Two iron tool pack for forming tall metal bottle shaped containers

Abstract

A tool pack is described that includes a redraw die, a first ironing die and a second ironing die. The tool pack may be incorporated in a bodymaker that has about a thirty-inch stroke to form a metal cup with a height to diameter ratio of about four. In some embodiments, the redraw die, the first ironing die and the second ironing die are situated in the body maker so that each reduces a sidewall thickness of the cup that is forced through the redraw die, the first ironing die and the second ironing die by a plunger by a predetermined amount to produce a cup that can be formed into a bottle-shaped container with low defect rates.

What is claimed is: 
     
         1 . An apparatus for making a bottle-shaped container, comprising:
 a bodymaker comprising a redraw die, a first ironing die and a second ironing die, wherein the bodymaker comprises about a 30-inch stroke length and forms a metal cup with a height of between about 8.83 inches and about 9.76 inches and a wall thickness between about 0.0083 inches and about 0.0096 inches.   
     
     
         2 . The apparatus of  claim 1 , wherein the first ironing die reduces a sidewall thickness of the cup by between about 10 and about 40 percent. 
     
     
         3 . The apparatus of  claim 1 , wherein the second ironing die reduces a sidewall thickness of the cup by between about 35 and about 44 percent. 
     
     
         4 . The apparatus of  claim 1 , wherein the second ironing die reduces a sidewall thickness of the cup by between about 38 and about 42 percent. 
     
     
         5 . The apparatus of  claim 1 , wherein the second ironing die reduces a sidewall thickness of the cup by between about 39 and about 41 percent. 
     
     
         6 . The apparatus of  claim 1 , wherein a contact portion of a working land of the redraw die is spaced about 4.5 inches from a contact portion of a working land of the first ironing die. 
     
     
         7 . The apparatus of  claim 1 , wherein a contact portion of a working land of the first ironing die is spaced about 6.6 inches from a contact portion of a working land of the second ironing die. 
     
     
         8 . The apparatus of  claim 1 , wherein a contact portion of a working land of the redraw die is spaced about 11.1 inches from a contact portion of a working land of the second ironing die. 
     
     
         9 . The apparatus of  claim 1 , wherein the metal cup has a height between about 9.08 inches and about 9.36 inches. 
     
     
         10 . A method of creating a metal bottle-shaped container, comprising:
 providing a redraw die, a first ironing die and a second ironing die, wherein a contact portion of the redraw die is positioned about 4.5 inches from a contact portion of the first ironing die and the contact portion of the first ironing die is positioned about 6.6 inches from a contact portion of the second ironing die;   forcing a cup through the redraw die, the first ironing die and the second ironing die; and   producing a finished cup with a height to width ratio of about four at production speeds of about 200 to 230 cups per minute.   
     
     
         11 . The method of  claim 11 , wherein forcing the cup through the second ironing die reduces a sidewall thickness of the cup by between about 38 and about 42 percent. 
     
     
         12 . The method of  claim 11 , wherein forcing the cup through the second ironing die reduces a sidewall thickness of the cup by between about 39 and about 41 percent. 
     
     
         13 . The method of  claim 11 , wherein forcing the cup through the second ironing die reduces a sidewall thickness of the cup by about 40 percent. 
     
     
         14 . The method of  claim 11 , wherein the height to width ratio of the finished cup is about 4.03. 
     
     
         15 . The method of  claim 11 , wherein a bottle formed from the finished cup is about 9.4 inches tall and has a sidewall thickness of between about 0.0083 inches and 0.0086 inches. 
     
     
         16 . The method of  claim 16 , wherein the cup comprises 3104 series aluminum alloy. 
     
     
         17 . The method of  claim 11 , further comprising providing a bodymaker, wherein the bodymaker comprises about a 30-inch stroke and the redraw die, the first ironing die and the second ironing die are located in the bodymaker. 
     
     
         18 . A bottle made by a process comprising the steps of:
 proving a bodymaker having about a 30-inch stroke;   providing a redraw die, a first ironing die and a second ironing die, wherein a contact portion of a working land of the redraw die is about 4.5 inches from a contact portion of a working land of the first ironing die and the contact portion of the working land of the first ironing die is about 6.6 inches from a contact portion of a working land of the second ironing die; and   forcing a cup through the redraw die, the first ironing die and the second ironing die to produce a formed cup with a height between about 9.08 inches and about 9.36 inches and a sidewall thickness of between about 0.0083 inches and about 0.0086 inches.   
     
     
         19 . The process of  claim 18 , wherein the first ironing die reduces the sidewall thickness of the cup by between about 10 and about 40 percent. 
     
     
         20 . The process of  claim 18 , wherein forcing the cup through the redraw die, the first ironing die and the second ironing die occurs at between about 200 to 230 cups per minute.