Pull Tab with Improved Accessibility and Associated Methods of Manufacture

This application is a Continuation-in-Part of U.S. Utility patent application Ser. No. 18/236,703, filed on Sep. 1, 2023, which claims the benefit of U.S. Provisional Patent Application 63/478, 185, filed on Jan. 2, 2023, as well as U.S. Provisional Patent Application 63/507,934, filed on Jun. 13, 2023, as well as U.S. Provisional Patent Application 63/507,938, filed on Jun. 13, 2023, all being incorporated herein by reference.

Not Applicable.

This invention relates to containers, and more particularly to improvements in containers opened by a pull tab.

Pull tabs have long served as essential mechanisms for accessing beverages, canned foods, and other sealed products. A conventional pull tab is designed with a rivet hole and a receiving portion, which together anchor the tab firmly to the container's lid. Additionally, it features a distinct nose that exerts the right amount of pressure to break the container's seal, and a lift section where users apply force to engage the nose.

The original ring-pull tab design from the 1960s presented certain challenges; primarily, the detached rings became environmental nuisances and potential safety hazards. Recognizing these concerns, the 1970s introduced the stay-on-tab design—a design where the tab remains attached to the can post-opening. While this design significantly reduced litter and safety issues, its flat orientation against the container's lid often made it challenging for certain users to grasp, especially those with limited dexterity or strength.

Against this backdrop, there is a clear and pressing need for a pull tab design that seamlessly combines enhanced accessibility with a design that doesn't stray too far from the tried and tested manufacturing methods. The objective is to offer a design innovation without ushering in complexities in production or surges in costs. The present invention stands as a testament to this vision, bringing forth a fresh perspective while staying rooted in pragmatic considerations. The present invention accomplishes these objectives.

The present device is a pull tab for opening a container of the type having a frangible region of a container lid and a rivet aperture adjacent to the frangible region. The pull tab comprises a nose configured to apply downward pressure on the frangible region of the container lid, a rivet receiving portion adjacent to the nose that includes a rivet aperture therethrough, a lift portion located distally from the nose, and a finger hole located in proximity to the lift portion.

One or more upward bends are situated on each of two opposing sides of the finger hole of the pull tab. The upward bends are placed such that the lift portion is elevated relative to a bottom plane of the pull tab, with a topmost point of the lift portion being positioned at a distance of preferably between 1 mm and 2 mm from the bottom plane of the pull tab. As such, user actuation of the pull tab is facilitated and efficient stacking of a plurality of the container lids during manufacturing thereof is achieved.

Preferably the one or more upward bends are situated between 1 mm and 6 mm from the lift portion of the pull tab. The upward bends at the two opposing sides of the finger hole are each set at angles of between 1 and 50 degrees, but most preferably between 30 and 45 degrees. The lift portion is preferably elevated above a top plane of the pull tab at a height of between 0.1 mm and 0.9 mm, and a center bar disposed between the nose and the lift portion has a minimum thickness of at least 1.9 mm. A length of the pull tab from the nose to the lift portion is between 20 mm and 25 mm. Optionally, a logo may be stamped or embossed onto the center bar during the manufacturing process.

In some embodiments, the invention includes the container lid and is adapted to fit over an open top end of the container. The container lid includes a cover having a peripheral edge that fits around and is mechanically fixed with the top end of the container to seal the container. The cover is preferably substantially flat. A rivet fixes the pull tab at the rivet aperture of the rivet receiving portion to the cover at the rivet apertures of the container lid. Other mechanical fasteners may be used instead of the rivet as is known in the art. In some embodiments, the cover includes an indentation that provides more space between the container lid and the lift portion to facilitate actuation of the pull tab. In some embodiments, the container, the container lid, and the pull-tab are all included in the product offered to the customer.

In some embodiments, a progressive die manufacturing method includes the steps of producing a tab blank in a first die stamping process, and forming the tab blank into a flat tab at a tab die. The flat tab has the nose configured to apply downward pressure on the frangible region of the container lid. The rivet receiving portion is formed adjacent to the nose and includes the rivet aperture therethrough. The lift portion is formed distally from the nose, and the finger hole is located proximately to the lift portion.

Then a lift station bends the flat tab upward at the two opposing sides of the finger hole such that the lift portion is elevated relative to the bottom plane of the pull tab. In some embodiments the lift station is integrated at an end of the tab die. Preferably in such embodiments the lift station is modular and can be interchanged with an alternate lift station having different bend angles, as desired. In some embodiments, a logo or other indicia is stamped or embossed onto the center bar of the pull tab.

The finished pull tab is assembled to one of the container lids by utilizing a rivet or like mechanical fastener. The container is filled with a liquid such as a beverage, and the container lid is affixed to the top open end of the container. In this way the container is sealed and ready to package, transport, and display for sale or the like.

The present invention is a pull tab design that combines enhanced accessibility with a design that doesn't stray too far from the tried and tested manufacturing methods. The present pull tab, in conjunction with a cooperative indentation in the container lid, provides additional room to facility grasping of the lift portion of the pull tab by a user. Space is provided for stamping a logo or other marketing message on the pull tabs, and such pull tabs of the present invention can be pre-assembled with container lids that are nestable to facilitate storage and transportation. Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

Illustrative embodiments of the invention are described below. The following explanation provides specific details for a thorough understanding of and enabling description for these embodiments. One skilled in the art will understand that the invention may be practiced without such details. In other instances, well-known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments.

Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” Words using the singular or plural number also include the plural or singular number respectively. Additionally, the words “herein,” “above,” “below” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. When the claims use the word “or” in reference to a list of two or more items, that word covers all of the following interpretations of the word: any of the items in the list, all of the items in the list and any combination of the items in the list. When the word “each” is used to refer to an element that was previously introduced as being at least one in number, the word “each” does not necessarily imply a plurality of the elements, but can also mean a singular element.

illustrate a pull tabfor opening a containerof the type having a frangible regionof a container lidand a rivet apertureadjacent to the frangible region.

The pull tabcomprises a noseconfigured to apply downward pressure on the frangible regionof the container lid, a rivet receiving portionadjacent to the nosethat includes a rivet aperturetherethrough, a lift portionlocated distally from the nose, and a finger holelocated in proximity to the lift portion.

One or more upward bendsare situated on each of two opposing sidesof the finger holeof the pull tab. The upward bendsare placed such that the lift portionis elevated relative to a bottom plane Pb of the pull tab, with a topmost pointof the lift portionbeing positioned at a distance D() between 1 mm and 2 mm from the bottom plane Pb of the pull tab. As such, user actuation of the pull tabis facilitated and efficient stacking of a plurality of the container lids() during manufacturing thereof is achieved.

Preferably the one or more upward bendsare situated between 1 mm and 6 mm from the lift portionof the pull tab(). The upward bendsat the two opposingsidesof the finger holeare each set at angles Aof between 1 and 50 degrees (), but most preferably between 25 and 40 degrees. The lift portionis preferably elevated above a top plane Pt of the pull tabat a height Dof between 0.1 mm and 0.9 mm, and a center bardisposed between the noseand the lift portionhas a minimum thickness of T() of at least 1.9 mm. A length Lof the pull tabfrom the noseto the lift portionis between 20 mm and 25 mm. Optionally, a logo() may be stamped or embossed onto the center barduring the manufacturing process.

In some embodiments, the invention includes the container lid() and is adapted to fit over an open top end() of the container. The container lidincludes a coverhaving a peripheral edge, or curl, that fits around and is mechanically fixed with the top endof the containerto seal the container. A rivetfixes the pull tabat the rivet apertureof the rivet receiving portionto the coverat the rivet aperturesof the container lid. Other mechanical fasteners may be used instead of the rivetas is known in the art. In some embodiments, the coverincludes an indentation() that provides more space between the container lidand the lift portionto facilitate actuation of the pull tab. In some embodiments, the container, the container lid, and the pull-tabare all included in the product offered to the customer.

illustrate methods of manufacturing the pull tab. In some embodiments, a progressive die manufacturing method includes the steps of producing a tab blankin a first die stamping process, and forming the tab blankinto a flat tabat a tab die. The flat tabhas the noseconfigured to apply downward pressure on the frangible regionof the container lid. The rivet receiving portionis formed adjacent to the noseand includes the rivet aperturetherethrough. The lift portionis formed distally from the nose, and the finger holeis located proximately to the lift portion.

Then a lift stationbends the flat tabupward at the two opposing sidesof the finger holesuch that the lift portionis elevated relative to the bottom plane Bp of the pull tab. In some embodiments the lift station is integrated at an end of the tab die(). Preferably in such embodiments the lift stationis modular and can be interchanged with an alternate lift stationhaving different bend angles A, or the like, as desired. In some embodiments, a logo or other indicia is stamped or embossedonto the center barof the pull tab.

The finished pull tabis then transferred to a Stake Station of the lane die using the scrap skeleton where it is assembled to one of the container lidsby utilizing a rivetor like mechanical fastener. The containeris filled with a liquid such as a beverage, and the container lidis affixed to the top open endof the container. In this way the containeris sealed and ready to package, transport, and display for sale or the like.

Now going into more detail, in, showing a conversion press, the tab die is where a raw tab stock is shaped into a final tabbefore being fastened onto aconverted container lid. The Lane Die, a type of transfer die, forms the blank shellswith integrated rivets, scores, and paneling across several stations. The tabs and shells come together at a staking station (not shown), where the tabsare riveted onto the shell or container lidto create a converted end, a stack of which is illustrated in.

To maximize finger accessibility of the user, the lift portionof the pull tab, that is proximate to where the finger holeis located, is formed or bent upwardly, creating additional room for a consumer's finger to reach under the lift portionof the pull taband open the container. The lift stationmay be added to the end of the tab die or incorporated into the tab reform station of current tab die embodiments to introduce this bend at the finger hole sidesof a fully-formed pull tab. The tab-bending or lift stationincorporates an upper pressure padand a lower pressure pad, which secures the flat tabduring the bending process. An upper assembly of the stationincludes an upper die shoe, an upper springan upper spring retainer plate, a punch retainer, upper bender punch, upper bender punch insert spacer, upper bender punch insert. The upper die shoeis secured to a press slide (or ram), housing all of the upper tooling. This upper die shoe is guided by linear bearings, aligning accurately with a lower die shoe.

The lower assembly, in comparison, consists of the lower die shoe, a lower spring, a lower spring pin, a lower spring retainer plate, a die retainer, lower bender die, lower bender die insert spacer, lower bender die insert, and a lower bender die pressure pad. The lower die shoeattaches to a press bed, aligning the lower tooling with the upper assembly using linear bearings.

The lower tab bender pressure padis spring-loaded, stripping the tab from the lower toolingand returning the stock to the standard pass line. Grind spacers in both upper and lower toolingand, respectively, allow for height adjustments of the tooling, ultimately influencing the final shape of the bent pull tab. This station is added after the Tab Reform station—presently the last station in the tab die—extending the complete length of the tab die by 1-2 progression lengths of the tab depending on the size constraints of the tooling.

The manufacturing process commences with the “Blank ShellFormation”. During this stage, blank shellsare created, integrating a rivet, score, and paneling, executed in multiple stations of the Lane Die.

In parallel or at the same time as the blank shell formation, the “Tab Formation” phase is initiated. At this stage, tab stock material is meticulously fashioned into the final tab design using the Tab Die.

Post the tab formation, an essential “Lift Station” process is performed. Depending on the method employed, this lift station may be added to the end of the tab die or incorporated into the existing tab reform station in the tab die. The station is responsible for meticulously crafting the upward bends on the finger hole sides of the tab, giving rise to a raised lift end. This specific feature augments user comfort and convenience during the can-opening process.

Finally, during the “Tab/Shell Assembly” phase, the innovative pull tab is securely attached to the shell using an integrated rivet at the Stake Station.

While a particular form of the invention has been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims.

Particular terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated. In general, the terms used in the following claims should not be construed to limit the invention to the specific embodiments disclosed in the specification, unless the above Detailed Description section explicitly defines such terms. Accordingly, the actual scope of the invention encompasses not only the disclosed embodiments, but also all equivalent ways of practicing or implementing the invention.

The above detailed description of the embodiments of the invention is not intended to be exhaustive or to limit the invention to the precise form disclosed above or to the particular field of usage mentioned in this disclosure. While specific embodiments of, and examples for, the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. Also, the teachings of the invention provided herein can be applied to other systems, not necessarily the system described above. The elements and acts of the various embodiments described above can be combined to provide further embodiments.

All of the above patents and applications and other references, including any that may be listed in accompanying filing papers, are incorporated herein by reference. Aspects of the invention can be modified, if necessary, to employ the systems, functions, and concepts of the various references described above to provide yet further embodiments of the invention.

Changes can be made to the invention in light of the above “Detailed Description.” While the above description details certain embodiments of the invention and describes the best mode contemplated, no matter how detailed the above appears in text, the invention can be practiced in many ways. Therefore, implementation details may vary considerably while still being encompassed by the invention disclosed herein. As noted above, particular terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated.

While certain aspects of the invention are presented below in certain claim forms, the inventor contemplates the various aspects of the invention in any number of claim forms. Accordingly, the inventor reserves the right to add additional claims after filing the application to pursue such additional claim forms for other aspects of the invention.