Single-Alloy Beverage Can Body and End for Recyclable Strength
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Solution Overview
Problem
Conventional beverage containers are produced from different aluminum alloys for their components, leading to inefficiencies and potential inconsistencies in mechanical properties and recyclability.
Innovation Solution
The method involves forming beverage containers using a single, substantially compositionally identical aluminum alloy for both the can body and can end, with the option of heat treating the alloy to enhance mechanical properties through age hardening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If different aluminum alloys are used for can body and can end, then each component can be optimized for its specific mechanical requirements, but manufacturing complexity increases and recyclability decreases
Solution Approach 1:
The patent applies homogeneity by using a single aluminum alloy composition (e.g., 5182 or 3104) for both the can body and can end components. This eliminates the need to manage multiple alloy types throughout the manufacturing process, simplifying production while maintaining adequate mechanical properties through optimized heat treatment and forming parameters.
Solution Approach 2:
The patent makes the single aluminum alloy universal by selecting an alloy composition that can serve multiple functions across different container components. The same base alloy is used for both can body and can end, allowing a unified material specification that simplifies supply chain management and recycling processes while meeting the mechanical requirements of both components through controlled processing.
2Strength
If different aluminum alloys are used for can body and can end, then each component can be optimized for its specific mechanical requirements, but recyclability and material consistency decrease
Solution Approach 1:
The patent ensures material consistency by maintaining a uniform aluminum alloy composition across all container components. This homogeneity in base material composition facilitates easier recycling since single-alloy containers can be processed together without the need for separation or complex sorting procedures, while still achieving component-specific mechanical properties through controlled forming and heat treatment.
Solution Approach 2:
The patent compensates for using a single alloy composition by adjusting processing parameters such as heat treatment temperature, forming temperature, and aging conditions. These parameter changes allow the same base alloy to achieve the different mechanical strength levels required for can body and can end components, thereby maintaining material consistency while meeting performance requirements.
3Ease of manufacture
If conventional different alloys are used, then component-specific optimization is achieved, but production efficiency and cost-effectiveness decrease
Solution Approach 1:
The patent improves production efficiency by using a homogeneous single-alloy system that eliminates the need for separate inventory management, handling, and processing lines for different alloy types. This simplification accelerates production throughput while maintaining ease of manufacture through well-established aluminum forming and heat treatment processes.
Solution Approach 2:
The patent merges the material specifications for can body and can end into a single alloy system, combining what were previously separate material streams into one unified flow. This consolidation simplifies manufacturing operations, reduces changeover times between production runs, and improves overall productivity while keeping the process easy to manufacture with standard equipment.
4Device complexity
If a single aluminum alloy is used for can body and can end, then manufacturing simplicity and recyclability improve, but component-specific mechanical optimization becomes more difficult
Solution Approach 1:
The patent overcomes the limitation of using a single alloy by adjusting processing parameters such as heat treatment temperature, holding time, cooling rate, and forming temperature. These parameter changes enable the same base alloy composition to achieve different final mechanical properties tailored to the specific requirements of can body and can end components, thereby maintaining manufacturing simplicity while achieving component-specific optimization.
Solution Approach 2:
The patent applies preliminary heat treatment or alloying adjustments to the single aluminum alloy before forming operations to pre-condition the material for achieving the required mechanical properties in specific components. This preliminary action allows subsequent forming and final heat treatment to produce the desired component-specific characteristics without changing the base alloy.
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 approach allows for the production of beverage containers with improved mechanical strength and increased recyclability, using a higher percentage of recycled aluminum materials, while also enabling the use of thinner aluminum sheets.
Implementation Method 1
the option of heat treating the alloy to enhance mechanical properties through age hardening
Data Source
AI summary
In a method of forming a beverage container, a can body is formed from a metal alloy. A can end is formed from a substantially compositionally identical metal alloy. The metal alloy is a heat treatable aluminum alloy. The heat treatable aluminum alloy is produced from up to 100% recycled aluminum material.