Metal End Closure Geometry for Buckle Strength and Jam-Free Forming

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Solution Overview

Problem

Existing metallic end closures for small diameter beverage containers face challenges in maintaining strength and buckle resistance while reducing material usage and manufacturing costs, often resulting in production inefficiencies and equipment downtime due to jamming issues.

Innovation Solution

The design incorporates a modified die core ring and inner pressure sleeve with specific geometry and coating to reduce material usage, enhance buckle strength, and prevent jamming, allowing for increased manufacturing efficiency and output.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If the diameter of end closure is reduced to save material, then material cost decreases, but buckle strength and structural integrity deteriorate

Engineering Contradiction:

Improvematerial usageVSAvoidbuckle strength

Core Design Contradiction:

Loss of substanceVSStrength

Solution Approach 1:

The end closure is segmented into distinct functional zones: a first region with a first radius of curvature and a second region with a second radius of curvature. This segmentation allows each region to be optimized independently - the first region maintains structural integrity while the second region reduces material usage, resolving the contradiction between strength and material savings.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the end closure are given different geometric properties (different radii of curvature) according to their specific functional requirements. The first region has geometry optimized for structural strength and buckle resistance, while the second region has geometry optimized for material reduction and cost savings, achieving both goals simultaneously.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If conventional end closure design is used, then manufacturing process is simple, but manufacturing equipment jams and runability deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidline output efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The end closure design incorporates dynamic geometric transitions with specific radius of curvature variations that prevent material snagging during the forming process. The controlled curvature changes allow the material to flow smoothly through the manufacturing equipment, preventing jams and improving runability while maintaining manufacturing feasibility.

Inventive Principle:

Principle #15Dynamics

3Reliability

If end closure operates under varying temperatures and pressure, then it must maintain structural integrity, but internal pressure up to 90 psi causes buckling and peak-and-leak failure

Engineering Contradiction:

Improvestructural integrityVSAvoidinternal pressure and temperature variation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The end closure geometry is designed with predetermined radius of curvature values that provide inherent resistance to buckling under internal pressure. The first region's larger radius of curvature acts as a structural cushion that distributes stress and prevents peak-and-leak failure, while the second region's optimized curvature provides additional support against temperature and pressure variations.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS12071280B2Metallic end closure for small diameter container

Publication Date: 2024.08.27 BALL CORP

AI summary

The present disclosure generally relates to containers and container end closures, and more specifically metallic end closures for small diameter metallic beverage containers. The present disclosure also relates to the tooling used to form the novel end closure, where the tooling is itself novel. The change of the angles on the die core ring improve the mobility of the metal while forming the end closure. Specifically, when manufacturing the new end closure with the new tooling, the press output is increased by over five times.