Systems and Related Methods for Manufacturing Ring Pull Bottle Crown

Abstract

Equipment and related methods for manufacturing ring pull crowns are disclosed herein. In one embodiment, a method of manufacturing a ring pull crown comprises forming a plurality of crown bodies from a first source material, and forming a plurality of pull ring and tab assemblies from a second source material. In addition, such a method may comprise forming a plurality of ring pull crowns by combining each crown body of the plurality of crown bodies with a corresponding pull ring and tab assembly from the plurality of pull ring and tab assemblies. Also, such method may also comprise forming a circumferential skirt that descends below a top of each ring pull crown, and removing the plurality of ring pull crowns from the first source material.

What is claimed is: 
     
         1 . A method of manufacturing a ring pull crown, the method comprising the steps of:
 forming a plurality of crown bodies from a first source material;   forming a plurality of pull ring and tab assemblies from a second source material;   forming a plurality of ring pull crowns by combining each crown body of the plurality of crown bodies with a corresponding pull ring and tab assembly from the plurality of pull ring and tab assemblies;   forming a circumferential skirt that descends below a top of each ring pull crown; and   removing the plurality of ring pull crowns from the first source material.   
     
     
         2 . The method of  claim 1 , further comprising the steps of:
 cutting the first source material into a plurality of rectangular strips;   forming scalloped edges on two opposite ends of each rectangular strip of the plurality of rectangular strips; and   nesting a first scalloped edge of a first rectangular strip of the plurality of rectangular strips in a second scalloped edge of a second rectangular strip of the plurality of rectangular strips.   
     
     
         3 . The method of  claim 2 , wherein the scalloped edges are curvilinear. 
     
     
         4 . The method of  claim 1 , wherein forming the plurality of pull ring and tab assemblies further comprises forming the plurality of pull ring and tab assemblies from the second source material using two or more progressive stages of production, and wherein a plurality of pieceworks formed by one stage of the two or more progressive stages of production are arranged on the second source material in diagonal rows. 
     
     
         5 . The method of  claim 1 , wherein combining each crown body of the plurality of crown bodies with a corresponding pull ring and tab assembly from the plurality of pull ring and tab assemblies further comprises aligning a diagonal row of crown bodies from the plurality of crown bodies with a corresponding diagonal row of pull ring and tab assemblies from the plurality of pull ring and tab assemblies. 
     
     
         6 . The method of  claim 1 , wherein forming the plurality of crown bodies further comprises forming a rivet on each crown body in the plurality of crown bodies, and wherein forming the plurality of ring and tab assemblies further comprises punching a rivet hole in each pull ring and tab assembly in the plurality of pull ring and tab assemblies. 
     
     
         7 . The method of  claim 6 , wherein combining each crown body of the plurality of crown bodies with a corresponding pull ring and tab assembly from the plurality of pull ring and tab assemblies further comprises:
 aligning the first source material over the second source material;   separating a diagonal row of pull ring and tab assemblies from the first source material; and   attaching each pull ring and tab assembly of the diagonal row of pull ring and tab assemblies to a corresponding crown body in a diagonal row of crown bodies by compressing each pull ring and tab assembly onto a corresponding crown body.   
     
     
         8 . The method of  claim 1 , wherein forming the plurality of crown bodies further comprises:
 forming one or more score lines on each crown body of the plurality of crown bodies, said score lines configured to tear a section of the crown body in response to a pulling force.   
     
     
         9 . The method of  claim 1 , wherein forming the plurality crown body further comprises forming one or more recessed portions on each crown body of the plurality of crown bodies, wherein the one or more recessed portions form corrugated cross-sections in each crown body. 
     
     
         10 . The method of  claim 9 , wherein the one or more recessed areas comprise a recessed seat for nesting an attached pull ring and tab assembly, and wherein the recessed seat is suitably dimensioned such that that the top surface of the attached pull ring and tab assembly is substantially flush with an adjacent shoulder of the corresponding crown body. 
     
     
         11 . The method of  claim 1 , wherein the first source material is tinplate and the second source material is non-metal. 
     
     
         12 . The method of  claim 1 , wherein the second source material comprises a plastic or a synthetic resin. 
     
     
         13 . The method of  claim 1 , wherein the first source material comprises a printed design. 
     
     
         14 . A system for manufacturing a ring pull crown, the system comprising:
 a first machine adapted to form a plurality of crown bodies from a first source material;   a second machine adapted form a plurality of pull ring and tab assemblies from a second source material; and   a third machine adapted to:
 (i) form a plurality of ring pull crowns by combining each crown body of the plurality of crown bodies with a corresponding pull ring and tab assembly from the plurality of pull ring and tab assemblies; 
 (ii) form a circumferential skirt that descends below a top of each ring pull crown; and 
 (iii) remove the plurality of ring pull crowns from the first source material. 
   
     
     
         15 . The system of  claim 14 , further comprising a fourth machine adapted to:
 cut the first source material into a plurality of rectangular strips;   form scalloped edges on two opposite ends of each rectangular strip of the plurality of rectangular strips; and   nest a first scalloped edge of a first rectangular strip of the plurality of rectangular strips in a second scalloped edge of a second rectangular strip of the plurality of rectangular strips.   
     
     
         16 . The system of  claim 15 , further comprising a fifth machine adapted to stack the plurality of rectangular strips. 
     
     
         17 . The system of  claim 14 , wherein the second machine comprises a progressive die press adapted to form the plurality of pull ring and tab assemblies from the second source material using two or more die stages, and wherein two or more dies of a die stage from the two or more die stages are arranged in a diagonal row with respect to the feed direction of the second source material. 
     
     
         18 . The system of  claim 14 , wherein the third machine is further adapted to align a diagonal row of crown bodies from the plurality of crown bodies with a corresponding diagonal row of pull ring and tab assemblies from the plurality of pull ring and tab assemblies. 
     
     
         19 . The system of  claim 14 , wherein the first machine is further adapted to form a rivet on each crown body in the plurality of crown bodies, and wherein the second machine is further adapted to punch a rivet hole in each pull ring and tab assembly in the plurality of pull ring and tab assemblies. 
     
     
         20 . The system of  claim 19 , wherein the third machine is further adapted to:
 align the first source material over the second source material;   separate a diagonal row of pull ring and tab assemblies from the first source material; and   attach each pull ring and tab assembly of the diagonal row of pull ring and tab assemblies to a corresponding crown body in a diagonal row of crown bodies by compressing each pull ring and tab assembly onto a corresponding crown body.   
     
     
         21 . The system of  claim 14 , wherein the first machine is further adapted to form one or more score lines on each crown body of the plurality of crown bodies, said score lines configured to tear a section of the crown body in response to a pulling force. 
     
     
         22 . The system of  claim 14 , wherein the first machine is further adapted to form one or more recessed portions on each crown body of the plurality of crown bodies, wherein the one or more recessed portions form corrugated cross-sections in each crown body.