Method for forming cut for tab and end manufacture

Abstract

A process is described for producing substantially continuous cuts or coils for tab or shell manufacture. A coil of aluminum alloy is split into at least first and second cut coils, each of the first and second cut coils having a cut strip width less than a width of the aluminum alloy coil, and the free ends of the cut strip coiled on the first and second coils are connected to form a continuous cut strip having a length longer than a length of the strip on the aluminum alloy coil.

What is claimed is: 
     
         1 . A process, comprising:
 splitting a coil of aluminum alloy into at least first and second cut coils, each of the first and second cut coils having a cut strip width less than a width of the aluminum alloy coil; and   connecting free ends of the cut strip coiled on the first and second coils to form a continuous cut strip having a length longer than a length of the strip on the aluminum alloy coil.   
     
     
         2 . The process of  claim 1 , wherein the continuous cut strip is coiled on the first and second coils, wherein the first and second coils are stacked one-on-top-of-the-other and separated by a spacer, and wherein the length of the continuous cut strip is at least about 150% of the length of the strip on the aluminum alloy coil. 
     
     
         3 . The process of  claim 1 , wherein the splitting step is performed by a splitter, wherein the free ends are connected by a welder, and wherein the connecting step comprises:
 placing the first and second cut coils on an entry mandrel; and   welding the free end of the first cut coil to the free end of the second cut coil.   
     
     
         4 . The process of  claim 1 , wherein the continuous cut strip is coiled on a common coil, wherein the coil is staggered back-and-forth across a face of a rewind mandrel, and wherein the length of the continuous cut strip is at least about 150% of the length of the strip on the aluminum alloy coil. 
     
     
         5 . The process of  claim 1 , wherein the splitting step is performed by a splitter, wherein the free ends are connected by a welder, and wherein the connecting step comprises:
 positioning the first and second cut coils on an entry mandrel;   locating the first cut coil at a selected point along a length of the entry mandrel;   unwinding the first cut coil from the entry mandrel and rewinding the first cut coil on a rewind mandrel;   when the first cut coil is unwound and rewound on the rewind mandrel, locating the second cut coil at the selected point; and   connecting the free end of the first cut coil to the free end of the second cut coil to form the continuous cut strip; and further comprising:   unwinding the second cut coil from the entry mandrel and rewinding the second cut coil on a rewind mandrel.   
     
     
         6 . The process of  claim 5 , wherein the rewind mandrel reciprocates back-and-forth while the first and second cut coils are rewound on the rewind mandrel to form a stagger wind of the continuous cut coil on the rewind mandrel. 
     
     
         7 . The process of  claim 1 , wherein the free end of the first cut coil is an inner diameter end of the first cut coil and the free end of the second cut coil is an outer diameter end of the second cut coil. 
     
     
         8 . The process of  claim 1 , wherein the continuous cut coil is marked in spatial proximity to a weld line connecting the free ends to enable sensor at a can plant to detect the weld. 
     
     
         9 . The process of  claim 1 , wherein the continuous cut coil is tab stock and further comprising:
 passing the continuous cut coil and can end shells through a conversion press to form a finished can end having a tab positioned on a can end.   
     
     
         10 . The process of  claim 1 , wherein the width of the aluminum alloy coil ranges from about 10 to about 75 inches and the width of each of the first and second cut coils ranges from about 1 to about 10 inches. 
     
     
         11 . A continuous cut strip having first and second strip ends welded together and being coiled on first and second coils, wherein the first and second coils are stacked one-on-top-of-the-other and separated by a spacer, and wherein the length of the continuous cut strip is at least about 150% of the length of the strip on the aluminum alloy coil. 
     
     
         12 . The continuous cut strip of  claim 10 , wherein the width of each of the first and second cut coils ranges from about 1 to about 10 inches and wherein the widths of the first and second cut coils are substantially the same. 
     
     
         13 . The continuous cut strip of  claim 10 , wherein the continuous cut strip is tab stock and wherein the first strip end is an inner diameter end of the first cut coil and the second strip end is an outer diameter end of the second cut coil. 
     
     
         14 . A continuous cut strip having first and second strip ends welded together, wherein the continuous cut strip is coiled on a common coil, wherein the coil is staggered back-and-forth across a face of a rewind mandrel, and wherein the length of the continuous cut strip is at least about 150% of the length of the strip on the aluminum alloy coil. 
     
     
         15 . The continuous cut strip of  claim 14 , wherein the width of each of the first and second cut coils ranges from about 1 to about 10 inches and wherein the widths of the first and second cut coils are substantially the same. 
     
     
         16 . The continuous cut strip of  claim 14 , wherein the continuous cut strip is tab stock and wherein the first strip end is an inner diameter end of the first cut coil and the second strip end is an outer diameter end of the second cut coil. 
     
     
         17 . A system for manufacturing can ends, comprising
 a splitter to cut an aluminum alloy coil into first and second cut coils, each of the first and second cut coils having a width less than a width of the aluminum alloy coil;   an entry mandrel to receive the first and second cut coils; and   a welder to connect an inner diameter end of the first cut coil to an outer diameter end of the second cut coil.   
     
     
         18 . The system of  claim 17 , further comprising:
 a lift to lift each of the first and second cut coils onto the entry mandrel; and   an upender unit to remove the first and second cut coils from the entry mandrel.   
     
     
         19 . The system of  claim 17 , further comprising:
 a lift to lift each of the first and second cut coils onto the entry mandrel.   
     
     
         20 . The system of  claim 19 , further comprising:
 a reciprocating rewind mandrel to unwind the first and second cut coils and stagger wind the continuous cut strip into a common coil; and   an upender unit to remove the common coil from the rewind mandrel.   
     
     
         21 . The system of  claim 19 , wherein each of the first and second cut coils is unwound from a common location on the entry mandrel.