Expandable Bubble Shell for Thin-Gauge Can End Rivets
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Solution Overview
Problem
The challenge in the can manufacturing industry is to reduce the amount of metal used in can ends while maintaining strength, particularly with thinner base thicknesses, as existing methods face issues with rivet formation and material stress during the forming process, leading to potential failures and uneven rivet collapse.
Innovation Solution
The introduction of a shell with an expandable bubble that forms into an expandable rivet button and then an expanded rivet, allowing for the use of sheet material with a base thickness less than 0.0082 inches, which enhances the overlap and stability of the rivet, thereby addressing the material thickness and forming stress issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If sheet material with base thickness less than 0.0082 inches is used, then material usage is reduced and weight is decreased, but rivet formation reliability deteriorates and forming stress increases
Solution Approach 1:
The patent applies preliminary action by forming an expandable bubble structure in advance during the shell forming process, before the actual rivet formation occurs. This pre-formed bubble serves as a stress-absorbing element that prevents material failure during subsequent rivet forming operations on thin-gauge material
Solution Approach 2:
The patent changes the physical state and geometry parameters of the material by creating a three-dimensional expandable bubble structure from the two-dimensional sheet material. This parameter change allows the material to accommodate forming stresses that would otherwise cause failure in thin-gauge rivet formation
2Weight of moving object
If sheet material with base thickness less than 0.0082 inches is used, then can end weight is reduced, but structural integrity during forming deteriorates
Solution Approach 1:
The expandable bubble is formed as a preliminary structural feature before final rivet formation, providing stress relief and structural support during the forming process while maintaining the lightweight characteristic of thin-gauge material
Solution Approach 2:
The patent utilizes the flexible nature of thin-gauge sheet material by forming it into an expandable bubble structure that can deform and accommodate forming stresses without failing, thereby maintaining structural integrity while minimizing material thickness
3Ease of manufacture
If conventional rivet formation is used on thin material, then manufacturing process is simple, but rivet collapse becomes uneven and reliability decreases
Solution Approach 1:
The expandable bubble structure is formed in advance to provide a controlled geometry that guides uniform rivet collapse during forming, preventing the uneven collapse that occurs with conventional direct forming methods on thin material
Solution Approach 2:
The expandable bubble acts as an intermediary structure between the sheet material and the final rivet formation, mediating the forming process to ensure uniform material flow and collapse while maintaining manufacturing simplicity
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 solution enables the production of can ends from thinner sheet materials with improved rivet strength and reduced material usage, enhancing the structural integrity and efficiency of the can manufacturing process.
Implementation Method 1
The expandable bubble is formed into an expandable rivet button
Implementation Method 2
thereafter, into an expandable rivet that has an enhanced overlap of the tab body
Data Source
AI summary
A shell including a central panel with an expandable bubble disposed thereon is provided. The use of an expandable bubble allows for an expandable rivet button and thereafter an expandable rivet that has an enhanced overlap of a tab body. Such an expandable rivet allows for the use of a metal sheet with a thinner base thickness.