Metal/plastic containers with reinforcing ribs and drawing and ironing

Abstract

A container is provided having a can body defining an interior region for containing a product. The can body is of a metal/plastic multi-layer structure construction. The can body includes a side wall, a bottom profile comprising an annular rim defining a stand for the can body, an outer transition portion integral with the annular rim, and an inner transition portion connecting the annular rim to a central dome portion. In one embodiment a plurality of reinforcing ribs e.g., between 15 and 120, inclusive, are formed in the metal/plastic multi-layer structure in at least one of the outer transition portion and the inner transition portion. The ribs are formed in a spaced apart relation around the perimeter of such portion(s). In another embodiment a can body is made from a metal plastic laminate which is drawn and ironed. In one embodiment, the upper portion is die necked in a plurality of necking steps. In another embodiment, a cone top having threads for receiving a threaded closure is attached to the metal/plastic can body.

1 . A container comprising:
 a can body defining an interior region for containing a product, the can body formed from a metal plastic multi-layer structure material;   wherein the can body comprises a side wall and a bottom profile comprising an annular rim defining a stand for the can body, an outer transition portion integral with the annular rim, a central dome portion and an inner transition portion connecting the annular rim to the central dome portion;   wherein a plurality of reinforcing ribs are formed in the metal plastic multi-layer structure in at least one of the outer transition portion and the inner transition portion, said ribs formed in a spaced apart relation around the perimeter of such portion(s).   
   
   
       2 . The container of  claim 1 , wherein the reinforcing ribs are formed in both the outer transition portion and the inner transition portion. 
   
   
       3 . The container of  claim 1 , wherein reinforcing ribs are formed in the inner transition portion, each of the reinforcing ribs projects inwardly towards the interior of the can body and has a variable depth with a maximum depth D, and wherein the maximum depth D of the ribs is located substantially at the center the curve defining the inner transition portion. 
   
   
       4 . The container of  claim 1 , wherein reinforcing ribs are formed in the outer transition portion, each of the reinforcing ribs projects inwardly towards the interior of the can body and has a variable depth and a maximum depth, and wherein the maximum depth D of the rib is located substantially at the center of the curve defining the outer transition portion 
   
   
       5 . The container of  claim 1 , wherein the thickness of the metal in the metal plastic multi-layer structure in the side wall of the can body is between 20 and 50 percent of the thickness of the metal of the starting gauge metal plastic multi-layer structure. 
   
   
       6 . The container of  claim 1 , wherein ratio of the thickness of the metal in the metal plastic multi-layer structure to the thickness of the plastic in the metal plastic multi-layer structure is from between about 0.8 to 1 to about 1 to 3. 
   
   
       7 . The container of  claim 1 , wherein there are between 15 and 120, inclusive, reinforcing ribs, in the at least one of the outer and inner transition portions. 
   
   
       8 . The container of  claim 2 , wherein there are between 15 and 120, inclusive, reinforcing ribs in both the outer and inner transition portions. 
   
   
       9 . The container of  claim 1 , wherein the plastic in the metal plastic multi-layer structure comprises polyethylene terepthalate (PET). 
   
   
       10 . The container of  claim 3 , wherein ribs have a variable depth and wherein the maximum depth of the ribs is between about 0.5 and about 7 times the thickness of starting gauge of the metal plastic multi-layer structure. 
   
   
       11 . The container of  claim 1 , wherein the container comprises a container for a pressurized beverage. 
   
   
       12 . The container of  claim 1 , wherein the plurality of reinforcing ribs are formed in a forming step forming the bottom profile. 
   
   
       13 . The container of  claim 1 , wherein the annular rim has a radius of curvature and wherein said radius of curvature is less than 0.040 inches. 
   
   
       14 . The container of  claim 1 , wherein the ribs have a length and a width and wherein the length and width of the ribs is between about 3 and about 10 times the starting gauge thickness of the metal plastic multi-layer structure. 
   
   
       15 . The container of  claim 14 , wherein the ribs have a variable depth and wherein the maximum depth of the ribs is between about 0.5 and about 7 times the starting gauge thickness of the metal plastic multi-layer structure. 
   
   
       16 . A method of making a metal plastic multi-layer structure can body from a multi-layer structure material having an aluminum alloy layer and a plastic layer, comprising the steps of:
 drawing the multi-layer structure material into a cup;   drawing and ironing the cup to form a can body having a sidewall;   forming a bottom profile on the can body, wherein the bottom profile comprises an annular rim defining a stand for the can body, an outer transition portion integral with the annular rim, a central dome portion and an inner transition portion connecting the annular rim to the central dome portion;   and wherein the forming step further comprises the step of forming a plurality of reinforcing ribs in the aluminum alloy and plastic multi-layer structure in at least one of the outer transition portion and the inner transition portion, said ribs formed in a spaced apart relation around the perimeter of such portion(s).   
   
   
       17 . The method of  claim 16 , wherein the reinforcing spaced ribs are formed in both the outer transition portion and the inner transition portion. 
   
   
       18 . The method of  claim 16 , wherein there are between 15 and 120, inclusive, reinforcing ribs, in the at least one of the outer and inner transition portions. 
   
   
       19 . The method of  claim 16 , wherein there are between 15 and 120, inclusive, reinforcing ribs in both the outer and inner transition portions. 
   
   
       20 . The method of  claim 16 , wherein ribs have a variable depth and wherein the maximum depth of the ribs is between about 0.5 and 7 times the thickness of starting gauge of the multi-layer structure material. 
   
   
       21 . The method of  claim 16 , wherein the can body comprises a container for a pressurized beverage. 
   
   
       22 . The method of  claim 16 , wherein the plurality of reinforcing ribs are formed in a forming step forming the bottom profile. 
   
   
       23 . The method of  claim 16 , wherein the annular rim has a radius of curvature and wherein said radius of curvature is less than 0.040 inches. 
   
   
       24 . The method of  claim 16 , wherein the ribs have a length and a width and wherein the length and width of the ribs is between about 3 and about 10 times the starting gauge thickness of the metal plastic multi-layer structure material. 
   
   
       25 . The method of  claim 24 , wherein the ribs have a variable depth and wherein the maximum depth of the ribs is between about 0.5 and 7 times the starting gauge thickness of the metal plastic multi-layer structure material. 
   
   
       26 . The method of  claim 16 , wherein the forming step comprises the step of forming the reinforcing ribs in the inner transition portion, each of the reinforcing ribs projecting inwardly towards the interior of the can body and having a variable depth, and wherein the maximum depth D of the ribs is located substantially at the center of the curvature defining the inner transition portion. 
   
   
       27 . The method of  claim 16 , wherein the forming step comprises the step of forming the reinforcing ribs in the outer transition portion, each of the reinforcing ribs projecting inwardly towards the interior of the can body and having a variable depth, and wherein the maximum depth of the ribs is located substantially at the center of the curvature defining the outer transition portion. 
   
   
       28 . The method of  claim 16 , wherein the drawing and ironing step further comprises the step of reducing the thickness of the metal in the metal plastic multi-layer structure in the side wall of the can body to between 20 and 50 percent of the thickness of the metal of the starting gauge metal plastic multi-layer structure. 
   
   
       29 . A method of making a metal plastic multi-layer structure can body from a multi-layer structure material including an aluminum alloy layer and a plastic layer, comprising the steps of:
 drawing the multi-layer structure material into a cup;   drawing and ironing the cup to form a can body having a sidewall;   forming a bottom profile on the can body, wherein the bottom profile comprises an annular rim defining a stand for the can body, an outer transition portion integral with the annular rim, a central dome portion and an inner transition portion connecting the annular rim to the central dome portion; and   die necking the can body in a multitude of die necking steps to form a tapered neck portion.   
   
   
       30 . The method of  claim 29 , wherein the forming the bottom profile step further comprises the step of forming a plurality of reinforcing ribs in the multi-layer structure in at least one of the outer transition portion and the inner transition portion, said ribs formed in a spaced apart relation around the perimeter of such portion(s). 
   
   
       31 . The method of  claim 29 , wherein the drawing and ironing step further comprises the step of reducing the thickness of the metal in the multi-layer structure in the side wall of the can body to between 20 and 50 percent of the thickness of the metal of the starting gauge multi-layer structure. 
   
   
       32 . The method of  claim 29 , wherein the step of forming the bottom profile further comprises the step of forming the annular rim with a radius of curvature less than 0.040 inches. 
   
   
       33 . The method of  claim 29 , wherein the ratio of the thickness of the plastic in the multi-layer structure to the thickness of the metal in the multi-layer structure is in the range of between 0.8 to 1 and 3 to 1. 
   
   
       34 . The method of  claim 16 , wherein the ratio of the thickness of the plastic in the multi-layer structure to the thickness of the metal in the multi-layer structure is in the range of between 0.8 to 1 and 3 to 1. 
   
   
       35 . The method of  claim 16 , further comprising the step of seaming a cone top onto the can body. 
   
   
       36 . The method of  claim 16 , further comprising the step of necking the can body into a bottle configuration with a threaded neck. 
   
   
       37 . The method of  claim 29 , wherein the necking step comprises the step of necking the sidewall to have a bottle configuration having a threaded top for receiving a threaded closure. 
   
   
       38 . The method of  claim 30 , wherein the step of forming the bottom profile further comprises the step of forming the annular rim with a radius of curvature less than 0.040 inches. 
   
   
       39 . A method of making a metal plastic multi-layer structure can body from a multi-layer structure material including an aluminum alloy layer and a plastic layer, comprising the steps of:
 drawing the multi-layer structure mateiral into a cup;   drawing and ironing the cup to form a can body having a sidewall;   forming a bottom profile on the can body, wherein the bottom profile comprises an annular rim defining a stand for the can body, an outer transition portion integral with the annular rim, a central dome portion and an inner transition portion connecting the annular rim to the central dome portion; and   attaching a cone top to the can body.   
   
   
       40 . The method of  claim 39 , wherein the cone top further comprises integral threads. 
   
   
       41 . The method of  claim 39 , wherein the forming the bottom profile step further comprises the step of forming a plurality of reinforcing ribs in the metal/plastic multi-layer structure in at least one of the outer transition portion and the inner transition portion, said ribs formed in a spaced apart relation around the perimeter of such portion(s). 
   
   
       42 . The method of  claim 39 , wherein the step of forming the bottom profile further comprises the step of forming the annular rim with a radius of curvature less than 0.040 inches. 
   
   
       43 . The method of  claim 39 , wherein the ratio of the thickness of the plastic in the multi-layer structure to the thickness of the metal in the multi-layer structure is in the range of between 0.8 to 1 and 3 to 1.