Metal Container Carrier Ring Forming for Air Conveyor Compatibility
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Solution Overview
Problem
Metal containers lack a carrier ring, making them incompatible with existing manufacturing lines that use air conveyor systems designed for plastic containers, which complicates transportation and processing.
Innovation Solution
A turret-head assembly and method for forming a metal container with a carrier ring, involving a rolling assembly with cam followers and rollers to radially move and shape the metal container's neck, creating a protrusion that functions as a carrier ring, allowing compatibility with existing processing lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal containers are manufactured without a carrier ring to simplify the forming process, then manufacturing complexity is reduced, but compatibility with existing air conveyor systems is lost
Solution Approach 1:
The carrier ring is formed as a distinct segment or feature on the metal container neck, separate from the main body forming process. This segmentation allows the carrier ring to be created through a specific localized operation (roller forming) while the rest of the container is formed using conventional metal forming techniques, thus maintaining overall manufacturing simplicity while adding the necessary compatibility feature
Solution Approach 2:
The carrier ring is formed during the necking process, which occurs early in the container forming sequence before final shaping and finishing operations. By incorporating the carrier ring formation into the preliminary necking stage, the patent ensures that the compatibility feature is established before subsequent forming operations, avoiding the need for additional post-forming steps
2Adaptability or versatility
If a carrier ring is added to metal containers to enable compatibility with air conveyor systems, then adaptability improves, but device complexity increases
Solution Approach 1:
The roller forming assembly is designed to perform multiple functions: it shapes the container neck, creates the carrier ring feature, and controls material flow during forming. By making the roller assembly multi-functional, the patent avoids adding separate dedicated equipment for carrier ring formation, thus improving adaptability while minimizing the increase in device complexity
Solution Approach 2:
The container neck itself serves as the forming tool for creating the carrier ring. The rollers apply force to the neck material, which then forms the carrier ring through self-contained plastic deformation. This self-service approach eliminates the need for separate forming tools or complex tooling changes, achieving compatibility through a relatively simple modification to the existing forming apparatus
3Adaptability or versatility
If the neck region is deformed to create a carrier ring, then compatibility with conveyor systems is achieved, but structural integrity may be compromised
Solution Approach 1:
The carrier ring is formed with specific local geometric characteristics including a controlled cross-sectional shape and appropriate wall thickness distribution. The forming process creates a localized feature with optimized geometry that provides the necessary mechanical strength for conveyor application while maintaining the overall neck integrity. The local quality of the carrier ring region is specifically tailored to balance compatibility requirements with structural strength
Solution Approach 2:
The carrier ring formation process incorporates controlled material deformation that pre-strengthens the neck region. The rolling action and material flow during carrier ring creation induce work hardening and create a reinforced structure that anticipates the mechanical loads the carrier ring will encounter during conveyor operation, thus protecting against future strength deficiencies
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
Enables metal containers to be transported and processed using existing air conveyor systems, enhancing compatibility and efficiency in manufacturing lines.
Implementation Method 1
Each of the plurality of roller arms further includes a cam follower configured to engage a respective one of the plurality of cams such that the rollers are configured to move radially with respect to a turret-head assembly axis
Implementation Method 2
engaging the rollers with a portion of the article, thereby at least partially forming a carrier ring on the article
Data Source
AI summary
A method of forming a carrier ring on a metal article having an open end and a sidewall extending therefrom. The method includes contacting an inner surface of the sidewall with an inner roller to form a protrusion and contacting an outer surface of the sidewall with an outer roller to form a first groove positioned below the protrusion. The protrusion forms a gap therein. The method further includes contacting a portion of the outer sidewall with at least one second outer roller to form a second groove below the protrusion. The method further includes contacting a portion of the outer sidewall with at least one third outer roller to flatten the protrusion, such that the gap is substantially reduced or eliminated. The flattened protrusion forms the carrier ring.