Embossing Tools With Compliant Pad For Metal Containers
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Solution Overview
Problem
Existing methods for forming embossed designs on metal containers, such as incising, often result in weakened or thinned areas and require separate tooling steps, which can be inefficient and prone to material damage.
Innovation Solution
A system comprising a pair of embossing tools with a raised profile and a compliant pad, where the tools are configured to deform the metal container's surface without substantial material removal, integrating embossing into the die formation process to create raised or sunken designs on metal containers like food cans, using a combination of rigid and compliant materials to support deformation and prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If incising methods are used to form embossed designs on metal containers, then embossed designs can be created, but the metal container experiences weakened or thinned areas and material damage
Solution Approach 1:
The patent changes the fundamental parameter of the embossing process from material removal (incising) to material deformation. By using a combination of rigid and compliant tools, the metal is deformed plastically to form raised or sunken designs without removing material, thereby maintaining container strength while achieving precise embossed designs
Solution Approach 2:
The patent employs a composite tooling system combining rigid tool portions (for structural support and precise geometry transfer) and compliant tool portions (for controlled deformation and protection of the metal container). This composite approach allows embossing without substantial material removal or weakening
2Manufacturing precision
If separate tooling steps are used for embossing, then embossed designs can be formed, but the manufacturing process becomes inefficient and prone to material damage
Solution Approach 1:
The patent merges the embossing operation with the existing die formation process. The embossing tools are integrated into the die set, allowing embossed designs to be formed simultaneously with or as part of the container shaping process, eliminating separate tooling steps and improving manufacturing efficiency
Solution Approach 2:
The die formation system is given multiple functions: it simultaneously forms the container shape and creates embossed designs. The rigid and compliant tool portions serve both as forming tools and embossing tools, reducing the need for specialized separate tooling and improving overall process efficiency
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
This method allows for the creation of clear, durable embossed designs on thin metal containers with consistent thickness, reducing the risk of material weakening and integrating embossing into the manufacturing process, enhancing tool life and wear resistance for high-throughput production.
Implementation Method 1
applying pressure to the wall of the metal food can between the first and second tools causing the deformation of the wall of the metal food can to conform to the shape of the raised profile
Implementation Method 2
a pad of polymeric material positioned within the recess and coupled to the inner surface of the head portion. The pad has an axially facing outer surface facing the raised profile of the first fastener
Data Source
AI summary
A system for formation of embossed indicia on the end wall of a metal food can. The system include a first die portion and second die portion opposing the first die portion. The system includes a first fastener coupled to the first die portion. The first fastener including an outer surface and a raised profile extending from the outer surface corresponding to the embossed indicia to be formed on the wall of the metal food can. The system includes a second fastener coupled to the second die portion. The second fastener includes a head portion including an inner surface and a recess formed in the head portion defined by the inner surface of the head portion. The system includes a pad of polymeric material positioned within the recess and coupled to the inner surface of the head portion.