Low-Spread Aluminum Bottle Forming for Narrow-Neck Production
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Solution Overview
Problem
Elongated aluminum bottles experience higher manufacturing defects and rejection rates due to increased plastic deformation and complex geometry, particularly in forming the narrow neck and slender shape, which traditional manufacturing methods struggle to address effectively.
Innovation Solution
Utilizing low-spread metal with a narrow difference between yield stress and ultimate tensile stress, combined with specialized thermal treatment, to form elongated bottles with reduced defects and increased production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional aluminum sheet material with high spread between yield stress and ultimate tensile stress is used to form elongated bottles with narrow necks, then the material has sufficient ductility for forming, but manufacturing defects increase and rejection rates rise due to excessive plastic deformation
Solution Approach 1:
The patent changes the material parameter by using low-spread aluminum alloy (spread ≤ 3.5 ksi) instead of traditional high-spread aluminum alloy (spread ≥ 10 ksi). This parameter change reduces the difference between yield stress and ultimate tensile stress, allowing the material to undergo necessary plastic deformation for forming narrow necks and slender shapes without excessive deformation that causes defects and rejections.
2Shape
If increased plastic deformation is applied to form the narrow neck and slender shape, then the bottle geometry is achieved, but manufacturing defects and rejection rates increase
Solution Approach 1:
The patent applies parameter changes by selecting aluminum alloy material with specifically controlled mechanical properties (low spread between yield and ultimate tensile stress). This enables the material to accommodate the large plastic deformation required for creating narrow necks and slender shapes while maintaining manufacturing precision and reducing defect rates.
3Productivity
If traditional aluminum can manufacturing methods are used for elongated bottles, then production speed can be maintained, but defect rates remain high due to material properties
Solution Approach 1:
The patent changes the material parameter from traditional high-spread aluminum alloy to low-spread aluminum alloy (spread ≤ 3.5 ksi). This parameter change allows the manufacturing process to maintain high production speeds (up to 1,200 bottles per minute) while simultaneously reducing defect rates to 3% or less, overcoming the limitation of traditional materials that caused high rejection rates at high speeds.
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 enables consistent, high-speed production of elongated aluminum bottles with lower defect rates and thinner side walls, achieving production rates of up to 1,200 bottles per minute with only 3% defects, compared to 10-60% with traditional methods.
Implementation Method 1
The increased deformation of the aluminum sheet has resulted in increased manufacturing defects
Implementation Method 2
combined with specialized thermal treatment, to form elongated bottles with reduced defects
Data Source
Figure 1
Figure 2A~2B
Figure 3~4
AI summary
A low-spread metal elongated bottle (100) and its production method are described for reducing rejection rates associated with the production of metal bottles at high speeds. The elongated bottle (100) includes a sheet metal formed body. The sheet metal (101) has a low spread between a yield state corresponding to the yield stress of the sheet metal and an ultimate tensile state corresponding to the ultimate tensile stress of the sheet metal(101). The body further includes a concave bottom portion (115) having a circular perimeter (117). A cylindrical portion (110) extends from the circular perimeter of the bottom portion (117) and has a uniform diameter. A neck portion (105) extends from the cylindrical portion (110) and has a tapered profile (107). The neck portion (105) may include a threaded portion (120) including threads exposed on the outer surface of the neck portion (105) or an area for crimping of a crown (300).