Process to manufacture large format aluminum bottles

Abstract

A high speed manufacturing process for large format aluminum bottles (up to 750 ml) based on the DWI process that uses 3xxx can body stock with high recycled content. The process can include forming a bottle preform by redrawing, drawing and ironing, and doming a cup. The bottle preform formed by the process has a diameter of about 2.5″ to about 3.0″, a height of about 10.0″ to about 12.5″, a wall thickness of about 0.006″ to about 0.020″, and a dome depth of between about 0.400″ to about 1.00″.

1 . A method of making an aluminum bottle comprising the sequential steps of:
 obtaining an aluminum sheet of a series 3xxx alloy having a gauge thickness ranging from about 0.0150″ to about 0.0250″;   blanking out a disk having a diameter ranging from about 7.0″ to about 10.0″;   forming the disk into a cup;   forming a bottle preform by redrawing, drawing and ironing, and doming the cup;   wherein the bottle preform comprises:
 a diameter of about 2.5″ to about 3.0″; 
 a height of about 10.0″ to about 12.5″; 
 a wall thickness of about 0.006″ to about 0.020″; and 
 a dome depth of between about 0.400″ to about 1.00″. 
   
     
     
         2 . The method of  claim 1 , wherein the wall thickness comprises a constant wall thickness of about 0.010″ to about 0.020″. 
     
     
         3 . The method of  claim 1 , wherein the wall thickness comprises a variable wall thickness with a thicker portion at the top of about 0.010″ to about 0.020″ and a thinner portion in the middle of about 0.006″ to about 0.012″. 
     
     
         4 . The method of  claim 1 , further comprising an annealing step at a temperature of about 100° C. to about 400° C. prior to necking and finishing operations. 
     
     
         5 . The method of  claim 1 , further comprising a bottle shape forming operation, wherein the bottle shape forming operation comprises at least one of necking or blow forming to produce a final bottle shape. 
     
     
         6 . The method of  claim 5 , further comprising mechanically shaping a threaded, corked, or crowned bottle closure after the bottle shape forming operation. 
     
     
         7 . The method of  claim 1 , wherein the 3xxx alloy is an AA3104 alloy. 
     
     
         8 . A bottle preform comprising:
 an AA3xxx aluminum alloy;   a diameter of about 2.5″ to about 3.0″;   a height of about 10.0″ to about 12.5″;   a wall thickness of about 0.006″ to about 0.020″; and,   a dome depth of between about 0.400″ to about 1.00″.   
     
     
         9 . The bottle preform of  claim 8 , further comprising a base profile, a body portion, and a finish portion. 
     
     
         10 . The bottle preform of  claim 9 , wherein the finish portion comprises a complex long neck profile, a straight wall transition portion, and a lip portion, wherein the lip portion is continuous with the straight wall transition portion. 
     
     
         11 . The bottle preform of  claim 10 , wherein the lip portion is threaded or crowned. 
     
     
         12 . The bottle preform of  claim 8 , wherein the 3xxx alloy is an AA3104 alloy. 
     
     
         13 . A method of making an aluminum bottle comprising:
 providing an aluminum sheet of a series 3xxx alloy having a gauge thickness ranging from about 0.0150″ to about 0.0250″;   forming a cup from the aluminum sheet with a double action press that cuts and draws the aluminum sheet in a single, continuous motion;   forming a bottle preform by redrawing, drawing and ironing, and doming the cup;   wherein the bottle preform comprises:
 a diameter of about 2.5″ to about 3.0″; 
 a height of about 10.0″ to about 12.5″; 
 a wall thickness of about 0.006″ to about 0.020″; 
 a dome depth of about 0.400″ to about 1.00″; and 
   forming a final bottle shape from the bottle preform.   
     
     
         14 . The method of  claim 13 , wherein forming the bottle preform by redrawing comprises reverse redrawing. 
     
     
         15 . The method of  claim 13 , further comprising forming a curled feature at an open end of the final bottle shape. 
     
     
         16 . The method of  claim 15 , further comprising forming a threaded portion and a recessed bead at the open end of the final bottle shape. 
     
     
         17 . The method of  claim 13 , wherein forming the final bottle shape from the bottle preform comprises die necking with a knockout. 
     
     
         18 . The method of  claim 13 , further comprising annealing the aluminum sheet or the bottle preform at a temperature of about 100° C. to about 400° C. 
     
     
         19 . The method of  claim 18 , wherein the annealing has a duration of about 1 minute to about 3 hours. 
     
     
         20 . The method of  claim 18 , wherein the annealing has a duration of about 1 hour to about 3 hours. 
     
     
         21 . The method of  claim 18 , wherein the annealing has a duration of about 1 minute to about 30 minutes. 
     
     
         22 . The method of  claim 18 , wherein the annealing is applied only to a portion of the aluminum sheet or the bottle preform.