Variable-Diameter Can Punch for Lighter Necked Beverage Cans
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Solution Overview
Problem
Existing beverage can manufacturing processes face challenges in reducing weight while maintaining strength and ensuring proper connection of the can end, particularly in the neck area, where material inhomogeneity leads to defects and increased material consumption.
Innovation Solution
A punch with a cylindrical body featuring a region forming a thick wall with variable diameter, comprising multiple sections with varying lengths and diameters, allowing for a semi-finished can with a thick wall of variable thickness, which is thinned in the neck area to reduce weight and material consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a conventional punch with constant diameter is used, then the can wall thickness is uniform, but the can weight is higher and material consumption is increased
Solution Approach 1:
The punch is designed with different diameter sections: a first section with diameter D1 for forming the can body, and a second section with smaller diameter D2 for forming the neck region. This local variation in punch geometry creates localized thinning of the can wall in the neck area, reducing overall can weight while maintaining uniform thickness in the body where strength is required.
Solution Approach 2:
The punch is divided into multiple functional sections along its length: a first section for forming the main can body and a second section for forming the neck. This segmentation allows each section to perform its specific function with optimized geometry, enabling selective material thinning in the neck region while preserving wall thickness in the body.
2Weight of moving object
If the punch diameter is reduced in the neck region, then material thickness is reduced and weight is decreased, but the structural strength may be compromised
Solution Approach 1:
The punch diameter parameter is changed along its length, with D2 in the neck-forming section being smaller than D1 in the body-forming section. This parameter variation enables controlled material thinning in the neck region. The specific diameter values and the transition zone length are optimized to achieve the desired wall thickness reduction while maintaining sufficient strength for double seam connection.
3Loss of substance
If a variable diameter punch is used, then material thickness in the neck area is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The punch incorporates a transition zone between the first and second sections where the diameter changes from D1 to D2. This dynamic geometry allows for controlled material flow and thickness variation during the drawing process. The transition zone design ensures smooth material deformation, preventing defects while achieving the desired thickness reduction in the neck region.
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 solution results in a lighter beverage can with reduced material usage and improved material distribution, maintaining quality and enabling a secure double seam connection.
Implementation Method 1
a punch for drawing beverage cans (140)... A punch with a cylindrical body and a region forming a thick wall, where the diameter in this region is variable and smaller than the sidewall diameter... allowing for a non-linear profile that reduces material thickness in the neck area
Data Source
AI summary
A punch for drawing beverage cans comprising a cylindrical body with a separated region (1) forming a can side wall having diameter D1, a step (2), and a region (3) forming a thick wall, characterized in that, the region (3) forming thick wall starts from the step (2), and the diameter D2 of the punch in this region (3) is variable and is smaller than the diameter D1 of the region (1) forming can's sidewall. The object of the invention is also a beverage can in the form of a semi-finished can, and a finished beverage can manufactured with use of the said punch.