoration applicationVSAvoidshoulder deformation

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Instead of pressing a mold from the outside onto the shoulder, the invention inserts a receiver from the inside of the can that protrudes into the shoulder. The receiver is pressed from the interior side while the shoulder is clamped from the exterior, reversing the conventional pressing direction to prevent external buckling

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The receiver acts as an intermediary tool that transfers the forming force from the interior side of the can. By using this intermediate component, the shoulder can be formed with uneven patterns without direct external pressure that would cause buckling

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of substance

If the wall thickness of the can is reduced for resource saving, then material efficiency is improved, but the shoulder becomes vulnerable to damage and abnormal deformation during processing

Engineering Contradiction:

Improvematerial usageVSAvoidshoulder strength

Core Design Contradiction:

Loss of substanceVSStrength

Solution Approach 1:

The pressing operation is inverted to apply force from the inside rather than outside. This allows thin-walled cans to be processed without external forces that would damage the weakened shoulder structure

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The receiver is designed with a specific shape that distributes pressure evenly across the shoulder area before forming begins. This pre-distribution of force prevents concentration of stress that would cause damage to thin-walled structures

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If a mold is pressed from the outside of the shoulder to form patterns, then decoration can be applied, but the shoulder causes abnormal deformation

Engineering Contradiction:

Improvepattern formationVSAvoidshoulder shape

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The forming operation is performed by pressing from the interior side using the receiver rather than from the exterior side. This inversion of the pressing direction allows pattern formation while maintaining the natural shape of the shoulder

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS20210308736A1Can manufacturing method, can manufacturing device, can, and can manufacturing tool set

Publication Date: 2021.10.07 TOYO SEIKAN KAISHA LTD

AI summary

An apparatus and tool set forming a three-dimensionally shaped portion on a shoulder of a can including an inner roll having a receiver for receiving the shoulder from inside; an outer roll for pressing the shoulder from outside; and a rotating unit for rotating the inner roll and the outer roll relative to the can. The shoulder is formed on a side of an upper end of a cylindrical body of the can in a can axis direction to be reduced in a diameter toward a side of a mouth of the can and to have a thickness of 0.1 to 0.3 mm. The receptor of the inner roll has at least one of a concave portion and a convex portion, and has a diameter reduced portion corresponding to a shape of the shoulder. Further, the inner roll and the outer roll are rotated by the rotating unit.