The desirability of reducing metal usage in can ends for pressurized beer and beverage cans has been well recognized for at least thirty years. Many patents have been granted on various end shell and easy opening end designs and methods of manufacture for achieving such reduced metal usage.

Most commercial end shells for pressurized beer and beverage ends today are formed by a so-called free forming or semi-free forming technique in which the countersink bead in the end shell is formed by causing the metal to be rolled into the shape of the countersink bead as is illustrated and described in U. S. Patent 4,109, 599 in the name of Freddy R. Schultz. According to the teaching of that patent, a first supporting tool is moved against the exterior surface of the peripheral end curl and a second stationary supporting tool is applied against the interior surface of the central wall portion to cause the countersink or reinforcing channel to form in the end shell.

The free forming technique of the Schultz patent has enabled the use of higher yield strength aluminum alloys (50 ksi and higher) and reductions in metal gauge while maintaining buckle resistance against relatively high pressures in containers. Figure 1 hereof shows a typical commercial end shell formed by such a technique. As shown in that figure, the end shell has a central wall portion 10, an inner wall 80, an annular groove 78, a frustoconical portion 14 and a peripheral flange 16. In a preferred embodiment, the central wall portion is disposed at a height h of from 0. 070-0.090 inch above the bottom of he annular groove 78.

U. S. Patent 6,065, 634 to Brifcani et al. discloses a can end and method for fixing it to a can body using less metal, while still permitting stacking. Figure 2 hereof is representative of end shells made in accordance with the Brifcani et al patent.

The can end has its chuckwall 24 inclined to vertical at an angle C° between 20° and 60°, and preferably between 40 degrees and 45 degrees, and has a concave bead (or countersink) 25 with a radius r3 less than about 0.75 mm (0.0295 inches). The can end is preferably made from a laminate comprising an aluminum magnesium alloy sheet such as 5182 or an aluminum manganese alloy such as 3004 with a layer of polyester film on one side. Table 2 in the patent includes dimensions of end shells made in accordance with the patent as having a countersink height h2of 6.87 mm (0.270 inch) to 7.37 mm (0.290 inch), a panel height h3 in a range of 2.39 mm (0.094 inch) to 2.80 mm (0.114 inch), and a lower chuckwall height h4 in a range of 2.29 mm (0.09 inch) to 2.74 mm (0.11 inch).

WO 98/34743 (Al) in the name of Carnaudmetalbox PLC illustrates and describes an unseamed can end and a method of reforming it similar to that disclosed by U. S. Patent 6,065, 634 except that the chuckwall has two parts comprising a first (upper) part inclined to vertical at an angle between 1° and 39° and a second (lower) part inclined to vertical at an angle of between 30° and 60°. The first part of the chuckwall is deformed during a seaming operation to be substantially vertical as constrained between the seaming roll and the cylindrical sidewall of the chuck.

U. S. Patents 4,217, 843 and 4,448, 332 to Kraska disclose a metal end shell and method and apparatus for forming it from sheet metal having reduced thickness. Fig. 3 hereof represents Kraska's end shell which has a countersink 20 having a radius Rl less than three times the metal thickness, a depth H of at least 0.075 inch, and an outer wall 24 in the countersink having an angle B that is preferably less than five degrees to a vertical plane P. The end shell further has a second wall portion 34 defined by an angle C that is preferably at least six times greater than angle B. A peripheral curl 12 and central panel portion 14 border the countersink 20 and wall portion 24. The patent states that several million 209 diameter ends were made in accordance with the invention from 0.012 gauge 5182-Hl9 aluminum in which the finished ends have a radius R, of approximately 0. 030 inches, an angle B of approximately 4 degrees and an angle C of approximately 25 degrees.

Other end shell profiles and techniques for reducing metal usage while maintaining acceptable buckle resistance are disclosed in U. S. Patents 6,102, 243 (Fields et al. ), 6, 089, 072 (Fields), 5, 685, 189 (Nguyen et al. ), 5,046, 637 (Kysh), 4,991, 735

(Biondich), 4,809, 861 (Wilkinson et al. ), 4,606, 472 (Taube et al. ), 4,093, 102 (Kraska), and 3, 843, 014 (Caspen et al.) ; and Japanese Utility Model No. 2,544, 222, among others.

Despite the significant progress that has been made in reducing the gauge of metal used in end shells while maintaining buckle resistance, further enhancements are needed that will facilitate the uses of higher yield strength metal in such end shells and thereby facilitate greater metal savings.

This invention is particularly addressed to end shells that are to be converted into easy opening ends for beer and beverage cans, and to such converted ends suitable to be double seamed on aluminum can bodies. Most end shells and can ends in commercial use today are made of hard temper aluminum alloys, most of which alloys contain magnesium in a range of about 4.0 to 5.0 weight percent. For example, most easy opening ends for beer and beverage containers are currently made of 5182 aluminum alloy containing about 4.5-4. 7 weight percent magnesium. Continual improvements in these aluminum alloys and their manufacture into sheet material are producing materials of higher longitudinal yield strength and ultimate strength. Such higher yield strength alloys provide opportunities for reducing metal usage through gauge reduction. One such alloy is 5019A aluminum alloy, as registered with the American Aluminum Association. That alloy contains a nominal weight percent of magnesium of 4.9, and has an average longitudinal yield strength of 53.5 ksi.

Can end diameters for beer and beverage cans have been getting smaller in order to reduce metal usage in the ends. Can end sizes are conventionally described in terms of inches and sixteenths of inches, such that a can end having a diameter of 2 6/16 inches, for example, is referred to as a 206 diameter can end. A 202 diameter can end has a diameter of 2 2/16 inches. Most beer and beverage can ends today are 204 and 202 diameters.

This invention is addressed to maintaining commercially required buckle resistance of can ends. Buckle resistance means the resistance of can ends to being permanently deformed by internal pressure in packed cans on which the ends are double seamed. Beer ends typically must be able to resist pressures of at least about 92 psig in the cans, and beverage ends typically must be able to resist pressures of at least about 90 psig.

A feature of end shells of this invention is that they have reduced age

buckle losses, which are losses in buckle resistance following manufacture of the end shells and easy opening can ends. As used herein, age buckle losses means the loss in buckle resistance within a certain number of days, such as 30 or 90 days, after manufacture of the end shells and ends. Excessive age buckle losses are a known shortcoming of current end shells since the losses make it difficult for manufacturers to predict the eventual buckle resistance of their can ends.

This invention provides a metal end shell having an annular countersink bead around a central panel portion, a substantially vertical lower chuckwall portion in the countersink bead, an upper chuckwall portion extending upwardly and outwardly from the lower chuckwall portion at an angle of about 20-35° to vertical, and a curved peripheral flange for double seaming to a container wall. The countersink bead has an internal width of about 0.020-0. 040 inch and the end shell has a countersink depth less than about 0.250 inch.

This invention provides a metal end shell profile that can be formed with a low draw ratio, thus permitting the use of higher yield strength metal.

Accordingly, it is an object of this invention to provide a metal end shell having commercially acceptable buckle resistance with reduced metal usage.

Another object of this invention is to provide an end shell that facilitates use of higher yield strength metal.

A further object of this invention is to provide a metal end shell that has reduced buckle losses during aging.

Another object of this invention is to facilitate the use of thinner gauge metal in end shells for pressurized containers.

A further object of this invention is to provide an end shell that is easier to form and which can be formed with a low draw ratio and with a shorter press stroke.

Another object of this invention is to provide an end shell that can be formed from a sheet metal disc having a reduced cut edge diameter.

A further object of this invention is to provide an end shell on which additional forming operations may be performed to enhance the performance characteristics.

The above and other objects and advantages of this invention will be more fully understood and appreciated with reference to the following description and

the drawings attached hereto.

Figure 1 (Prior Art) is a fragmentary cross-sectional view through a typical commercially produced metal end shell known in the can making industry.

Figure 2 (Prior Art) is a cross-sectional view through a metal end shell of the type illustrated and described in U. S. Patent 6,065, 634 (Brifcani et al.).

Figure 3 (Prior Art) is a fragmentary cross-sectional view through a metal end shell of the type illustrated and described in U. S. Patents 4,217, 843 and 4,448, 322 (Kraska).

Figure 4 is a cross-sectional view through a preferred embodiment of a metal end shell of this invention.

Figure 5 is a graph showing changes in buckle resistance of end shells of this invention as a function of the angle of the upper chuckwall portion of the shells and the location of the chuckwall bend between the upper and lower chuckwall portions.

Figure 6 is a plan view of a metal disc suitable for forming into a metal end shell of this invention.

Figure 7 is a fragmentary view, in partial cross-section, of an easy opening end of this invention double seamed on a metal can body.

Figure 8 is a graph showing age buckle resistance losses in end shells of this invention.

A preferred embodiment of a metal end shell 30 of this invention is illustrated in Figure 4 as including a central panel 32, a panel radius 34 around the panel 32, a panel wall 36 extending downwardly from the panel radius, a countersink radius 38, a lower chuckwall portion 40 extending upwardly from the countersink radius 38, a chuckwall bend radius 42 at the top of the lower chuckwall portion 40, an upper chuckwall portion 44 extending upwardly and outwardly from the chuckwall bend radius 42, a seaming panel radius 46 at the top of the upper chuckwall portion, a seaming panel 48 extending outwardly from the seaming panel radius, and a curl 50 on the outer end of the seaming panel. The term"radius"as used above means the curved <BR> <BR> segment of sheet metal and not the radius of curvature, i. e. , not the length of the straight line extending from the center of curvature. The radii of curvature are described below.

Figure 4 shows a series of curved and generally straight portions of the end shell 30 (in cross-section). The extent of the curved portions, such as panel radius

34, countersink radius 38 and chuckwall bend 42, is generally to the point of tangency with the contiguous straight portion, such as central panel 32, panel wall 36, lower chuckwall portion 40 and upper chuckwall portion 44, or to the point of intersection between the contiguous curved segments of the seaming panel radius 46, seaming panel 48 and curl 50.

The extent of the straight (in cross-section) portions of the end shell 30 include dl as the diameter of the central panel 32 as measured between the points of tangency of the panel radius 34 with the panel wall 36 on product side of the end shell on both ends of a diametrical line through the center of the end shell. The curl diameter of the end shell is shown as d2, and the panel depth h, is measured from the undersurface of the countersink radius 38 to the undersurface of the central panel 32 at its point of tangency with the panel radius 34. The height h2of the panel wall 36 is the vertical distance between the points of tangency of the panel wall 36 with the panel radius and the countersink radius. And h3 is the vertical height of the lower chuckwall portion 40 as measured between the point of tangency of the countersink radius 38 with the lower chuckwall portion and the midpoint in the chuckwall bend 42. The overall depth h4 (vertically) of the end shell is called the countersink depth and is measured from the top surface of the seaming panel to the upper or public surface of the countersink radius 38 at the bottom of the radius.

As used herein, the term"product side"means the undersurface of the end shell 30 since that is the side that faces the product when the end shell has been converted into an easy opening end and double seamed onto a filled can body. The product side may also be referred to as the undersurface or bottom surface. The"public side"is the top surface or upper surface of the end shell opposite the product side of the end shell.

This invention provides a unique and non-obvious profile for the end shell 30. This profile includes an upper chuckwall portion 44 having an angle a to vertical in the range of 20-35° and a countersink bead having a width w in the range of 0.020-0. 040 inch as measured on the inside of the countersink groove (public surface) between the points of tangency of the countersink radius or radii with the panel wall 36 and the lower chuckwall portion 40. It is also a feature of this invention that it has a countersink depth h4 that is less than about 0.250 inch and preferably less than about

0.243 inch depending on several factors such as the size of the end shell, the alloy, temper and thickness of the metal in the end shell, and the angle a of the upper chuckwall portion among other factors. The countersink depth h4 may even be as low as 0.235 inch for some end shells.

The countersink depth h4 in the preferred embodiments is generally independent of the diameter of the end shell. For example, end shells having 202 and 204 diameters preferably have about the same range of countersink depths with this invention.

An end shell 30 of this invention preferably has a panel depth hl that is less than about 0.070 inch and preferably about 0.065 inch. The length h3 of the lower chuckwall portion is influenced by the panel depth hl and the desired location of the chuckwall bend radius 42. The center of the radius of curvature r of the bend radius 42 is preferably within about 0.010 inch of a plane through the line of tangency of the central panel 32 with the panel radius 34. This location of such bend radius 42 is desirable for maintaining buckle resistance of the can ends formed from the end shell.

Figure 5 is a graph showing predicted changes in buckle resistance of end shells of this invention as a function of the location of the bend radius 42 and the angle of the upper chuckwall portion 44 to vertical. The data for this graph was generated by an analytical software program and partially confirmed by test data on end shells. If the other dimensions of the end shell remain constant, then raising or lowering the bend radius 42 also changes the angle of the upper chuckwall portion 44. The unique combination of the angle and the bend radius according to this invention is important in maintaining buckle resistance of the end shell.

Referring again to Figure 4, the lower chuckwall portion 40 is preferably substantially vertical but may have a small angle to vertical. The panel wall 36 is also substantially vertical, but may have a small angle to vertical (see for example Biondich U. S. Patent 4,991, 735). The seaming panel 48 and the curl 50 are preferably conventional.

The countersink radius 38 may be either a simple radius or a compound radius depending on several factors such as the tools used to form the end shell and/or reform it. A simple radius means a uniform or unchanging radius of curvature for the full extent of the countersink radius 38. A compound radius means that the radius of

curvature changes along the length of the curved segment 38. The radius of curvature may be smaller or larger at different points along the length of the countersink radius.

Generally speaking, the radius of curvature of the countersink radius 38 is preferably in a range of about 0: 010 to 0.020 inch for a simple radius and about 0.006 to 0.040 inch for a compound radius of curvature.

End shells 30 of this invention are preferably formed from aluminum alloy sheet material having relatively high longitudinal yield strengths and/or longitudinal ultimate strength. Preferred alloys preferably have average longitudinal yield strengths of about 53.5 ksi and a minimum of about 52 ksi. They may have longitudinal ultimate strengths of more than about 59 ksi. As used herein, longitudinal yield strength and longitudinal ultimate strength are measured with the grain of the metal and parallel to the rolling direction. End shells of this invention are preferably formed from relatively thin gauge aluminum alloy sheet material having thicknesses of less than about 0. 0088 inch or even less than about 0.0084 inch, but can be formed from thicker sheet metal. End shells of this invention may also be formed from steel sheet metal of various gauge thicknesses.

Figure 6 shows a metal disc of a type suitable for forming into an end shell of this invention, and includes an exaggerated representation of grains in the metal.

The grains in the metal are produced by elongation of the metal during the rolling process used to form the sheet material. The grain runs generally parallel to the direction of rolling. Grain in the metal must be taken into consideration in the manufacture of end shells because the metal in the disc tends to elongate non-uniformly and"ear"or form a slightly irregular outer lip on the manufactured end shell. The discs used to manufacture end shells are therefore conventionally slightly out-of-round to accommodate for this earing. The cut edge diameter d4 of the disc is conventionally measured transverse to the grain of the metal in the disc. It is believed that this invention may reduce the impact of earing on the final end shells and can ends that occurs in the manufacture of such end shells and can ends.

End shells 30 of this invention can be formed by a variety of methods and tools known in the art, with some modification of such tools. Representative of such methods and tools are those shown in U. S. Patent 5,857, 734 and 5,823, 040 (Stodd), U. S. Patent 4,109, 599 (Schultz), and U. S. Patent 4, 808, 052 (Bulso et al), the disclosures

of which are incorporated herein by reference. As stated above, the methods and tools disclosed by these patents free form or partially free form the countersink radius in the end shells. The manufacture of end shells of this invention facilitate the use of a shallower draw using such methods and tools and may permit a shorted press stroke.

This facilitates operation of the tools at faster speeds and lets the tools run more smoothly. It is believed that this invention will permit a shorter press stroke and may save energy in the operation of the presses.

End shells 30 of this invention are suitable to have performance enhancement reforming or coining performed on them. Several such techniques are known in the art as shown, for example, in U. S. Patents 5, 685, 189 (Nguyen et al.), 5,149, 238 (McEldowney et al. ), and 4,991, 735 (Biodich), among others. Such reforming or coining operations may be performed as separate operations or as part of the conversion of the end shells into easy opening can ends.

Figure 7 shows an easy opening can end 52 formed from an end shell of this invention on a can 54 filled with beer or beverage 56. The can end 52 has a pull tab 58 attached to a portion of the central panel of the end that is at least partially removable in order to form a pour opening in the can end. An integral rivet 60 is conventionally used to attach the pull tab 58 to the can end 52. The conversion of end shells into easy opening can ends is well known in the art. As stated above, such conversion processes may include reforming or coining of the end shell to enhance its resistance to buckling.

Figure 8 is a graph showing age buckle losses in can ends made in accordance with this invention. The age buckle losses are typically measured over a period of 90 days, after which time there are minimal additional losses. As seen in this chart; 202 end shells of this invention made of HI 9 aluminum alloy have age buckle losses of less than 6% over a period of 35 days. The end shells have age buckle losses of less than about 8% and as low as about 6% over a period of 90 days. This is substantially less age buckle loss than in typical conventional prior art end shells, which have age buckle losses of approximately 8-9% at 30 days. Reduced age buckle losses with end shells of this invention will improve the manufacturer's ability to predict the eventual buckle resistance of his can ends when double seamed onto cans of pressurized beer or beverage.

The following table shows dimension of 202 end shells made in

accordance with this invention in comparison with three typical commercially produced prior art end shells. The Prior Art 1 is typical of end shells made in accordance with U. S. Patent 6,065, 634 (Brifcani et al. ) ; Prior Art 2 is typical of end shells made by tools sold by Redicon Corporation of Canton, Ohio; and Prior Art 3 is typical of end shells made by tools sold by Formatec Tooling Systems in Dayton, Ohio.

This Dimension (inch Invention Prior Art 1 Prior Art 2 Prior Art 3 Cross Grain Cut Edge Diameter 2.759 2.74 2.854 2.854 Countersink 0.235 0.255 0.270 0.270 Panel Depth 0.065 0.095 0.090 0.090 Wall Transition 0.065 0.060 0.060 0.060 Countersink Radius 0.015 0.020 0.020 0.020 Panel Diameter 1.847 1.690 0.855 0.851 Cut Edge/Panel Diameter 1.49 1.62 1.54 1.54 Cut Edge/Countersink 11.74 10.75 10.57 10.57 Cut Edge/Panel Depth 42.45 28. 84 31.71 31.71 Countersink/Panel Depth 3.62 2.68 3.00 3.00 In accordance with this invention, the panel depth h of the end shell is preferably less than about 0.070 inch and more preferably about 0.065 inch. The countersink depth h4 is preferably less than about 0.250 inch and more preferably less than about 0.243 inch, and about 0.235 inch. A preferred end of this invention has a panel depth hl of about 0.065 inch and a countersink depth h4 of about 0.235 inch. As previously described, end shells of this invention have an upper chuckwall portion 44 disposed at an angle of about 20-35 degrees to vertical, a countersink width of about 0.020-0. 040 inch, and a chuckwall bend radius location within plus or minus about 0. 010 inch of a plane through the line of tangency of the central panel portion 32 with the panel radius 34. These dimensions are preferred regardless of whether the end shell is 202 or 204, and possibly other shell diameters. The exact dimensions of the end shells will vary depending on a variety of factors such as metal alloy, temper and gauge, the particular tools used to form the end shells and the dimensions of such tools, and the preference of the particular manufacturer. The spring back of metal following

completion of forming of the end shell at the bottom of the press stroke will also vary slightly, so the dimensions of the end shells will also vary accordingly.

Particular note should be taken of the substantially smaller panel depth h, and countersink depth h4 of end shells of this invention while maintaining the panel diameter d, in order to provide a large enough central panel 32 in which to form easy opening features (tear strips and pull tab). The cut edge diameter of end shells of this invention is also close to the smallest cut edge diameter for the prior art, while providing a larger central panel diameter. End shells of this invention preferably have a ratio of the cut edge diameter to panel diameter of less than about 1.53, with a typical ratio of about 1.49. End shells of this invention also have a relatively high ratio of the countersink depth h4 to the panel depth hl, such as a preferred ratio of at least 3.50, and a typical ratio of about 3.62.

It is therefore seen that this invention provides end shells and converted easy opening ends that are well suited for manufacture from newer higher longitudinal yield strength metal. The end shells of this invention provide commercially acceptable buckle resistance with lower age buckle losses and facilitate metal savings. The invention reduces the draw required to form the end shells and improves performance of the forming tools. The unique combination of relationships in the end profile of this invention provides optimization of multiple parameters to minimize metal usage while maintaining acceptable commercial performance of the end shells.

Preferred embodiments of the invention have been described and shown for illustrative purposes. It will be apparent to those skilled in the art that many modifications can be made to the preferred embodiments without departing from the spirit of the invention or the scope of the appended claims.