Aluminum impact extruded bottle with threaded neck made from recycled aluminum and enhanced alloys

Abstract

The present invention relates generally to forming a threaded neck in a metal bottle manufactured by a process known as impact extrusion. More specifically, the present invention relates to methods, apparatus and alloy compositions used in the impact extrusion manufacturing of containers and other articles with sufficient strength characteristics to allow threading the container necks to receive a threaded closure on the threaded neck.

1 - 16 . (canceled) 
     
     
         17 . An aluminum alloy for a slug used in an impact extrusion process to form a threaded metallic container, comprising:
 at least about 0.16 wt. % Si;   at least about 0.37 wt. % Fe;   at least about 0.08 wt. % Cu;   at least about 0.48 wt. % Mn;   at least about 0.34 wt. % Mg;   at least about 0.06 wt. % Zn;   at least about 0.01 wt. % Cr; and   a balance being aluminum, titanium, and impurities.   
     
     
         18 . The aluminum alloy of  claim 17 , wherein the aluminum alloy is blended from at least about 60% of a recycled scrap aluminum and no more than about 40% of a relatively pure aluminum alloy. 
     
     
         19 . The aluminum alloy of  claim 18 , wherein the relatively pure aluminum alloy comprises at least one of a 1050 and a 1070 aluminum alloy. 
     
     
         20 . The aluminum alloy of  claim 18 , wherein the aluminum alloy is blended from between about 60% and about 80% of the recycled scrap aluminum and between about 20% and about 40% of the relatively pure aluminum alloy. 
     
     
         21 . The aluminum alloy of  claim 17 , comprising:
 no more than about 0.24 wt. % Si;   no more than about 0.48 wt. % Fe;   no more than about 0.15 wt. % Cu;   no more than about 0.71 wt. % Mn;   no more than about 0.52 wt. % Mg;   no more than about 0.12 wt. % Zn;   no more than about 0.04 wt. % Cr; and   between about 0.00 wt. % Ti and about 0.04 wt. % Ti.   
     
     
         22 . The aluminum alloy of  claim 17 , comprising:
 between about 98.15 wt. % aluminum and about 98.50 wt. % aluminum;   between about 0.16 wt. % Si and about 0.20 wt. % Si;   between about 0.37 wt. % Fe and about 0.41 wt. % Fe;   between about 0.08 wt. % Cu and about 0.12 wt. % Cu;   between about 0.48 wt. % Mn and about 0.54 wt. % Mn;   between about 0.34 wt. % Mg and about 0.40 wt. % Mg;   between about 0.06 wt. % Zn and about 0.10 wt. % Zn;   between about 0.01 wt. % Cr and about 0.04 wt. % Cr; and   between about 0.00 wt. % Ti and about 0.04 wt. % Ti.   
     
     
         23 . The aluminum alloy of  claim 17 , comprising:
 between about 97.70 wt. % aluminum and about 98.05 wt. % aluminum;   between about 0.20 wt. % Si and about 0.24 wt. % Si;   between about 0.44 wt. % Fe and about 0.48 wt. % Fe;   between about 0.11 wt. % Cu and about 0.15 wt. % Cu;   between about 0.65 wt. % Mn and about 0.71 wt. % Mn;   between about 0.46 wt. % Mg and about 0.52 wt. % Mg;   between about 0.08 wt. % Zn and about 0.12 wt. % Zn;   between about 0.01 wt. % Cr and about 0.04 wt. % Cr; and   between about 0.00 wt. % Ti and about 0.04 wt. % Ti.   
     
     
         24 . The aluminum alloy of  claim 17 , wherein a concentration of between about 1 lb/ton to about 2.6 lbs/ton of a titanium boride material is added to said aluminum alloy. 
     
     
         25 . An aluminum alloy slug for use in an impact extrusion process to form a metallic bottle with a threaded neck, comprising:
 between about 60 and about 80 wt. % of a recycled scrap aluminum; and   a balance being a relatively pure aluminum alloy.   
     
     
         26 . The aluminum alloy slug of  claim 25 , wherein the relatively pure aluminum alloy comprises at least one of a 1050 and a 1070 aluminum alloy. 
     
     
         27 . The aluminum alloy slug of  claim 25 , wherein the recycled scrap aluminum comprises:
 between about 0.20 wt. % Si and about 0.32 wt. % Si;   between about 0.47 wt. % Fe and about 0.59 wt. % Fe;   between about 0.10 wt. % Cu and about 0.22 wt. % Cu;   between about 0.78 wt. % Mn and about 0.90 wt. % Mn;   between about 0.54 wt. % Mg and about 0.66 wt. % Mg;   between about 0.06 wt. % Zn and about 0.18 wt. % Zn;   between about 0.00 wt. % Cr and about 0.08 wt. % Cr; and   between about 0.00 wt. % Ti and about 0.08 wt. % Ti.   
     
     
         28 . The aluminum alloy slug of  claim 25 , wherein the recycled scrap aluminum comprises at least one of a 3104 alloy, a 3004 alloy, a 3003 alloy, a 3103 alloy, a 3013 alloy, and a 3105 alloy. 
     
     
         29 . The aluminum alloy slug of  claim 25 , comprising:
 between about 97.40 wt. % aluminum and about 98.71 wt. % aluminum;   between about 0.14 wt. % Si and about 0.27 wt. % Si;   between about 0.32 wt. % Fe and about 0.55 wt. % Fe;   between about 0.07 wt. % Cu and about 0.17 wt. % Cu;   between about 0.41 wt. % Mn and about 0.81 wt. % Mn;   between about 0.29 wt. % Mg and about 0.59 wt. % Mg;   between about 0.05 wt. % Zn and about 0.13 wt. % Zn;   between about 0.01 wt. % Cr and about 0.04 wt. % Cr; and   between about 0.00 wt. % Ti and about 0.04 wt. % Ti.   
     
     
         30 . The aluminum alloy slug of  claim 25 , comprising:
 between about 97.70 wt. % aluminum and about 98.50 wt. % aluminum;   between about 0.16 wt. % Si and about 0.24 wt. % Si;   between about 0.37 wt. % Fe and about 0.48 wt. % Fe;   between about 0.08 wt. % Cu and about 0.15 wt. % Cu;   between about 0.48 wt. % Mn and about 0.71 wt. % Mn;   between about 0.34 wt. % Mg and about 0.52 wt. % Mg;   between about 0.06 wt. % Zn and about 0.12 wt. % Zn;   between about 0.01 wt. % Cr and about 0.04 wt. % Cr; and   between about 0.00 wt. % Ti and about 0.04 wt. % Ti.   
     
     
         30 . The aluminum alloy slug of  claim 25 , comprising:
 between about 97.88 wt. % aluminum and about 98.33 wt. % aluminum;   between about 0.18 wt. % Si and about 0.22 wt. % Si;   between about 0.39 wt. % Fe and about 0.46 wt. % Fe;   between about 0.10 wt. % Cu and about 0.13 wt. % Cu;   between about 0.51 wt. % Mn and about 0.68 wt. % Mn;   between about 0.37 wt. % Mg and about 0.49 wt. % Mg;   between about 0.08 wt. % Zn and about 0.10 wt. % Zn;   about 0.02 wt. % Cr; and   about 0.02 wt. % Ti.   
     
     
         32 . The aluminum alloy slug of  claim 25 , wherein said slug has a diameter of between about 1.61 inches and about 1.91 inches, a height between about 0.17 inches and about 0.27 inches, and a mass of between about 0.69 ounces and about 0.875 ounces. 
     
     
         33 . A method of forming a recycled aluminum alloy slug used for manufacturing a metallic bottle in an impact extrusion process, the recycled aluminum alloy of the slug having a mechanical strength such that integral threads can be formed on the metallic bottle, comprising
 melting a scrap aluminum material;   blending the melted scrap aluminum material with a relatively pure aluminum alloy to form a recycled aluminum alloy, wherein the blend comprises between about 60 and about 80 wt. % of the scrap aluminum material;   casting the recycled aluminum alloy into a slab;   rolling the slab to a specified thickness;   cooling the slab; and   punching a slug from the slab.   
     
     
         34 . The method of  claim 33 , wherein the relatively pure aluminum alloy comprises at least one of a 1050 and a 1070 aluminum alloy. 
     
     
         35 . The method of  claim 33 , wherein said recycled aluminum alloy comprises:
 between about 0.14 wt. % Si and about 0.27 wt. % Si;   between about 0.32 wt. % Fe and about 0.55 wt. % Fe;   between about 0.07 wt. % Cu and about 0.17 wt. % Cu;   between about 0.41 wt. % Mn and about 0.81 wt. % Mn;   between about 0.29 wt. % Mg and about 0.59 wt. % Mg;   between about 0.05 wt. % Zn and about 0.13 wt. % Zn;   between about 0.01 wt. % Cr and about 0.04 wt. % Cr;   between about 0.00 wt. % Ti and about 0.04 wt. % Ti; and   a balance being aluminum and impurities.   
     
     
         36 . The method of  claim 33 , wherein the scrap aluminum material comprises:
 between about 0.20 wt. % Si and about 0.32 wt. % Si;   between about 0.47 wt. % Fe and about 0.59 wt. % Fe;   between about 0.10 wt. % Cu and about 0.22 wt. % Cu;   between about 0.78 wt. % Mn and about 0.90 wt. % Mn;   between about 0.54 wt. % Mg and about 0.66 wt. % Mg;   between about 0.06 wt. % Zn and about 0.18 wt. % Zn;   between about 0.00 wt. % Cr and about 0.08 wt. % Cr; and   between about 0.00 wt. % Ti and about 0.08 wt. % Ti.   
     
     
         37 . The method of  claim 33 , further comprising adding a concentration of between about 1 lb/ton to about 2.6 lbs/ton of titanium boride to the blend.