Systems and methods for forming a double dome container

Abstract

A bottom forming system for a metal container includes a domer assembly that forms a double dome in a bottom of the metal container during a bottom forming process. The domer assembly includes a first domer and a second domer that is movable relative to the first domer. A method of forming a bottom of a metal container includes forming a first dome profile in the bottom of the metal container using the first domer and the second domer of a domer assembly. The method includes forming a second dome profile in the bottom of the metal container by moving the second domer relative to the first domer.

That which is claimed: 
     
         1 . A domer assembly for a bottom forming system, the domer assembly comprising:
 a first domer comprising a first surface configured to engage a bottom of a metal container during a bottom forming process; and   a second domer comprising a second surface configured to engage the bottom of the metal container during the bottom forming process, wherein the second domer is movable relative to the first domer.   
     
     
         2 . The domer assembly of  claim 1 , wherein the second domer is movable within the first domer. 
     
     
         3 . The domer assembly of  claim 1 , wherein the first domer is a sleeve and the second domer is an insert movable within the sleeve. 
     
     
         4 . The domer assembly of  claim 1 , wherein the second domer is axially movable relative to the first domer. 
     
     
         5 . The domer assembly of  claim 1 , wherein the domer assembly is positionable in a first configuration and a second configuration, wherein, in the first configuration, the first surface is continuous with the second surface and together forms a first dome profile, and wherein, in the second configuration, the second surface is offset from the first surface and the second surface forms a second dome profile. 
     
     
         6 . The domer assembly of  claim 1 , wherein the first domer and the second domer are configured to together form a first dome in a bottom of a metal container during a first stage of a bottom forming process, and wherein the second domer is configured to form a second dome in the bottom of the metal container during a second stage of the bottom forming process. 
     
     
         7 . A bottom forming system for forming a metal container, the bottom forming system comprising a domer assembly configured to form a double dome in a bottom of the metal container during a bottom forming process comprising a first dome having a first dome profile and a second dome having a second dome profile. 
     
     
         8 . The bottom forming system of  claim 7 , wherein the domer assembly comprises a first domer and a second domer, wherein the second domer is selectively movable relative to the first domer. 
     
     
         9 . The bottom forming system of  claim 8 , wherein the domer assembly comprises a first configuration and a second configuration, wherein, in the first configuration, the second domer is at a first position relative to the first domer such that the first domer and the second domer are configured to together form the first dome, and wherein, in the second configuration, the second domer is at a second position relative to the first domer such that the second domer is configured to form the second dome. 
     
     
         10 . The bottom forming system of  claim 8 , wherein the first domer is a sleeve, and wherein the second domer is an insert movable within the sleeve. 
     
     
         11 . The bottom forming system of  claim 8 , wherein the second domer is axially movable relative to the first domer. 
     
     
         12 . The bottom forming system of  claim 8 , wherein the first domer comprises a first surface and the second domer comprises a second surface, wherein the second domer is movable relative to the first domer such that, in a first position of the second domer relative to the first domer, the first surface is continuous with the second surface, and, in a second position of the second domer relative to the first domer, the second surface is offset from the first surface. 
     
     
         13 . The bottom forming system of  claim 7 , further comprising:
 a punch; and   a retainer comprising a receiving area for a metal container, and wherein the domer assembly is movable within the receiving area.   
     
     
         14 . A method of forming a bottom of a metal container, the method comprising:
 forming a first dome profile in the bottom of the metal container using a first domer and a second domer of a domer assembly; and   forming a second dome profile in the bottom of the metal container by moving the second domer relative to the first domer.   
     
     
         15 . The method of  claim 14 , wherein forming the second dome profile comprises axially moving the second domer relative to the first domer. 
     
     
         16 . The method of  claim 14 , wherein forming the first dome profile comprises axially moving the first domer and the second domer together in a first direction to engage the bottom of the metal container, and wherein forming the second dome profile comprises moving the second domer relative to the first domer in the first direction. 
     
     
         17 . The method of  claim 14 , wherein forming the first dome profile comprises using a punch to further form the first dome profile in the bottom of the metal container. 
     
     
         18 . The method of  claim 14 , wherein the first domer is a sleeve and the second domer is an insert within the sleeve, and wherein forming the second dome profile comprises moving the second domer while the second domer is at least partially within the sleeve. 
     
     
         19 . The method of  claim 14 , wherein forming the first dome profile comprises engaging a first surface of the first domer and a second surface of the second domer with the bottom of the metal container. 
     
     
         20 . The method of  claim 19 , wherein forming the second dome profile comprises moving the second domer relative to the first domer such that at least a portion of the bottom of the metal container does not contact the first surface or the second surface. 
     
     
         21 . A metal container comprising a bottom formed by the method of  claim 14 . 
     
     
         22 . The metal container of  claim 21 , wherein the metal container comprises aluminum or an aluminum alloy. 
     
     
         23 . The metal container of  claim 21 , wherein the bottom comprises a reduced metal gauge.