A THREE-DIMENSIONAL BODY WITH MEANS FOR

TRANSFERRING A FLUID FROM THE BODY TO A

NARROW ORIFICE AND A METHOD AND APPARATUS

FOR MAKING THE SAME

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a three-dimensional body having means for transferring a fluid from the body into a narrow orifice and a method and apparatus for making the same. More particularly, this invention concerns a metal container having a stack portion with a reduced cross- section that is sized and proportioned to completely and stably fit within an orifice of a gas tank of the majority of motor vehicles available such that the fluid contents of the container may be transferred to the gas tank without spillage. Furthermore, this invention concerns a method and apparatus for making the container which employs a series of dies to reduce the cross-section of the stack portion of the container.

2. Description of the Related Art

One conventional container for automotive products comprises a cylindrical body member, a neck portion and a shoulder wherein the shoulder is positioned intermediate the neck portion and the body member. The cross-section of the shoulder is larger than that of the neck portion and smaller than that of the body member.

A typical gas tank for a motor vehicle has a conduit with one end thereof being connected to and extending from the gas tank which is positioned within the body of the automobile and the other end of the conduit ending in an orifice which leads to the exterior of the automobile body.

The nozzle of a gas pump engages the orifice and extends into the conduit to transfer gasoline to the gas tank from the gas pump. A flap is usually pivotably disposed within the conduit and blocks the orifice to trap the vapors emitted from the gasoline. When the nozzle is inserted into the conduit, it engages the flap which pivots out of the path of the conduit so that the gasoline can travel uninterrupted through the conduit to the gas tank.

When the conventional container carrying automotive products is inserted within the gas tank orifice, the edge of the gas tank orifice contacts the shoulder of the container and prevents the shoulder from being positioned within the gas tank orifice because the cross-section of the shoulder is larger than the cross-section of the orifice. Because the neck is not long enough to engage the flap, the flap may not completely pivot out of the path of the fluid being transferred through the conduit. Consequently, the fluid will be obstructed from passing through the conduit by the flap and may back up in the gas tank conduit and spill onto the exterior of the automobile and in some cases, onto the skin and clothing of the user. In the instance where the conduit does not have a flap to trap vapors, the neck portion may not extend deep enough within the conduit resulting in the fluid splashing off the side wall of the conduit and spilling out onto the automobile and the user.

Because most containers are made from metal, it is difficult to eliminate the intermediate shoulder to produce a longer neck portion with a cross-section that fits completely within the gas tank orifice. A metal container having such a configuration is desirable in order to transfer fluid through the conduit to the gas tank without spillage. Specifically, when deforming a large surface area of metal which is needed to produce a longer neck portion, heat is produced resulting in the deterioration of

the quality of the metal. For instance, the neck portion may fail and crack or paint may not adhere to the deformed neck portion.

No where in the prior art is there disclosed a metal container having a means for transferring a fluid from the container to a narrow orifice of a gas tank without spillage or a method or an apparatus for making the same. Therefore, there is a definite need for a container having means for transferring a fluid from a container into a narrow orifice of a gas tank that will prevent spillage of fluid and a method and an apparatus for making the same.

SUMMARY OF THE INVENTION

Accordingly, the preferred embodiment of the present invention provides a three-dimensional metal body comprising a body member and means for transferring substantially all of the fluid within the body member to a narrow orifice wherein the transferring means is a stack portion being sized and proportioned such that the stack portion is capable of stably and completely fitting within a gas tank orifice without spilling the fluid. Although the three-dimensional body may be made from a variety of metal materials, it is preferable that it be made from aluminum.

A preferred method according to the present invention comprises the steps of providing a metal slug; drawing the metal slug into a three-dimensional body having a first end portion, a second end portion, an interior surface and an exterior surface; ironing the walls of the three- dimensional body; coating the interior surface with a lacquer; and deforming the first end portion by pressing the first end portion successively in a plurality of dies whereby each time the first end portion is pressed into one of the plurality of dies the cross-section of the first end portion is further reduced to form a stack portion having

a substantially constant cross-section along the length of the stack portion which is sized and proportioned to stably and completely fit within a gas tank orifice.

The dies may contain a ceramic insert or be coated with a ceramic material such that the ceramic insert or the ceramic material will come into contact with the first end portion which is being pressed into the die.

Preferably, the deformation step comprises pressing the first end portion into successive dies thereby reducing the cross-section of the first end portion at least approximately sixty-six percent (66%) . Further, it is preferred that the greatest amount of reduction of the first end portion occurs during the steps of pressing the first end portion into the first four dies. This preferred method further provides for the step of painting substantially all of the exterior surface of body with a base coat in order to facilitate the adherence of the subsequent layers of paint to the exterior surface of the container. A preferred apparatus according to the present invention comprises an extruder that forms metal slugs into a three-dimensional body, a wall ironing device, a device for coating the interior surface with a lacquer, a mechanism for applying at least one layer of paint to the exterior of the three-dimensional body, a press having two platforms, one of the platforms having a plurality of die stations each with a center guide and a mold and the other of the platforms having means for holding the body during the deformation of the first end portion and a conveyor system which transports the three-dimensional body from one element of the apparatus to the other. The apparatus further comprises at least two stations on the first platform; one station at which the first end portion is threaded and a station at which the first end portion is trimmed.

7/47408 PC77US97/10154

Other details, objects and advantages of the present preferred embodiment, apparatus and method will become more apparent with the following description of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, the preferred embodiment of the invention and preferred method and apparatus for practicing the same are illustrated in which:

Figure 1 is a front elevational view of a container having means for transferring a fluid into a narrow orifice of a gas tank according to the present invention.

Figure 2 is a flow chart of the method of making the container shown in Figure 1.

Figure 3 is a cross-sectional view of a metal slug being drawn into a three-dimensional body according to the method of the present invention.

Figure 4 illustrates the ironing step of the method of the present invention.

Figure 5 illustrates the step of coating the interior of the container with a lacquer in accordance with the method of the present invention.

Figure 6 illustrates the step of coating the exterior of the container with a base coat and a layer of paint in accordance with the method of the present invention. Figure 7 illustrates the neck down machine of the apparatus of the present invention which deforms the first end portion of the container.

Figure 8 is a perspective side view of the apparatus shown in Figure 7. Figures 9a-9n are cross-sections of each of the dies of the neck down machine shown in Figure 7.

Figure 10 is a cross-sectional view of the threading station of the apparatus of the present invention.

Figure 11 is a cross-section of the trimming station of the apparatus of the present invention.

DETAILED DESCRIPTION OF THE PRESENT PREFERRED INVENTION

Although this invention is suitable for other uses, it will be described as being used in a container for transferring automotive products into a motor vehicle gas tank. Such description is for the purpose of explanation and is not intended to limit the scope of this invention.

Figure 1 illustrates a container 10 having a body member 12 and an elongated stack portion 14 with a cross- section which is substantially less than the cross-section of the body member 12. The body member 12 has a side wall 16 and a bottom wall 18. The body member 12 is in the shape of a cylinder but can take any configuration such as, hexagonal, square, or rectangular. The stack portion 14 defines threads 20 at the top thereof such that a cap (not shown) can be tightly sealed on the container 10. Although the stack portion 14 meets the body member 12 and forms ridges around the circumference at 22, the ridges are not required as part of the present invention.

The stack portion 14 is sized and proportioned such that it can engage a flap of an orifice of a gas tank of the majority of motor vehicles available and completely fit within the orifice without spilling any of the fluid being transferred therethrough. The length of the stack portion 14 is such that the stack portion 14 will extend deep within the conduit of a gas tank whereby no fluid will splash off the walls of the conduit or back up within the conduit and spill onto the automobile exterior or the user. The stack portion 14 preferably has a constant cross- section for its entire length. The stack portion cross- section is preferably approximately one-third the size of the cross-section of the body member 12. Preferably, the body member 12 has a diameter of between approximately 59mm

and 66mm and the stack portion 14 has a diameter of approximately 22mm.

Figure 2 illustrates a flowchart depicting a present preferred method for making the container 10 shown in Figure l. Such method substantially comprises providing a metal slug; drawing the metal slug into a three-dimensional body having a first end portion, a second end portion, an interior surface and an exterior surface; ironing the side wall 16 of the container 10; coating the interior surface with a lacquer; applying a base coat and at least one layer of paint to the exterior surface of the container 10; deforming the first end portion by pressing the first end portion successively into a plurality of dies such that a stack portion 14 is formed that will completely and stably fit within an orifice of a gas tank of the majority of motor vehicles available; threading the end of the stack portion 14; and trimming the end of the stack portion 14. Although the step of ironing the side wall 16 of the container 10 is not necessary to the method, it is preferred.

As shown in Figure 3, the metal slug 26 can be drawn into the three-dimensional body 19 shown in Figure 4 using a punch 24 to force the metal slug 26 to deform into the shape of a die 28. Specifically, the pressure of the punch 24 on the metal slug 26 forces the metal slug 26 into the recess 30 of the die 28 such that the metal slug 26 takes on the cylindrical shape of the die 28. Although the recess 30 is configured such that the three-dimensional body 19 forms a cylindrical shape, the interior of the die 28 may define many various shapes.

After the slug 26 is drawn into a substantially cylindrical configuration, a conveyor moves the three- dimensional body 19 to a wall ironing device where the side wall 16 is ironed so that the side wall 14 is relatively smooth. This process is shown in Figure 4. A planar body

25 having a first side surface 21, a second side surface 23 and a cylindrical surface 27 extending between the first side surface 21 and the second side surface 23 defines a tapered opening 29 which engages the exterior surface 31 of the three-dimensional body 19. The opening 29 is larger at the first and second side surfaces and tapers towards the middle of the cylindrical surface 27. The diameter of the three-dimensional body 19 is larger than the middle diameter of the opening 29. Thus, when the planar body 25 moves in the direction of the arrows such that the cylindrical surface 27 engages the three-dimensional body exterior surface 31, the diameter of the three-dimensional body 19 is reduced and creates a relatively smooth exterior surface. The planar body member 25 is drawn around the three-dimensional body 19 only once. The metal slug 26 is preferably made from aluminum.

The next step of this preferred method is shown in Figure 5. In this step, the interior surface 33 of the three-dimensional body 19 is coated with a lacquer. In the preferred method, a conveyor transports the three- dimensional body 19 such that a high powered sprayer 35 is positioned therein. The lacquer is then sprayed on the interior surface 33 of the container 10 using the high powered sprayer 35 which rotates when the lacquer is being applied such that the interior surface 33 of the container 10 is covered. Applying the lacquer to the interior surface 33 facilitates further processing of the three- dimensional body 19 by the machines discussed below and protects the three-dimensional body 19. Next the exterior surface 31 may be painted with a base coat and additional layers of paint for aesthetic purposes with the apparatus 45 as shown in Figure 6. This base coat prepares the exterior surface 33 of the three- dimensional body 19 for printing, protects the metal substrate and provides flexibility. The containers 10 are

positioned on cylindrical rods 37 of a rotating member 39. A second rotating member 41 has an ink fountain (not shown) which supplies paint to rubber rollers which then transports the paint to a plate and then to a blanket which paints the container 10. The container 10 is rotated 360° so that paint is applied by the blanket on the exterior surface 31. Preferably, the base coat is polyester and is cured at 160° C. After the base coat dries, additional layers of paint can be added to the exterior surface of the three-dimensional body 19 to provide various indicia. The step of curing the desired number of layers of paint to the base coat is preferably done at approximately 180° C.

After the layers of paint have completely dried, a conveyor belt 32 moves the three-dimensional body 19 to a neck down machine 34, shown in Figures 7 and 8. The neck down machine 34 deforms the first end portion of the three- dimensional body 19 to form the stack portion 14, threads the stack portion 14, and trims the stack portion 14. The neck down machine 34 is a press having two platforms 36 and 38. The first platform 36 reciprocates back and forth the length of a stroke 40 from the second platform 38 and contains die stations 42, shown in greater detail in Figures 9a through 9n. The station 47 for threading the stack portion 14 is shown in greater detail in Figure 10, and the station 49 for trimming the stack portion to a desired length is shown in greater detail in Figure 11. The second platform 38 rotates relative to the first platform 36 and holds a plurality of three-dimensional body 19. Referring to Figures 9a through 9n, die stations 42 each having a mold 44 and a center guide 46 are shown wherein the mold 44 is concentric to and surrounding the center guide 46. In progression from the first die station to the last die station, the interior surface 50 of the mold 44 is positioned closer and closer to the longitudinal

center axis 51 of the mold 44. The first die station 42 (Figure 9a) has a mold 44 with an interior surface 50 and a center guide 46 positioned concentric with the longitudinal center axis 51 of the mold 44 wherein the interior surface 50 defines a bore 54. The second die station (Figure 9b) also has a mold 44 with an interior surface 50 that defines a bore 54. The horizontal cross- section of the bore 54 of the second die station is slightly smaller than that of the bore 54 of the first die station 42. Also, comparing the die stations 42 going from the first die station (Figure 9a) to the last die station (Figure 9n) , as the bores 54 become smaller, the diameter of center guides 46 also become smaller. When using a deformation process such as pressing an aluminum body 19 successively into a series of die stations 42, the molds 44 must be spaced from the center guides 46 concentrically such that the die stations 42 allow for the increase in thickness of the side wall 16 of the body 19 resulting from the deformation process. A mold 44 is machined to roughly mimic the negative of the desired shape of the container 10 and then polished by forcing a compound through the mold 44 in the direction that the metal will flow while being deformed. In the present invention, when the container 10 is being pressed within the die station 42, the metal of the container 10 will flow concentric to the longitudinal axis of the mold 44. The interior surface 50 of the mold 44 is therefore, preferably polished concentrically with respect to the longitudinal center axis of each mold 44. Alternatively, in order to reduce the friction created during the deformation steps, the interior surfaces 50 of the mold 44 may be coated with a ceramic material 56

(Figure 9a) or a ceramic insert 58 (Figure 9b) can be inserted within the mold 44 to form an interior ceramic surface 52.

In operation, the second platform 38 holds the containers 10 such that the stack portion 14 will be guided over the center guide 46 which will support the stack portion 14 while the stack portion 14 is being deformed so that the deformation will occur uniformly over the surface of the stack portion 14. The first die station 42 (Figure 9a) engages container 10 at the beginning of the deformation process with the forward stroke of the first platform 36. During the backward stroke of the first platform 36, the die station 42 is withdrawn from contact with the container 10 and the second platform 38 rotates such that the containers 10 are advanced and the second die station 42 (Figure 9b) and the stack portion 14 will next engage which thus, further reducing the cross-section of the stack portion 14. This process is repeated for each of the die stations 42. Preferably, the stack portion 14 is deformed the most when the stack portion 14 engages the first four die stations 42. A various number of die stations 42 may be utilized depending on the type of metal being deformed, the degree of deformation desired and the amount of deformation desired or obtainable in each deformation step.

After being deformed, the station 47 engages the stack portion 14 such that the stack portion 14 is then roll threaded as shown in Figure 10. The station 47 has an aligning structure 62, a cutter 64 and a supporting structure 66. The aligning structure 62 is preferably cylindrical. The cutter 64 has teeth 68 and is positioned adjacent to the supporting structure 66. The support structure is also preferably cylindrical and has circular teeth 70 around its circumference. The profile of the teeth 68 mesh with the teeth 70. The stack portion 14 is positioned between the supporting structure 66 and the cutter 64. A first motor 72 turns the container 10 while the stack portion 14 is being threaded by the cutter 64.

Specifically, the teeth 70 push out on the stack portion 14 and the teeth 68 push inward on the stack portion 14 to form the threads 20.

The station 47 disengages from the container 10 and the second platform 38 rotates such that during the forward stroke, the station 49 engages the stack portion 14. The stack portion 14 is placed around a center guide 74 which is within a cylindrical housing 76, where the container 10 is rotated by a second motor 78 such that a knife mounted on the holder 80 trims the stack portion 14 to a desired length as it rotates.

The following commercially available components can be used to construct the apparatus which will perform the present preferred method:

While the present preferred embodiment, method and apparatus of making the same have been described herein, it is distinctively understood that the invention is not limited thereto, but may be otherwise variously embodied within the scope of the following claims and any equivalence thereof.