CRIMPING 9 CRIMPING is certainly one of the most critically impor-

tant steps in the production of an aerosol package. A

tight, dependable crimp effectively locks the formula-
tion within the package, guaranteeing that it will not
seep away at an excessive rate, thus creating a defective
unit.
Factual, definitive data on crimping is rather hard to
come by. Perhaps the first such information was pro-
vided by the Crown Cork & Seal Company for their
"Spra-tainer" cans about 1950. They listed two mea-
surements, that of crimp diameter, suggesting
1.065+0.005" (27.05 ±0.13 mm); and crimp depth,
recommending a specification of 0.242" ±0.005"
(6.15 ±0.13 mm). This latter distance was measured
from the top plane of the valve cup curl to the bottom of
the 3/64;' (0.047" or 1.19 mm radius) crimping collet.
Because of the many controversies and complaints
which arose as a result of these published specifications,
Crown has probably wished, in retrospect, that they
had been promulgated by some other source. Neverthe-
less, they have served a useful purpose and are still in
use today, restricted to "Spra-tainer" applications, and
with the crimp depth specifications revised to
0.195 ±0.005 " (4.95 ±0.13 mm) to reflect a measure-
ment which can be used to check cans directly, rather
than crimper settings. The distance now extends verti-
cally from the plane of the valve cup curl to the center-
line of the 3/64 " collet radius. As such, it differs by exactly
one %4 " collet radius, or 0.047 " (1.19 mm), from the
previous specification.
The Crown ' 'Spra-tainer'' figures remained the only
published crimping data until about 1960 and 1961,
when several articles appeared which provided similar
data for three-piece tinplate cans. Compensations for
the use of aluminum valve cups and unique can bead
dimensions were also provided. During those days
there were very significant differences between the
dimensions of three-piece can beads. Some canmakers
supplied very tightly curled beads; others supplied rela-
tively large ones. Different throat contours were used.
Measuring methods for the thickness of the curl around
the one-inch opening (G-Dimension) differed in both
choice of contact point and angle of measurement.
These and other factors delayed the establishment of
firm crimping diameter and depth specifications for the
most common of all aerosol containers.
Meanwhile, similar difficulties were being encoun-
tered in the case of glass and plastic-coated glass aero-
sols. Variations in the finish dimensions of the glass,
thickness of plastic coating, and thickness of valve gas-
ket and housing flange all accrued to obstruct the deter-
mination of a useful crimping specification. Indeed,
this complex matter was resolved by about 1968, after
industry agreement on a formula approach, where the
dimensions of the crimp were determined against those
of the aerosol unit being considered.
Aluminum cans and tubes present special problems,
due to the large variation in bead contours (the smallest
units do not even have a bead, as such), and the radial
drawing grooves (eye lashes) which often cause leakage
to occur. Even the bead dimensions of an individual can
may sometimes show surprising latitudes.
Much progress has been made on all these crimp-
related problems during the past decade, and much
more should logically be made in the near future as
large committees of aerosol experts from both the
CSMA and (in Europe) the FEA tackle the complex
relationships involved in crimping valves to aerosol
containers.
Because of the diversity of special-situation crimping
problems, and since the state of the art is such that
TABLE I
(Gas volume compared to weight loss of dispenser)
many important questions still remain unresolved, no
crimping specifications given in this book are to be con-
strued as necessarily having official significance, or
even the benefit of general industry agreement. They
should not be used in the litigation of product liability
cases. Valve manufacturers sometimes feel that the
publication of crimping specifications might place them
in an unfavorable position in such actions—particularly
in the case of crimping maximums for the diameter
measurement.
General Considerations
Recognizing the importance of the crimping opera-
tion (sometimes called clinching, hermetic sealing or
swaging) most fillers pay special attention to this step.
Dimensional attributes of the can bead, valve cup and
gasketing compound are generally checked rather thor-
oughly. Crimp diameters, crimp depths, and some-
times torque resistances are taken at frequent intervals
during the production run. The practice of hot-tanking
is followed at nearly all aerosol plants. It is required by
law for most metal containers, e.g. as certain heat-
sensitive products may be exempted. However, it is not
a requirement for glass and plastic aerosol units.
Hot-tanking is a simple process, yet one which some-
times conveys a sense of false security. Only very high-
rate leakers will be detected in the hot tank, as shown in
Table I.
The three minute time is that during which the con-
tainer is completely submerged in a slow moving, full
length hot-tank. Ten seconds is average checking time
(waiting for an additional gas bubble or two) with the
operator standing in one position, such as behind a
vertical Plexiglas shield near the end of the tank. The 48
Propellent Loss

Weight Loss Seepage Rate (ml at 7O0F (210C)

Propellent Per Year
at 7O0F (210C) 48 hours 3 minutes 10 seconds

Nitrogen 2.84 13.6 0.0142 0.00079

Methylene Chloride* 2.84 4.6 0.0048 0.00027
Propellent-12 2.84 3.3 0.0034 0.00018
Propellent-11 2.84 2.9 0.0030 0.00016
Propellent-114 2.84 2.3 0.0024 0.00013
Iso-butane 2.84 6.55 0.0067 0.00037
Propane 2.84 8.94 0.0091 0.00051
Carbon Dioxide** 2.84 8.94 0.0091 0.00051

* Slightly soluble in 14O0F hot-tank water.

**Significantly soluble in 14O0F hot-tank water.
hour readings refer to results in the CSMA Standard
Seepage Rate Test. In the case of soluble gases, such as
carbon dioxide, Propellent-152a, and so forth, a 25%
brine solution could be used instead of water, but this is
quite impractical except in a laboratory setting.
Assuming that an alert operator could detect seepage
at the rate of 0.02 ml per ten seconds in the hot tank,
this still relates to extremely high annual weight losses;
e.g. 150 g/yr. for isobutane and 300 g/yr. for Propel-
lent-12. The solubility of carbon dioxide in heated
water is such that hot tanking is almost valueless as a
means of detecting low rate seepage losses of propellent.
Finally, hot tanking cannot be used effectively to
detect latent leakage problems, caused by changes in
the shape, size or porosity of the flowed-in gasket, due
to long-term actions of the product upon the elastomer.
Particularly insidious are products which contain large
amounts of gasket shrinking ingredients, such as etha-
nol, with no compensating solvents which might exert a
corrective swelling action.
In spite of certain limitations, the hot tank remains a
vital part of the aerosol filling operation. It detects
extravagant leakers, defective cans and improperly
made valves. It also provides an effective water flush to
rinse product from the exterior of the can. Where a
labeling job is required, warm cans will be found much
more convenient to work with during the pick-up glu-
ing operation.
Three machines are utilized in can crimping opera-
tions, depending upon availability and the overall fill-
ing requirements:
a. Standard Crimper
i. Air-operated (noisy).
ii. Electric motor operated via flexible shaft.
(Rare.)
iii. In-line type. Rated up to 70 cans per minute
per head.
iv. Rotary type. Normally three to six stations.
b. Vacuum Crimper
i. Requires high capacity vacuum pump as
auxiliary equipment.
ii. Rotary type. Normally three to six stations.
c. "Under-the-Cap" Gasser by Kartridg Pak
Company.
i. Vacuum or atmospheric,
ii. Rotary type; nine or eighteen head frames.
d. Composite Filler/Crimper/Gasser Rotaries.
Regardless of the machine used to make the crimp, it
is necessary to feed the cans and adjust the device in
such a way that the units will be essentially vertical at
the time of crimping. Otherwise, depending upon the
spring pressure, either a slanted crimp, or a "flat"
crimp in a slanted can bead and valve will result. In the
second instance, the downward spring pressure may be
sufficient to drive the high part of the valve and can
bead downward slightly into the breast portion of the
can dome. <rUnder-the-Cap" machines are normally
supplied with 175-pound springs (more rarely,
310-pound springs for use with higher pressure propel-
lents) and this is usually enough to depress the valve
and can bead. Some distortion of the can bead itself
may take place if the can is non-vertical during crimp-
ing, regardless of spring pressure. Gasket redistribution
problems may result as a result of both uniform and
non-uniform pressure applied during can crimping.
This may or may not be beneficial, depending upon
extent.
A certain amount of controversy has arisen on the
matter of spring pressures during crimping. Many
experts feel that compressing the valve cup downward
on the can bead immediately prior to crimping is
undoubtedly helpful, but not vital in most instances.
This is done on an exclusive basis in some laboratory
crimpers. Aerosols containing only the concentrate can
be crimped very effectively with no mechanical down-
ward pressure. The crimping action itself generates
Figure 1. Split Ring and Nut for Temporary Seal
Assembly unit for temporarily sealing aerosol valves to one-inch
(25mm) can bead. Assembly consists of a 3" (76mm) diameter knurled
ring, split and hinged, with an inward flange at the base of the 1.238"
(31.45 mm) hole to fit below the can bead, plus a knurled cap ring,
threaded inside to fit the split ring. The split ring is positioned on the
can dome and closed under the bead. A valve is placed in the ring.
Then the cap ring is screwed down, sealing the valve to the can. This
assembly allows valves and cans to be used repeatedly, and product
changes to be compared, using the exact same valve each time.
 both a horizontal and downward force vector, with the
latter being quite effective in snugging the valve down
upon the can bead. For "problem" products, such as
formulas which tend to shrink flowed-in gasketing com-
pounds, and for "Sepro-can" products of all types, the
downward spring pressure approach would be particu-
larly recommended, plus the use of crimp depth dimen-
sions that will help insure a tighter seal.
The amount of spring pressure which should be used
seems to be largely a matter of opinion and experience.
Some years ago it was suggested that the range was nor-
mally between 55 lbs (25 kg) and 88 lbs (40 kg), with
some manufacturers of crimpers setting about 74 lbs
(33.6 kg) as an upper limit. The Alusuisse Metals, Inc.
firm, which markets Boxal aluminum cans in the
Figure 2. Closed and Open Curl Configurations
U.S.A. has recommended the use of a maximum down-

Figures 3 and 4. 1Ox and 2Ox Magnifications of Open and Closed Curl Configurations
ward pressure of 176 to 198 lbs (80 to 90 kg) for alumi-
num cans that contain only concentrate.
In the case of Under-the-Cap (U-t-C) gassers, we
have a special situation because the propellent is nor-
mally added to the cans just prior to the crimping stage.
As a result, the head must be forced down upon the can
valve with extra pressure to prevent a possible "blow-
by" event. A spring pressure pad with four "brown"
springs is provided by Kartridg Pak as standard equip-
ment. The springs are rated individually at compres-
sions of 175 Ibs/inch (3.13 kg/mm) and considering the
various deflections used, are sufficient for all propel-
lents except the highest pressure types, such as propane
A-108 and CC>2. For these gases a combination of diag-
onal "brown" and "blue" springs is recommended. A
more complete discussion of this topic is found in the
Aerosol Filling and Packaging Equipment chapter,
under Kartridg Pak and Mace U-t-C machines.
A practical approach to the determination of opti-
mum spring pressure is that the can curl must not be
deformed significantly during crimping and the
Flo wed-In® * gasket (if used) should be compressed by
at least 0.005" (0.13 mm). Cut gaskets and the PE-
sleeve gaskets are more uniform in thickness and are
probably not compressed more than about 0.002 " (0.05
mm) as a result of normal crimping operations.
Another area in which there has been substantial
industry disagreement is the contour of the can bead, as
it may affect the sealing integrity of the crimp. Since
1953 aerosol three-piece cans had been made with a so-
called "closed curl"; that is, where the cut end of the
can curl was tucked all the way underneath so that it
contacted the can metal at the throat area, generally at
about a 90° angle. But about 1965, when "Under-the-
Cap" gassers came into widespread use, complaints
about "phantom leakers" began to reach serious pro-
portions. Actually, a fraction of a gram of propellent
had been forced within the can curl during the gassing
cycle, under about 600 psig (4.14 MPa) of liquistatic
pressure, from which it afterwards escaped, either rap-
idly or slowly. The rate was dependent upon tightness
of the metal-to-metal seal and other factors. Some of the
"slower" cans entered the hot tank and gave signs of
apparent leakage through the crimped seal. These were
the ''phantom leakers'', which were, in some instances,
hard to distinguish from the true crimp leakers.
Reacting to these complaints, the canmakers
enlarged the plug diameter for domes going through the
*® A registered trademark of the W.R. Grace Corporation.
punch press, causing the formation of so-called "open
curl" tops, where the cut end was perhaps 0.02 " from
the metal at the throat section. With this alteration,
* 'phantom leakers'' ceased to be a problem. For crimp-
ing purposes, however, it seemed that this new bead
contour was less satisfactory since it could be deformed
more easily.
When the crimp is effected, the metal of the valve cup
wall is pressed tightly against the metal at the can
throat. This is essential if the valve is to be wrapped
sufficiently under the can curl so that the crimp is tight.
In most cases there is a very slight outward movement
of the throat section, due to the crimping force. With a
"closed curl", where an essentially 90° angle exists at
the cut edge and throat junction, the can bead itself is
also pushed upward and out slightly during crimping.
This exerts an extra compressive action upon the
flowed-in gasket, resulting in a tighter fit without undue
metallic distortion. This advantage does not apply to
the "open curl", which is not normally contacted dur-
ing crimping.
At this point, it should be noted that if a "closed
curl" can is made without the approximately 90° angu-
lation, so that the cut edge of the can bead can slip
upward along the throat metal during crimping, or if
the crimping operation is sufficiently out of control so
that excessive throat distortion will cause such cut edge
slippage even with good angulation, then a much
greater potential problem may ensue. By slipping
upwards, the can bead is rendered smaller in diameter,
sometimes by as much as 20% in the "G" dimension,
and the compressive seal of the flowed-in compound is
abrogated. Unless the formula exerts a swelling action
on the compound, such units are very likely to become
latent leakers. This type of leaker appears to have a
satisfactory seal for several weeks or months, after
which a relatively high level of seepage commences. For
curl comparisons see Figures 2, 3, and 4.
In practice, conversion to the "open curl" appeared
to bring about a serious leakage problem at several
plants which specialized in filling hair sprays. Three
factors seemed to be involved whenever such crimp
leakage was noted:
a. Use of "open curl" cans.
b. Storage of finished units in the inverted position.
c. Use of an U-t-C Propellent Reclaim unit during
production.
Inverted storage had been used as a cure for prob-
lems caused by concentrate entrapment in the dip tubes

Figure 5. Dimensions Surrounding Crimped Can Curl
Used in the Calculation of Crimp Settings
as a result of container evacuation prior to gassing in the
U-t-C.
It is now thought that the "open curl" is able to
deform downward to a certain extent under the com-
bination of the downward force vector resulting from
crimping, plus the downward pressure applied by the
four springs in the U-t-C. When the spring compres-
sion force is removed after crimping, the valve cup can
then recover and spring back slightly, more so than the
shorter radius arm can bead. This has a loosening effect
upon the flo wed-in gasket. The absence of any reinforc-
ing from the cut edge part of the bead would have a
similar slight loosening effect upon the throat wall.
These two effects would then act in concert to make the
gasket more accessible to the product, particularly in
cases where the can was stored inverted. It is known
that, after several weeks of such inverted storage, some
hair spray formulations (principally the P-11 or methyl-
ene chloride ingredients) can extract enough material
from GK-45 gasketing compound so that it will become
relatively porous, causing leakers to appear.
Sub-committee "C" of the Aerosol Division Com-
mercial Standards Committee, CSMA, was formed
around 1969 to investigate this and related problems
and continues to be very active. Thus far, the hair spray
situation has not been completely explained, particu-
larly the involvement of the reclaim units, unless this
was fortuitous, as some now think. By changing to
GK-70 as the gasketing material, it appears that the
problem can be avoided completely, since this elas-
tomeric blend is more resistant to extractions than
GK-45. However, it is somewhat more expensive, said
to cost about $1.50/M more, as a part of finished
valves. In 1977, when CFC propellents were replaced
with hydrocarbon types, the problem vanished
altogether.
The aerosol filler exercises control of the crimp dur-
ing the crimping operation by adjustments in crimp
diameter and crimp depth. Various changes in the
dimensions of other critical factors can often be com-
pensated by altering the crimp settings. Correspond-
ingly, crimp specifications which can be used to cover a
particular production run can be calculated from a
knowledge of the dimensions of the other critical fac-
tors. It is necessary to measure each of the component
dimensions, checking a sufficient number of parts for
each one so that the actual dimensions and tolerances
can be established with reasonable precision. A knowl-
edge of the relationship of these factors is also useful as a
means of determining the cause of crimping problems.
The interrelationship between crimp diameter and
crimp depth can be scaled out geometrically or calcu-
lated trigonometrically from Figure No. 2, devised by
Roy Rousseau of the Kartridg Pak Company.
As a crimp diameter decreases, so must the crimp
depth (on a lesser scale) in order to maintain the same
degree of crimp tightness. This is found to be a change
of 0.002 " in crimp depth for a change of 0.005 " in crimp
diameter. The variation is direct, over a reasonable
range of typical values.
Crimping Specifications for Metal Cans
The CSMA Crimp Committee (Subcommittee C)
has not yet developed any recommendations on what
specifications should be adopted for crimping. Actu-
ally, the committee takes the view that it would be
unwise and perhaps impossible to recommend a stand-
ard crimping practice until basic standards are first
developed on how crimp should be measured. Sample
lots of containers have been shipped to laboratories of
about ten companies participating in the crimp study to
see if reproducible results can be obtained by these lab-
oratories in measuring crimp, and to determine how
closely the results obtained by any one laboratory will
match those obtained by others. Different gauges, such
as the Federal Tool Company and Kile Machine Shop
crimp diameter and crimp depth gauges are currently
being compared for reproduceability and accuracy by
Sub-committee C. The variations have been consider-
ably larger than anticipated.
Participating laboratories have also been asked to
report on what procedures they follow in measuring
crimp. Some companies take a gauge reading on every
segment of the crimp—others measure at a single point.
A few measure between segments, but most firms mea-
sure from the middle of each segment. The committee
plans to urge all in the industry to follow a standard pro-
cedure in measuring crimp, taking a reading for depth
and diameter in the middle of each segment. Only after
they have standardized procedure in measuring crimp,
and been able to demonstrate that different laboratories
can obtain reproducible results, will they be in position
to approach the eventual goal of developing basic stand-
ards for crimping.
Some years ago the committee devised and approved
a listing of sixteen critical mechanical considerations
which affect the crimp. Roy Rousseau has assigned
specifications and other conditions to these dimensions,
These dimensions are provided in the CSAiA "Aerosol
Guide3 ^eventh Eauion, (1981) as "Industry Specifications for Tin Plate Fabricated Aerosol Cans".
Critical Dimensions of the Can
1. Diameter of can opening 1.000 ± 0.004 "
2. Can Curl Thickness: 0.130 ± 0.007 "
Critical Dimensions of the Vjilve Cup
These dimensions may be considered as " Proposed
Tentative Standard Dimensions" provided through the
CSMA. They apply only to tinplate valve cups.
3. Outside Cup Diameter: Bv
4. Inside Skirt Radius: RV-TV
5. Tinplate Thickness: Tv 0.011 ±0.001"
6. Flowed-In Gasket Thickness (Dry) Dv
0.023 ±0.010"
7. Flowed-In Gasket Length: Ev
Critical Dimensions of the Crimping Collet
Applies only to 6-segment, %*" radius collets
designed for standard one-inch valves.
8. Collet Foot Radius: 0.047 ± 0.002 "
9. Check Diametral Integrity of Collet in Ex-
panded Positon. (Ring Gauge)
10. Check Corner Radius at Each Edge of all
Segments. (Radius Gauge)
based upon geometrical and mathematical analysis.
The individual dimensions are taken from accepted
manufacturing standards.
The data presented in Table II (Page 286) illustrate
this relationship.
Similar relationships can be established to show the
way in which a number of other critical dimensions
affect optimal crimp depth. The following five dimen-
sions are now considered:
a. Gasket material thickness.
b. Collet foot thickness.
c. Tinplate thickness of valve cup.
d. Can curl thickness, (G-Dimension).
e. Diameter of the can opening.
When the crimp diameter is fixed at 1.070 ", a crimp
depth setting of 0.185 " is used when these five dimen-
sions are all at their midpoints or targets. The individ-
ual effect of each of these critical dimensions upon
Critical Dimensions of Crimped Valve Cup
These dimensions apply only to one-inch tinplate
valve cups, crimped onto tinplate cans.
11. Measure Crimp Diameters Across All Seg-
ment Impressions: 1.070 ± 0.005"
12. Measure Crimp Diameters Across all Segment
Gaps:*
13. Measure Gap Width Between Sections of
Crimped Impressions:*
14. Check for Contact Between Can Curl and
Valve Cup at Segment Impression:*
Check for Contact Between Can Curl and
Valve Cup at Gaps Between Segment
Impressions:*
15. Measure Crimp Depth at Each Collet:
0.185 ± (Variable)
16. Measure Mounting Cup Gasket Compression
at Top of Can Curl, after Crimping:*
a. Measure gasket thickness before crimping.
b. Measure distance between top of can curl
and inside surface of metal valve cup.
* Industry specifications not developed as of 1982.
 TABLE II adjustment of the crimp depth can be elucidated from
Crimp Depth vs. Crimp Diameter Settings the ''Delta h" values in the five tables which follow.
The total adjustment of crimp depth thus becomes
Crimp Diameter Crimp Depth
0.185 " ± the sum of these five "Delta h" values.

1.065" 0.183" Gasket Material Thickness

1.068" 0.184"
1.070" 0.185" The thickness of the flowed-in gasket material had
1.072" 0.186" earlier been specified as 0.022 ±0.007 ". The origin of
1.075" 0.187" this specification appears uncertain, but it is now
regarded as too tight for gaskets made under ordinary
TABLE III
methods of production and control. A more reasonable
Crimp Depth vs. Gasket Material Thickness specification is 0.023 ± 0.010 ".
In the preparation of a crimp of proper tightness, the
Gasket Gasket
,P. . .
Thickness rr-i • i
Thickness Crimp ,Depth Ah gasket is ideally compressed to about 50% of the initial
/, iv in • j\ Value Value
(I n-cnmped.) (Crimped) thickness, or to a final specification of 0.012 ±0.005 ".
A change in the final thickness of the gasket will require
0.013" 0.007" 0.180" —0.005"
a correspondingly large change in the crimp depth set-
W 0.010" 0.183" —0.002"
,.J23" 0.012" 0.185" 0.000" ting. A variation in the thickness of an uncrimped gas-
0.027" 0.014" 0.187" 0.002" ket will necessitate a half-sized change in the crimp
0.033" 0.017" 0.190" 0.005" depth. These ideas are illustrated in Table III.

TABLE IV Collet Foot Thickness

Crimp Depth vs. Collet Radius Both 1 A 2 " (0.031" or 0.79 mm radius) and % 4 "
(0.047 "or 1.19 mm radius) crimping collets are avail-
Collet Radius Crimp Depth Ah
able, but the Vs 2 " size is less reliable and is being phased
0.045" 0.183" —0.002" out in favor of the %4 " collet. These discussions consider
0.047" 0.185" 0.000" only the 3/64" collet size, which has a foot radius speci-
0.049" 0.187" 0.002" fication of 0.047 " ± 0.002" (1.19 ± 0.05 mm). A change
in this radius affects crimp tightness by a direct relation-
ship, as shown in Table IV.
TABLE V
Crimp Depth vs. Valve Cup Thickness
Thickness of Tinplate Valve Cup
Thickness of Valve Cup Crimp Depth Ah Tinplate valve cups are nearly always produced from
100# plate, which has an average thickness of about
0.010" 0.1844" —0.0006"
0.011" 0.185" 0.000" 0.011" (0.28 mm). Variations are usually within ± 4%
0.012" 0.1856" 0.0006" for a given lot of valve cups, but may extend to as high
as ± 10% for different lots.
TABLEVI A change in metal thickness of the valve cup requires
a corresponding change of about 0.6 the amount in
Crimp Depth vs. Can Curl Thickness
crimp depth, to maintain the same crimp tightness.
This relationship is shown in Table V.
An increase of 0.001 " (0.025 mm) increase in crimp
Can Curl Thickness Crimp Depth Ah
depth, due to the vertical vector introduced at the crown
0.123" 0.178" —0.007" of the cup, plus a decrease of 0.0004 " (0.01 mm) due to
0.127" 0.182" —0.003" the vertical vector of the thickness at the point of hard
0.130" 0.185" 0.000" contact. The net result is an increase of 0.0006 " (0.015
0.133" 0.188" 0.003"
0.137" 0.192" 0.007" mm). For all practical purposes the effect of plate thick-
ness on crimp depth can be neglected, unless the cup is
made from aluminum alloy, in which case the effect is TABLE VII
significant because the cup is much thicker.
Crimp Depth vs. Bead Contact Height

Can Curl Thickness (or "G" Dimension—CSMA)

Can Bead. Contact „
Crimp r\ •
Depth AAh
U
Can curl thickness is a measurement taken at an
arbitrary angle of 20° from the horizontal, using a spe-
0.155" 0.178" —0.007"
cial micrometer. The barrel type micrometer was devel-
0.159" 0.182" —0.003"
oped by the Commercial Standards Committee of the 0.162" 0.185" 0.000"
Aerosol Division of CSMA, and has since been slightly 0.165" 0.188" 0.003"
modified by the manufacturer. 0.169" 0.192" 0.007"
The can curl thickness measurement carries a speci-
fication of 0.130 ± 0.007 " (3.30 ± 0.18 mm), as applied
TABLEVIU
to cans made in the U.S.A. and Canada. The dimen-
sion relates, in a generalized way, to the effect of the can Crimp Depth vs. Can Opening Diameter
bead in the establishment of correct crimp depth. A
change in curl thickness requires an equal change in Diameter of the Can CrJ D h
crimp depth, as seen in Table VI. Opening
Since the can curl thickness may be determined
0.996" 0.187" 0.002"
accurately and rapidly, and since it exerts a greater 0.998" 0.186" 0.001"
effect upon the establishment of proper crimp depth 1.000" 0.185" 0.000"
than any of the other critical factors, the measurement 1.002" 0.184" —0.001"
should be taken from at least three points around the 1.004" 0.183" —0.002"
can curl, and the results averaged.
The can curl thickness measurement should not be
confused with a similar measurement: that of contact
height, which is used widely in Europe. The normal
range of contact heights for U.S.A. tinplate cans can be
given as 0.163 ±0.007", (4.15 ±0.19 mm), as deter- Figure 6. Device to
Measure Throat
mined by the BAMA or Kroplin (S-2002) "ball-and-
Radius of
anvil" gauges, or the Boxal gauge, which is of the the Can Dome
"drum-and-anvil" type. If one of these gauges is avail-
able (the BAMA and Boxal cost about $600 each, but
the unofficial Kroplin gauge costs only about $180), it
may be used to determine the height of the can bead as
it directly affects the crimp depth; e.g. Table VII.
Assembled and separated views of a device engineered by the
Diameter of the Can Opening American Can Company and produced by the Paramount Machine &
Tool Corp., Fairfield, NJ, to determine the throat radius of the can
A variation in the diameter of the can opening affects dome. The three small circles at right in the picture below are gauge
standards.
the tightness of the crimp in an inverse fashion. If the
assumption is made that an increase in the minimum
diameter of the opening, normally 1.000 ±0.004"
(25.4 ±0.1 mm), will relate to an equal increase in the
diameter at the point of hard contact, usually about
1.028 ± 0.004 " (26.1 ± 0.1 mm), then, if the contour of
the can throat at the point of contact is at an angle of
about 36° to 54°, increasing the radius of the can open-
ing by 0.001 " (0.025 mm) will require a decrease in the
crimp depth of 0.001 " (0.025 mm) in order to maintain
tightness. The relation to the can opening diameter,
then, is an inverse 1:2 ratio, as shown in Table VIII:
 Where the can contour at the point of hard contact is
between about 30° to 36° with the horizontal plane, the
ratio between crimp depth and can opening diameter
becomes about an inverse 2:5 relation. A more precise
ratio can be derived trigonometrically for any particular
contour, but such refinements are rarely necessary.

Figure 7. Upper Portion of 211-Diameter Can

Figure 9. j
BAAAA Gauge

Figure 8. Can Dome and Upper Body of Aerosol

Upper portion of aerosol can is encapsulated in clear amber plastic
and cross-sectioned. After polishing the cut surface, exact
measurements can be taken at critical areas. The technique is used
to measure key dimensions without allowing can areas to warp or Device developed by the British Aerosol Manufacturers Association
deform due to cutting. Sealing efficiency, potential strength can be to determine "point of hard contact" for various can domes. Gauge
studied. setting standard ring is illustrated at side.

TABLE IX
Variation of Crimp Depth as a Function of Dimensions of Six Factors

Description of Crimp
Critical Factor ——
Ideal Crimp Typical Crimp Abnormal Situation

Crimp Diameter
Measurement 1.070" 1.068" 1.075"
Difference from Ideal (AJ* 0.000" -0.001" +0.002"
Gasket Material Thickness
Measurement 0.012" 0.015" 0.017"
Difference from Ideal (A h ) 0.000" { 0.003" +0.005"
Collet Foot Thickness
Measurement 0.047" 0.047" 0.049"
Difference from Ideal ( A h ) 0.000 0.000" +0.002"
Tinplate Thickness of Cup
Measurement 0.011" 0.011" 0.012"
Difference from Ideal ( A h ) 0.000" 0.000" + 0.0006"
Can Curl Thickness
Measurement 0.130 0.127" 0.137"
Difference from Ideal ( A h ) 0.000" —0.003" +0.007"
Diameter of Can Opening
Measurement 1.000" 1.002" 0.996"
Difference from Ideal ( A h ) 0.000" —0.001" + 0.002"
Crimp Depth
Measurement 0.185" 0.183 0.2036"
Difference from Ideal Depth 0.000" —0.002" +0.0186"**

*Represents amount of crimp depth adjustment necessary for compensation *Sum of maximum positive crimp depth adjustments, as given in Tables II, III, IV, V, VI, and VIII
Calculation of Crimp Depth
Having described the six critical factors which influ-
ence crimp depth, it is now possible to illustrate their Toint of
Hard Con-
quantitative effects by citing three examples: an ideal tact.
Valve Cup
situation, a typical situation and a highly unlikely situa-
tion, where each factor acts to increase the required
1.2 mm Radius
depth. This is shown in Table IX. (0.047")
From this development it might appear that the
crimp depth should be specified as 0.185 ±0.019"
(4.70+0.48 mm), in the event that the six critical
dimensions which affect the depth dimension are all at
Figure 10. 27.1 mm (1.067") Diameter
the positive limits (or the negative limits) of their
individual specifications. However, these circum- Point of Hard Contact
stances have an occurrence probability of less than a
Contact Height of the Can Bead
million to one.
Note: For practical purposes the crimp depth may be specified as As mentioned previously, the concept of contact
0.185 ±0.005" (4.70 ±0.13 mm), unless some particular deviation in the
other critical dimensions is noted, making it desirable to change the midpoint
height was developed in Europe, where it has been
of the crimp depth specification accordingly. widely used since about 1969. Contact height may be
Note 2: defined as the vertical distance from the top plane of the
Assuming the tolerances represent normal 2-sigma values (95.46% confi-
can bead to the centerline of a measuring ball (of radius
dence levels), the chance for all six to be at their maxima or minima at the equal to the thickness of the proposed valve cup, plus
same time is calculated as one in 1.142 x 108.
the radius of the proposed clinching collet toe) when the
If no preliminary study of the six critical dimensions which affect crimp depth
is undertaken, then the tolerance for the crimp depth must be derived from
ball is positioned so as to touch the can throat profile at
the theorem that the standard deviation of the sum of any number of indepen- the "Point of Hard Contact". See Figure 10. The
dent variables is the square root of the sum of the squares of the standard
deviations of the independent variables. In the present instance:
"Point of Hard Contact" in turn, is an exact position,
horizontally around the can throat, which represents
the uppermost point of contact between can and valve
cup, during normal clinching. It is also the highest
Independent Variable X] 2 cr * 0°
point at which the valve cup is still under direct control
Crimp Diameter 1.070 0.002 0.001 of the clinching collet.
Gasket Material Thickness 0.012 0.005 0.0025
Collet Foot Thickness 0.047 0.002 0.001 To measure this point, a hardened steel ball of about
Tinplate Cup Thickness 0.011 0.0006 0.0003 0.059 "(1.50 mm) radius is positioned within the can so
Can Curl Thickness 0.130 0.007 0.0035
Diameter of Can Opening 1.000 0.002 0.001
that it touches the wall lightly at this exact location, and
the measurement is taken in terms of contact height, as
So that:
described above. The vertical centerline through the
ball will be found (trigonometrically or mathematically)
to be about 0.0135 " (0.34 mm) inward from the radius
^ 'CD = -\M rf >CDl)2
* (c?/ GMT)2 + (a/ >CFT)2
' * (0/ 'TCr)2 + (0/ >CCT)2 + (cr/ >DC )2
°
of the can curl—or about 0.4865 " (12.36 mm) from the
°"CD = ~\/(0-001) 2 + (0.0025) 2 + (0.001)2 + (0.0003)2 + (0.0035) 2 + (0.001)2 centerline of the can. This offset distance is dependent
<y' CD =-J 21.59 x 1(T6 '
upon the can having a normal throat profile, the valve
cup having a normal diameter of 0.992 ±0.004"
tf 'CD = 4.646 x 10'3 (25.20 ±0.10 mm), and on other factors as shown by
2o/
CD = °-0093 the formula:

From this treatment it can be seen that the 2-sigma specification for crimp Y _ p , t _ ( S + 21 — D ) (FEA Standard
A
depth, as an average figure plus deviations for the six critical dimensional fac- " "+ l 2 401 E; indicating
tors, will be 0.185 ± 0.009 " (4.70 ± 0.23 mm). This specification can be nar- derivation) ;
rowed to the more usual one of 0.185 ± 0.005 " (4.70 ± 0.13 mm) only if it is or alternately, by the simplified formula:
first ascertained that high-influence factors such as compressed gasket thick-
ness and can curl thickness are pre-checked and found to be within tighter
limits than their normal specifications would indicate. This is often the case
X = R-Il^L
on individual lots.

Contact Height
Variable
Measured by Means
of Dial Gauge
Measuring Anvil
1.5 mm (0.059")
Radius Constant Built
into instrument
Figure 11. Gauge to Measure Contact Height
in which:
R = Radius of the clinching tool — normally
0.047 " (1.2 mm) in the U.S.A. and Europe.
t = Plate thickness of the valve cup — normally
0.010 " (0.25 mm) in the U.S.A. and 0.012 "
(0.30 mm) in Europe; allowing a 0.001 "
(0.025 mm) reduction during drawing.
S = Diameter across expanded clinching collet —
normally 1.070" (27.18 mm) in the U.S.A.
and 1.067" (27.10 mm) in Europe.
D = Internal diameter of the can opening — nor-
mally 1.000" (25.4 mm) in the U.S.A. and
Europe.
The value for "X", (0.0135" or 0.014" in Europe),
can be calculated for U.S.A. cans and clinching specifi-
cations as:
X =0.047"- (1.070-1.000")
2 a 20° measurement, so the company proposes one
X =0.012" (or 0.305 mm)
The value for the diameter of the hardened ball
"R8 ", (0.059" in Europe), can also be calculated for
U.S.A. cans as:
RB - R + t
RB =0.047 "+0.01O"
RB =0.057" (or 1.45mm)
These deviations from the European situation are
small, but even then, since the U.S.A. ball (0.002"
smaller in radius) is brought 0.0015 " (0.033 mm) closer
to the can wall, the original situation is restored almost
exactly.
Typical specifications for contact height are provided
in Table X.
At least for U.S.A. tinplate cans, a direct relationship
appears to exist between crimp depth and contact
height:
Crimp Depth = Contact Height ± t + Gc, in which
t = Plate thickness of the valve cup — nor-
mally 0.010 " (0.25 mm) for tinplate and
0.015" (0.38 mm) for aluminum, allow-
ing for a reduction of 0.001 " (0.025 mm)
during drawing.
Gc = Flowed-in gasket thickness after crimping
— normally 0.012 " (0.30 mm).
Thus, for tinplate:
Crimp Depth =0.163" +0.010" +0.012"
Crimp Depth =0.185 " (or 4.70 mm)
For aluminum:
Crimp Depth =0.171" +0.015" +0.012"
Crimp Depth =0.198" (or 5.03 mm)
These results match generally accepted figures for
crimp depths in the United States, provided the crimp
diameter is targeted at 1.070" (27.18 mm).
Since curl thickness (CSMA "G" Dimension) is
taken at an arbitrary 20° angle, there is no direct rela-
tionship between it and contact height. The contact
height circle appears to be about 0.014" (0.36 mm)
higher on the can throat than the curl thickness circle, in
the case of tinplate cans. A similar relation exists with
aluminum cans, except for J.L. Clark Manufacturing
Company tubes where the throat profile will not permit
made at about 10°.
The BAMA (British Aerosol Manufacturers Asso-
ciation) gauge is the most favored one for measure-
ments of contact height. It is available from British
Indicators, Ltd., Acrewood Way, Hatfield Road, St.
Albans, Hertfordshire, England, at a cost of about
$600. The Boxal gauge is fairly popular in France and
may be purchased from Boxal France, S. A., 38 Beaure-
paire, France. The principle is similar to that of the
BAMA gauge. The main difference in construction is
that a "barrel" or "drum" with a vertical axis replaces
the ball. The Kroplin S-2002 gauge is best known,
although unofficial. It operates on the ball principle.
Flowed-In Gaskets
A highly essential element in the job of sealing the
valve into the container is the mounting cup gasket. Its
major function is to serve as an effective sealant for the
valve into the clinched seam. This is accomplished in
two ways. The primary seal is provided by the shoulder
portion of the film of gasketing material. The thicker,
channel portion of the film provides a necessary second-
ary seal, thereby insuring sealing latitude to the filler. It
also serves as a cushioning device during the crimping
operation. This is of particular importance when con-
tainers are being gassed and crimped on automatic
machines such as Under-the-Cap fillers.
The material from which the flowed-in gasket is com-
pounded must have physical properties so that initial
sealing will be provided against gas leakage, and the
gasket must also resist product attack and gas transmis-
sion during the shelf life of the product. Because of the
wide range of products packaged as aerosols, and the
variety of propellents used, the development of satisfac-
tory gasketing materials has presented quite a problem.
Early in the development of aerosol containers, the
need for a valve mounting cup gasket which would seal
effectively yet would remain in the cup through valve
assembly and filling operations was met by the Flowed-
In® Gasket. In 1952, the Dewey and Almy Chemical
Division of W.R. Grace & Co. introduced a peptized,
vulcanizable dispersion of chloroprene rubbers (neo-
prene) which could be applied in a "flowed-in" opera-
tion. The compound, properly cured, provides a rub-
bery, highly resistant gasketing material. Now, thirty
years later, the aerosol industry still uses a modification
of that original compound, as Darex® GK-45 NVH.
Other early attempts to provide a sealing system con-
sidered alternate approaches such as a natural latex gas-
keting system, Darex Cap 48, some of which is still
used, but only on a special order basis. A modification
of that formulation, called Darex Cap Compound 1564
was developed in England for the European market,
since raw materials for the GK-45 formulations were
not available in Europe. The 1564 Compound provided
a thicker, somewhat softer film, which proved suitable
for the sealing conditions encountered in the European
market. Today it is an important compound used to
seal aerosol valve mounting caps in Europe.
In a given country, compound selection involves a
combination of factors, not the least of which is the gas-
ket's ability to perform under a specific set of condi-
tions. Which material is used depends on the domestic
availability of raw materials for manufacture, the seal-
ing requirements of the local aerosol industry, the types
of cans used, and the methods for filling them. For
example, GK-45 NVH is used in many of the major

TABLE X
Contact Height Specifications for Various Cans and Valve Cups
V alve
Can , Valve Contact Height Specifications
Continent Materia| MateriaJ Wall .
Thickness hnglish Units Metric Units

No. America E.T.P. E.T.P. 0.009" to 0.1634 f 0.006"* 4.15 ± 0.15*

0.011" 0.1634 i 0.008"** 4.15 ± 0.20**

No. America E.T.P. Aluminum 0.015" to 0.1712 f 0.008"** 4.35 ± 0.20**

0.017"

No. America Aluminum Aluminum 0.015" to (No data) (No data)

0.017"

Europe E.T.P. E.T.P. 0.012" to 0.1575 ± 0.006"* 4.00 ± 0.15*

0.016"

Europe E.T.P. Aluminum 0.020" to 0.1653 ± 0.006"* 4.20 ± 0.15*

0.024"

Europe Aluminum Aluminum 0.020" to 0.1673 ± 0.006"* 4.25 ± 0.15*

0.024"
*Figures supplied by F.E.A. (Italians, suggest 4.25 ± 0.15mm)
**Figures supplied by Editor from tests.
 aerosol markets, but only to a vanishing small extent in
Europe. It seals effectively the entire range of aerosol
products packaged, and performs extremely well in
Under-the-Cap filling.
In the European market, there is still a great deal of
curl dimension and profile variation among countries
and among different types of containers. The natural
rubber latex compounds, Darex Cap 1564 and 1586,
used in Europe, provide a thick, soft gasket which will
seal over this wide range of curl configurations. While
1564 Compound is used successfully in many Under-
the-Cap filling operations, it does not typically exhibit
the wide latitude that GK-45 NVH demonstrates in
these applications. Improvements are being made to
the 1564 type of compound to improve its performance
in Under-the-Cap filling.
The relative cost of these compounds will vary from
country to country. For example, the Darex GK-45
NVH series compounds would probably be more
expensive than Darex Cap 1564 in Europe. Con-
GAGING COMPONENT SPECIFICATIONS
versely, in the U.S.A. the reverse is true. Cost is pri-
A I RA<t c I FEDERAL PRODUCTS
marily a function of the availability of raw materials
A BAS£
OR EQUIVALENT
and the manufacturing equipment located in that coun-
B INOlCATORBALLOlA. 093 DlA
try, but may also be affected by tariffs and trade agree-
C WEIGHT GRAMS ments, if the material is not manufactured in that
D VALVE CUP PLATFOR7 3
&%*"sScJO~ country.
E Q t At.HO.CATOR 00.-^OOO^NOE
To review the chronology of the currently-used seal-
c TOTAL WEIGHT OF .. An ftRAMe
r
I BALLANDMECHANISMl W-gQ WAKS ants in the U.S.A., the original GK-45 compound was
introduced in 1946. It consisted of a solvent solution of
peptized, vulcanizable special neoprene rubbers which
upon drying and curing formed the final gasket. The
Figure 12. Gasket Thickness Gauge
Diagram of Thickness Gauge for 1-inch valve cup flowed-in gasket.
first major improvement in this type of compound was
Darex-45 NV which eliminated the necessity for
SET-UP: vacuum stirring before application and greatly reduced
1. Check that ball indicator point is screwed tightly into indicator stem. the incidence of gasket pinholes. A higher total solids
2. Ball point must rest on one of the three valve cup platform supports.
version offering certain application advantages, Darex
3. Remove gasket from one of the lot of valve cups to be measured.
GK-45 NVH, was developed subsequent to the GK-45
4. Place the stripped valve cup on the platform, and with ball indicator
resting in gasket groove rotate the dial to point zero. NV version and is now the standard Flowed-In® gas-
5. Remove valve cup from platform and proceed to measure valve ket type in the U.S.A.
cups. In response to an industry need for a sealing material
PROCEDURE:
with more latitude for ethanol-containing products
1. Raise indicator stem and place valve cup on platform, release indi- which tend to shrink GK-45 series compounds, Darex
cator gently and record thickness shown on dial indicator. (This will GK-70 was developed. This material, which swells in
be thickness of the gasket only).
the presence of alcohol or pure propellents, increases
2. Raise indicator stem, ro.tate valve cup approximately 90 degrees,
release indicator down gently, and record second reading. the margin of sealing latitude available to the filler. It is
3. Rotate cup 90 degrees two additional times, proceeding as in step 2; now only rarely needed, and available only on special
record readings #3 and #4. order. Most commonly used gasket thickness specifica-
4. Record average of the four readings, plus the high and low reading of tions call for a .025"±.007", or .022"±.010" for
each cup measured.
Available from Alpha Gage & Machine Tool Co., Downers Grove, IL. ® Registered trademarks of the W.R. Grace & Company.
 GK-45 NVH. Allowable side-to-side variation (high to
low) may be from .005 "to .015 " depending upon the
requirements of the individual user.
Standard quality control procedures should ascertain
film thickness and variation and insure that the com-
pound film is continuous, without voids which might
Figure 13. Photo of Device
develop into leakage paths. It is also important that the to Measure Gasket
gasketing system be fully cured to develop its best resist- Thickness within the Arch
ance properties. A color cure chart, which gives a visual of the Aerosol Valve Cup.
indication of cure, is available from the Dewey & Cups are positioned on three
studs. Platform is rotated to
Almay Division for most compounds. obtain three or more readings
per valve cup. The device was
Years of field experience and compound testing indi- developed by the Aerosol
cate that the major factor in obtaining a good seal is a Division, CSMA.
good clinching operation. The gasketing material func-
tions as sealing insurance to allow for variations in
package components and process, as well as to provide
abuse resistance in handling and distribution. The seal-
ing compound's latitude allows the filler to operate an filler due to special situations. It is not yet clear as to
efficient high-speed operation with the equipment and whether there is a real difference in clinch formation or
personnel conditions common to the industry. It is the perhaps a difference in technique and methods of mea-
consensus among industry experts that most field leak- suring clinches. Investigatory work is still being con-
age complaints are a function of less than satisfactory ducted in this area.
clinching practices. In summary, the Flo wed-In Gasket system provides
For a one inch tinplate mounting cup with a GK-45 the aerosol package with efficient, field proven, sealing
NVH gasket, a clinch depth of .185 ±.005" and a insurance.
diameter of 1.070 ± .005" are considered to be best. A substantial and complementary discussion of valve
Crimping practices may vary somewhat from filler to cup gaskets is provided in the Aerosol Valve chapter

TABLEXI
Properties of Flowed-In Gasketing Compounds

T0I-I Specific ^ ^ Film Weight Commercial

0
Compound ^,.^ Gravity Compound ^ Range (WET) Gasket Gauge
r
(Dry Film) Milligrams Range

DAREX GK-45 NV 56-58% 1.45 Chloroprene Rubber ! h o u r air dry 505-545 .018"-.032"
Solvent Solution 1 hour @ 155° F
1 h o u r @ 200° F
1 hour C«> 325 0 F

DAREX GK^5 NVH 60-62% 1.45 Chloroprene Rubber lhourairdry 470-510 .018"-.032"
Solvent Solution 1 hour @ 155° F
1 hour Co? 200° F
1 hour@325° F

DAREXGK^SW 60.5-62.5% 1.50 Chloroprene Rubber * !hour air dry 485-525 .018"-.032"
Solvent Solution 1 hour @ 155° F
1 hour ® 250° F
1 hour ® 325°F

DAREX GK-70 45-47% 1.51 Chloroprene Rubber *lhourairdry 595-635 .015"-.029"

Solvent Solution 1 hour @ 155° F
1 hour @ 250° F
1 h o u r ® 325 0 F

DAREX CAP 1564 84-87% 2.50 Natural Latex 2 hours® 165° F 750-800 .030"**
Dispersion
and should also be consulted. This material also
includes in-depth descriptions of cut gaskets, which are
the most widely used form in Europe and enjoy signifi-
cant use in the U.S.A. [especially for aluminum cans
with one-inch (25.4 mm) openings], as well as the Pre-
cision Valve Corporation PE-sleeve gasket, first used
commercially in 1981. The PE-sleeve gasket is probably
the most important single development in the valve gas-
ket area in thirty years and should capture a large share
of the worldwide aerosol market during the 1980s.
In order to accommodate the 0.012 to 0.014 "(0.31 to
0.36 mm) thick sleeve on the side wall of the valve
mounting cup and still have it fit within the
1.000 ±0.004" (25.4 ±0.1 mm) can or plastic bottle
openings, the cup has been modified to have a side wall
i.d. of 0.944 ±0.003" (23.97 ±0.07 mm), and o.d. of
0.964 ±0.003 " (24.49 ±0.07 mm). Production experi-
ence has shown that new or fairly new 6-segment
crimping collets often have difficulty in entering these
smaller diameter valve cups. They may not come back
out, once forced in for the crimping operation, and this
causes "hang-ups" in the crimper or U-t-C gasser.
Depending upon the degree of wear, the 6-segment col-
let will cause various degrees of vertical scoring or
scratching on the inside wall of the valve cup — often
right down to the steel itself. A new 6-segment collet will
have a fully compressed minimum average diameter of
0.946 " (24.03 mm) and is generally slightly larger. The
six segments do not come together in a true circle, but
as a sextet of arcs representing the original diameter of
the bar stock used to make the collet, which is variously
1.060 " to 1.070 " (26.92 to 27.18 mm), depending upon
the manufacturer. As a consequence, the diameters

TABLE XII
Influence of Crimp Cap Height Upon Valve Cup Gasket Leakage Rate
Formula: 5% Isopropanol, 65% Methylene Chloride and 30% Hydrocarbons A-46
Valve: PVC, with 0.020" stem, 0.080" body, 75A Durometer Viton stem gasket, dimpled cup, Latex WDH cup gasket
Crimp Diameters: 1.076 to 1.080" as noted Crimp Depths: 0.173 to 0.177 " Temperature: Ambient

One Year Weight Loss at 10O0F

Can Crimp Diameter Sum of Opposing Crimp Gap Heights* Low Medium High
No. Range 1 to 4 2 to 5 3 to 6 Prediction Prediction Prediction

1 1.077-1.078" 0.011" 0.013" 0.011" 2.75

2 1.077-1.078" 0.012" 0.013" 0.014" 4.05
3 1.077-1.079" 0.014" 0.012" 0.013" 3.63
4 1.076-1.078" 0.014" 0.012" 0.014" 5.95
5 1.077-1.079" 0.012" 0.012" 0.014" 3.95
6 1.077-1.078" 0.015" 0.013" 0.013" 6.07
7 1.077-1.078" 0.012" 0.014" 0.011" 6.29
8 1.077-1.078" 0.014" 0.012" 0.014" 3.34
9 1.076-1.079" 0.012" 0.014" 0.017" 5.99
10 1.077-1.078" 0.012" 0.017" 0.013" 3.79x
11 1.077-1.078" 0.013" 0.012" 0.012" 2.53
12 1.077-1.078" 0.012" 0.013" 0.014" 7.24
13 1.077-1.079" 0.014" 0.012" 0.012" 10.18
14 1.078- .079" 0.013" 0.012" 0.012" 210.5Ox
15 1.078- .079" 0.013" 0.012" 0.012" 266.81x
16 1.078- .080" 0.012" 0.016" 0.017" 9.68x
17 1.077- .079" 0.013" 0.013" 0.014" 13.18
18 1.078- .080" 0.012" 0.014" 0.012" 254.72x
19 1.077- .080" 0.013" 0.013" 0.012" 11.82x
20 1.078- .080" 0.012" 0.011" 0.015" 312.78x
21 1.078- .080" 0.012" 0.014" 0.012" 310.73x
22 1.078- .080" 0.012" 0.018" 0.012" 32.58
23 1.078- .079" 0.011" 0.013" 0.013" 61.33x
24 1.078- .080" 0.012" 0.018" 0.012" 311.70
* Average of adjacent crimp diameters less gap diameter. Note: individual opposing gap heights may be considerably different; e.g. they are not necessarily one half
the sum of opposing gap heights.
xPrediction was incorrect, based on gap height sums (9/24 or 37.5% wrong.)
Cans 12, 14, 18, 20 and 22 showed partial gasket outward extrusion.
across the splits in the fully closed segments are about
0.004" (0.1 mm) larger than the average, or about
0.950 " (24.12 mm). Since this diameter is equal to the
average i.d. of the valve cup it is not hard to visualize
how a below average i.d. cup would be "hung-up",
badly scratched or possibly distorted by 6-segment
collets.
As an example of collet-making, one major manufac-
turer uses a 0.060" (1.52 mm) wide grinding disc to
slice the formed bar stock into the six desired segments.
As the abrasive disc wears, one can expect that the kerf
of these slices would drift down to something below
0.060" (1.52 mm), and this would have the effect of
making the fully compressed diameter of the sextet of
segments somewhat larger. For instance, if the grinding
kerf became an average of 0.057 " (1.45 mm) due to
wear on the discs, the fully compressed diameter would
increase by the same 0.003 " (0.08 mm) difference. This
Figure 15. Eight Segment Crimping Collet
would then act to exaggerate the problem. Initial diameter of uncut bar across collet toes is 1.060", shown as
It would, of course, be possible to use grinding discs segments 3 and 4. The fully compressed (minimum average)
diameter is 0.943", shown as segments 1 and 2.
of greater thickness to cut the collet segments from the
Typical crimping (average diameter is 1.070", shown as segments 5
original shaped bar stock. Using a 0.070" (1.78 mm) and 6 (Range ± 0.001"). The maximum crimping (average) diameter
grinding disc on 1.060 " (26.92 mm) diameter bar stock is 1.075", shown as segments 7 and 8 (Range ±0.001")
would give a 6-segment collet with a fully compressed
minimum average diameter of 0.927" (23.55 mm) has been made on the basis of a one-year weight loss
across the toes, which would resolve the problem of assessment. The results are reported in Table XII.
crimping the PE-sleeve type cup. However, when the
collet is spread to a typical 1.070 " (27.18 mm) to effect Data was obtained with the crimp diameter gauge
the crimp, the segments will then be separated or and holder shown in Figure 14.
gapped to an excessive 0.075 " (1.90 mm) and gap leak- The predictions of leakage rate, as low, medium or
age (often related to latent leakage) will be invited. high, were 62.5% accurate, which is probably signifi-
A study of gap height (which is a function of gap cant statistically, considering that an average height of
length — the greater the length the greater the height) opposing gaps was used (not the true individual gap
heights), and that a number of other factors influenced
Figure 14. Kile Crimp Diameter Gauge weight loss.
The Kile Machine Shop aerosol crimp diameter gauge, shown with a
slotted turret accessory for increasing accuracy, and particularly for During 1980 it occurred to Franklin D. Haase of the
the determination of gap diameters between crimping indentations.
Peterson/Puritan, Inc. research staff that, if an 8-seg-
ment collet were to be used the kerf of the dividing cuts
could be much less than for the 6-segment collets and
still allow the fully compressed collet toes to slip within
the PE-sleeve type valve cup. About the largest 8-seg-
ment collet that will still work easily with the PE-sleeve
valve cup is illustrated in Figure 15.
When the segments are opened to produce a 1.070 "
(27.18 mm) crimp—measured across the center area of
each opposing crimping indentation — the collet gap is
then only 0.050 "(1.27 mm), which is substantially less
than that of any 6-segment collet. Haase arranged for
the preparation of some 8-segment collets, meeting the
dimensions indicated in Figure 15, and found that they
were able to apply an excellent, scratch-free crimp on
PE-sleeve valve cups. In addition, weight loss studies
using both high-alcohol and high methylene chloride
formulations showed conclusively that average weight
losses were reduced, probably because of the signifi-
cantly reduced gap length and gap height.
Production tests later showed that this particular
design had an average life-span of only about 200,000
Figure 16. Device to Measure Valve Cup Inside
Diameter and Fully Closed Diameter of Crimping Collets
The tool is machined to initially include the dotted portion at the
bottom. This area is turned to an i.d. of 0.960" for a vertical distance
of 0.100" in order to establish a base point for the 1:50 taper. Taper
dimensions are:
A = 0.900"
B = 0.959"
C = 0.960"
The bottom 0.147" portion is cut off after the taper is produced in
order to facilitate closed diameter measurements for 3/64" radius
crimping collets.
To measure the closed diameter, insert the collet firmly into gauge.
Measure protruding length. Subtract from total length to obtain the
inserted length "Y". Calculate closed diameter from the expression:
C.D. = 0.960"-0.02OY
Closed collets should have maximum diameters of 0.942" for PE-
sleeve type mounting cups and 0.965" for regular Flowed-ln or cut-
gasket mounting cups.
The 0.941" "go/no-go" gauge at the top is designed for incoming
inspection of PE-sleeve type valve mounting cups, which should
have an inside diameter of 0.944 ±0.003". If the gauge end goes
into the cup quite easily the cup is satisfactory. If it enters with any
difficulty or friction, then the cup i.d. is too small or out of round.
crimps, whereas the average 6-segment collet averages
about 550,000 crimps, when used for a variety of prod-
ucts. (Some products, such as starches, shorten the life
of a collet considerably, whereas non-aqueous solution
type products enhance collet life. Collet cleanliness is
also important.) In response to the short life-span prob-
lem, Haase then set about designing a greatly improved
segment profile. By switching to a different alloy he was
able to both harden and case harden the new collets to
about the Brinnell 64 level, making them substantially
more wear resistant than the average collet. The new
Mark V 8-segment collets are currently (1982) passing
the 850,000 crimp level in a production setting, with a
variety of products, and none has broken or shown any
appreciable sign of wear.
A series of Mark IV 10-segment crimping collets
have also been prepared and these are performing satis-
factorily as well, on production lines running a variety
of products. In this case, the gap length and gap height
are reduced still further. The evaluation of any benefits
from additional weight loss reduction will have to await
the results of tests now in progress.
As a part of the research program relating to the
crimping of PE-sleeve valve cups and the development
of 8 and 10 segment collets of a superior design, Frank
Haase also devised a testing device (a) to check PE-
sleeve type cups for acceptably large inside diameters
on a go/no-go basis and (b) to determine the maximum
circumscribing diameter of the fully closed collet across
the collet toe area. The device is illustrated in Figure 16.
Not all well-worn 6-segment collets will work with
the PE-sleeve for crimping purposes; many still scratch
the inner cup wall and leave the exposed steel free to
discolor or corrode. Not all 8-segment collets work
either, for that matter. Collets of this type have been
sold by the Mace Engineering Company (California)
and at least two other firms for a number of years, and
none of these particular designs appear to work in pro-
duction with the PE-sleeve cups. By using the gauge in
Figure 16 one can predict whether a particular lot of
PE-sleeve valve cups will work in production with a spe-
cific group of crimping collets.
Causes of Container Leakage at the Crimp
The largest single cause for defective crimped seals is
the use of an incorrect setting for crimp depth. It is
necessary to consider this dimension rather carefully,
and in context with the six critical factors which influ-
ence it. Special circumstances, such as the use of alumi-
num valve cups, aluminum cans, pre-formed gaskets, Aluminum tubes and cans are more difficult to crimp
PE sleeves, unusual aerosol compositions and so forth satisfactorily than are those of tinplate construction.
may also have to be considered. The CSMA, FEA, and The can curl is almost always more variable in terms of
some can suppliers are against the publication of any contact height, planarity and metal smoothness. Some
specific figure for crimp depth, since so many factors containers have radial grooves resulting from the form-
significantly influence this dimension. The usual alu- ing operations running across the crown of the curl
minum can with inward or outward curl will seal at a area. This condition can be detected better by running
typical 1.069 " (27.15 mm) diameter and 0.193 " (4.90 the fingernail very lightly along the crown than by
mm) depth (Boxal specification for flowed-in gaskets). direct visual scrutiny or other methods. Crown grooves
Aluminum cans with solid beads (certain two-piece will sponsor crimp leakage with flowed-in gaskets
varieties) are rarely encountered in the U.S.A., but unless the seal is made very tightly. The use of cut gas-
they require a depth of about 0.202 ±0.006" kets improves seal reliability. Extra thick flowed-in gas-
(5.13+0.15 mm) for a good seal. The use of extra-thick kets can be supplied by some cup manufacturers, which
or double-thick flowed-in gaskets can pose substantial also improve crimping integrity.
problems unless the crimp depth is let out by some A study on the optimum crimping of 1.375" and
0.006 " to 0.012 " in compensation. The relative novice 1.500" diameter aluminum tubes has shown that
may use the normal crimp depth figure of 0.185 " with U.S.A. aluminum valve cups are best sealed using a
little or no appreciation of the many related factors. crimp diameter of about 1.091" and a crimp depth of
Generally the figure will give a good crimp, but there about 0.164 ". The work was performed on ' Teerasol''
are enough instances where it will not, so that industry tubes, and is not necessarily relatable to tubes made by
associations and suppliers naturally hesitate to propose other manufacturers.
what may be looked upon as a hard figure; one that will Glass aerosols are generally more difficult to crimp
always provide a good crimp. than metal cans, one reason being that there is more
variation in the shape of glass containers than there is in
Crimp diameter is usually specified as metal cans; thus it has not been possible to set up as
1.070 ± 0.005 " (27.18 ±0.13 mm) in the United States. tight specifications for glass bottles as for cans. Crimp-
In Europe crimp diameter is specified by the FEA as ing has been a particularly severe problem on plastic
1.067 ( +0.008/-0.004") of 27.1 the metric equivalent coated glass aerosols.
27.1 +0.2/-0.I) mm. The range of 1.063" to 1.075"
matches very closely the most recent U.S.A. range of
1.065" to 1.075". These specifications apply only to
three-piece tinplate aerosol cans, fitted with tinplate
valve cups.
Since an aluminum valve cup is about 0.005 " (0.13
mm) thicker than a tinplate cup, at least in the U.S.A.,
compensation must be made for this fact in the settings
of both crimp depth and crimp diameter. The depth
should be deepened, as previously described. The
diameter could be specified as 1.060 ±0.005", but is
usually set for a little more than this to compensate for
spring-back effect.
Aluminum valve cup alloys are more subject to
cracking than tinplate, and hot tank leakers are some-
times seen where the gas bubbles emerge from metal
splits at the end of one or more crimp indentations.
Procter & Gamble and other firms have made an inten-
sive study of this problem, and as a result, specifications
are now available for suitably rounding the edges of the
crimping collet toe so that split leakage is minimized,
Figure 17. Shoulder Profile of Aluminum Can
while still retaining a good hermetic seal.
 One of the reasons why crimping of glass aerosols has
continued to be a problem is because testing glass aero-
sols for crimp has itself been a problem. Grip test,
torque test, study of crimp profile — none of these test
methods has been satisfactory for glass. Thus Ed
Budzilek of Wheaton Aerosols Company has suggested
(Aerosol Age, Apr. 1967, pg. 40) that the same method
used in checking crimp on metal cans be applied, with
modifications, to glass aerosols — using a crimp height
and crimp diameter measurement. But, instead of
establishing a single specification for heights and diam-
eters, he suggests establishing separate measurements
for each combination of valve and container from dif-
ferent suppliers. His suggested system, and a formula
to be used in its application, are described in the article
in Aerosol Age referred to above.
Modern crimping machinery can usually apply
crimps at depth and diameter tolerances of ±0.005"
( ±0.13 mm). With close attention, diameters can be
held to ± 0.002 " ( ± 0.05 mm) for the three diameters
(1-4, 2-5 and 3-6) on an individual can, and to about
± 0.0035 " ( ± 0.09 mm) for cans and valves out of sin-
gle lots. Crimp depths can rarely be held much better
than ±0.003" (±0.08 mm) for the six indentation
depths on a single can (or the eight indentation depths
on single cans clinched with eight segment collets). For
cans and valves within the same lot, ± 0.005" ( ±0.13
mm) is a minimum tolerance. The "Under-the-Cap"
gassers made by Kartridg-Pak, Inc. may be fitted with
either molded seals or simple "O" ring seals. With the
molded seals, crimp depth tolerances of ±0.005"
( ± 0.13- mm) can be held, but problems leading to pro-
RUMER CASKETS
RUtMIl CASKfTS
SEALING IEADS
SCAlINC UADS
VAlVE FERRULE
VAlVE FEMmE
PlASTIC COATING
UASTIC COATING
GLASS IOTHE
GlASS IOTTLE
Figure 18. Glass Valve Figure 19. Latent Leaker
Correctly Crimped Incorrectly Crimped Too Loose
duction line slow-downs may occasionally develop. The
"O" ring seals give better overall machine perform-
ance, but the depth tolerances must normally be
increased to ± 0.008 " or so.
A broken piece of a segmented collet can be replaced
with a new one. However, this practice may produce an
unbalanced collet, where the new tooth may indent the
valve cup somewhat more deeply than before, or pro-
duce a groove a few thousandths higher or lower than
before. It is often better, whenever possible, to replace a
broken segment with a used one from another collet. In
any event, the repaired segmented collet should be
checked carefully by crimping a few cans and measur-
ing the diameter and depth of the six indentations.
Alterations in the new segment can sometimes be made
by careful grinding.
A particularly good crimp must be made whenever
the aerosol formulation may be expected to exert a
strong solvent effect on the flowed-in compound gasket,
or whenever the formulation will cause gasket shrink-
age. Some formulas, such as diethyl ether types, will
often do both. The ideal aerosol composition, from a
gasket standpoint, is one which will cause a mild swell-
ing effect, in the area of 4% to 15%, without bringing
about plasticizer extraction or other solvent related
problems. Weight loss data, taken in part from unpub-
lished results obtained by the Specialty Chemical Cor-
poration, show that most of the seepage from an aerosol
takes place through the valve itself. See Table XIII.
The seepage weight loss from this aerosol composi-
tion is probably about 0.2 g/yr through the crimped
seal, and about 0.2 g/yr through the container double
RlWtER GASKETS
SfAlING ItAOS
VAlVE FERRUlE
FlASTIC COATING
GLASS tOTUE
Figure 20. Plastic Bulged
Crimped Too Tight and Too High
 TABLEXIU
Weight Loss Through Precision Valves, for a Hair Spray in a 202x509 Can

rp. • Weight Loss During Upright Storage of Hair Spray (Grains)

Stora e
S Buna Gaskets Neoprene Gasket Viton Gaskets Blank Valve Cup
L
(mo.)
75 100 130 75 100 130° 75 100 130 75 100 130

1 0.2 0.3 0.4 0.1 0.3 0.5 0.0 0.1 0.1 0.0 0.0 0.1

3 0.5 1.2 2.6 0.4 0.8 1.5 0.2 0.2 0.3 0.0 0.1 0.2

6 0.9 2.1 — 0.6 1.4 — 0.3 0.6 — 0.2 0.1 0.3

9 1.6 3.3 — 0.9 2.0 — 0.4 0.9 — 0.3 0.3 0.7

12 2.0' 4.5 — 1.2 2.8 — 0.6 1.2 — — — —

Simulated Hair Spray Formula:

(Fill - 200 grams)
Propellent-12 25%
1,1,1-Trichloroethane 10%
Ethanol - Anhydrous 50%
Methylene Chloride 15%
seams, at a temperature range of from about 7O0F to
1050F. These figures are quite low, considering that the
average aerosol container shows a weight loss of about
3.0 g/yr.
Methylene chloride, acetone, xylenes and Propel-
lent-21 are ingredients which cause strong solvent and
leaching effects upon the flowed-in gasket compound.
They are profound gasket swellers, often causing the
gasket to expand and push partially out of the normal
position, provided they can contact it sufficiently well.
Weight losses of products high in these solvents will
often be in the range of 6 to 12 g/yr.
Ethanol, isopropanol, diethyl ether, propylene
glycol, polyethylene glycols, Propellent-12 and Propel-
lent-114 exert either a negligible swelling effect, or a
shrinking effect upon ordinary Dewey & Almy GK-45
NVH neoprene-based gaskets. The shrinking effect of
ethanol is about 7 v%. In the case of products contain-
ing these solvents without the presence of substantial
amounts of swelling type solvents, such as personal deo-
dorants, feminine hygiene sprays and engine starter flu-
ids, the gasket must be drawn up very tightly during the
clinching operation, or leakage may result. This type of
leakage is often described as "latent leakage" since it
does not commence until a certain degree of gasket
shrinkage has taken place: a matter of a few weeks or
months. For example feminine hygiene sprays have
been crimped most successfully into tinplate cans, less
successfully into beaded aluminum cans with one-inch
openings, still less successfully into beaded aluminum
cans with openings for 20 mm ferrule closures, and with
least success into aluminum tubes with "corrugated"
finishes, also designed to accommodate the 20 mm
ferrule-type closure.
In any closed aerosol system the gasket compound
tends to build up an equilibrium relationship with the
formulation after about two weeks. At this time, the
rate of weight loss stabilizes, and several other para-
meters also cease to fluctuate. The effect of the solution
upon the gasket is directly proportional to the avail-
ability of contact between the two. A tight crimp will
strongly reduce this contact, but maintaining the dis-
penser in an upright condition will also be quite benefi-
cial. The use of lower temperature storage reduces the
concentration of vapors in the outage space and also
minimizes the solvent activity of these vapors. These
considerations show the wisdom of storing aerosols cool
and upright, wherever possible.
Certain gasket materials are more resistant to aerosol
solutions than others. For instance, Dewey & Almy
GK-70 material is less affected by ethanol and diethyl
ether than is GK-45, and is therefore a preferred com-
position for use with these solvents. More on this is pre-
sented in the section dealing specifically with flowed-in
valve gaskets.
Measuring the Finished Crimp
Crimped aerosol cans are measured for crimp diam-
eter and depth with good frequency in any well organ-
ized operation. See Figures 21 and 22. In a few
instances, especially where the product is hard to hold,
the can is measured for diameter between crimp inden-
tations. This figure varies, but is often about 1.040".
When it becomes less, there is a possibility of leakage
between indentations. Double crimping, which statisti-
cally will remove over 90% of these higher areas, has
been shown to reduce the seepage rate of personal deo-
dorant formulas (mostly ethanol and P-12) to less than
half the former averages. It is not feasible for production
purposes.
Finished aerosols are sometimes checked by means of
a torque tester. The tester developed by Dr. Winston
Reed is by far the most popular in the U.S., and is
available as a set of specific tools with accessories
designed to clamp onto the housings of various aerosol
valves. Under no circumstances should any torque
tester clamp outward against the crimped seal, or
inward against the maximum diameter of the valve
cup, since this will distort the very area under measure-
ment. With the tester attached, the can is held rigidly in
place and the torque arm is slowly rotated, noting the
dial gauge, until the valve cup begins to turn in its seat.
The maximum dial reading is recorded. As a rule, a
value of between 30 and 60 inch-pounds indicates a
satisfactory crimp.
This test, which has the disadvantage of destroying
the aerosol unit, is a poor measure of comparative seal-
ing efficiency. The torque reading is a rough summa-
tion of such conditions as:
a. Out-of-roundness of the crimp sealing area, as
ellipticity.
Figure 21. Kile Gauge for Crimp Diameter
A dial read-out crimp diameter measuring gauge, made by the Kile
Machine Shop, Danville, IL. Considered by many to be the most
accurate and reproducible device available for such measurements.
Operation is simple and direct.
b. Smooth versus rough finish on the gasket
compound.
c. Burrs or other interruptions of the smooth metal
surface.
d. Lubricity of product spills on the can-to-valve
interface.
e. Formulation of plastic jacket of aerosol bottles in
relation to factional effects.
One cannot determine what portion of all these
extraneous conditions is present to affect the final read-
ing of crimp tightness. The test will definitely not deter-
mine gasket thickness variations, gasket channels,
grooves or other imperfections, or slight-to-moderate
can bead distortions.
The Reed instrument, complete with various acces-
sories, costs about $420. Torque testers are in use in the
United States, Canada, and Italy, but do not seem to be
widely used elsewhere in the world.
Perhaps the best method of full laboratory crimp
evaluation, but used to a limited extent, is the deter-
mination of crimp profile. A gauge for this purpose is
shown as Figure 23.
It has been used to determine throat profiles of a
given can both before and after crimping, as illustrated
in Figure 24.
W.E. Hensen and J.W. Thomas of S.C. Johnson,
Inc., described such a method, which they developed,
at the May, 1970, meeting of the CSMA Commercial
Standards Committee in Chicago. They pointed out
Figure 22. Kile Crimp Depth Dial Gauge
Unlike some gauges, the depth is read as the distance below a knife
edge laid on the crown of the valve cup, directly over the crimping in-
dentation to be measured. Thus, any non-planarity or molded cap
seal impressions are not able to influence the determination.
 INfJSR TMfIOAT PROFILE FOR ZQt-OiAMKTEK

AM&AlCAN CAN C.O»APAHY GAH -CHICAOOfLAMT.

BEFORK AMD AFTE.R CRlMPtUS-

XMTHtS CASF CKIMfVNf DfPKfSSCD TOP QF GVHl.

BY O-O20" AHO CAUSmO F^ATTfNtHS- Of »OTM COML.

AHO OVST COVfM AUfAOF DOMf.

A = POtHT OF MAKD COHTACT (8AHA 9AV9S).

SfFOKS Ct-t-C CKlKWNO-

AFTEfI U-t-C CtUtAPtN*

Figure 25. Inner Throat Profile Graph

that, when an investigator measures crimp diameter

and depth, he sees and studies only the external config-
uration of the crimped valve. It was their purpose to see
what actually happens inside the can after the valve is
crimped, and thus be able to observe the cause of the
crimping problem.
They observed that the method of examining the
cross section of a crimped valve by exposing a cross sec-
Figure 23. Kile Gauge for Throat Profile
A compound gauge for the determination of throat profile in the
tion by cutting would provide some insight into crimp
depth range of 0.06 to 0.25" (1.52 to 6.35 mm) below the top plane of integrity. However, this method would not allow them
the can bead. A dial gauge radius may be read for each depth setting to observe the actual state of the crimped valve, because
of the needle connected to the barrel micrometer. Readings are then
plotted to show contour. Made by Kile Machine Shop, Danville, IL. the very act of cutting through the can dome with a saw
would release pressure on the dome, permitting it to
spring from the crimped position and resulting in defor-
mation of the crimp seal. What they determined to do to
avoid this problem was to cast the can dome and
Figure 24. Throat Profile Graph
crimped valve in plastic before cutting through dome
and valve with a saw. They would then examine the
THHQAT PROFILE : : : : : : : i ' . : : : exposed cross section under magnification. The step-
A foiERlCA N CAN ,0.OMfV(MY,4Q2 *.SQ9cAH \ \ \ \

S O 30-i.l3Z NO. 90798 -CHJCAGO ' . ' . ' . } ' , \ \ wise procedure is as follows:
' . ' . ' . ' . ' . ' . ' . ' ' . BfFOfIE ' . ' : AfTfK : ! !
, DIMENj5<qMS

TOTAL. CAH fi£t&HT

CP,!M 1*1 NIj . Cf^IMf3IHa , j

'.'.'.'. 938". '. ', 32A* ! ] .!

a. Puncture can base and expel the contents.
PL./U& Z.D.

<JRL O.O
' . ' . . ' . ' . ' . ' . ' ' . ' . .9*4"! ! ' .

Zt(*' '.
983* ' . I ' ,

ZZS', . .
b. Remove dome at top chime with EKCO can
UUL DMMETCR IHOHIi.)

(JKL *e"rMMENSIOfi '.

'. .Hi"

./27" ! ;
'. /</"! ! !

.113" I '.
opener or similar instrument. Wipe dome and
AM.A, POINT Qf HARD
CONTACT (A)
.H,35" '. JSJQ'l
; i . . .
valve section clean and dry of product. Remove
HIMP OIAMB.r£R
RIMf OBPTH
. — ] 1.07^ * O OJOC"
' . ' . ' . ' . ' . ' . ' . ' . ' — . ' . ' . ' . O./«Z5*O.OQOS"
diptube.
&AP (.9AOCTLE? DlAMETSR

COLLBT
.'.'—.'.

SE.&MKNTS ' . ' ' ' . ' — ' . ' . ' . ' . ' . ' . ' .
i J.OtS * O.OQI"

6 . ' . ' . ' .

c. Pour liquid resin into casserole for casting. The
resin (Castolite Company, Woodstock, Illinois) is
mixed with one part catalyst to 99 parts resin.
THKQAT PROFILE
Immerse can section in resin, using care to mini-
0£fOft£ CR/MPM&
mize trapped air.
THROAT FFtQFiLE.
AFTeK CfUMPiMG- zi-jAM-iaei
d. Place sample in vacuum chamber at about 20"
Hg0 for 15 minutes to further remove entrapped
air.
 e. Allow resin to harden slowly over 24 hours at
4O0F. Tacky resin is then conditioned at about
UO 0 F for 2 to 4 hours until hard.
f. Make a vertical cut through the center of the
valve, using a fine tooth band saw.
g. Rough polish sample on a drum sander to remove
saw tooth marks.
h. Do final polishing with waterproof abrasive paper
in a sink with water runing continuously over
sample. Polish with #320 paper and then #600
paper.
i. Dry and polish with Johnson's " Favor".
j. Project sample image with Model 814 Ex-cell-o
contour projector set for 1Ox magnification.
Tracings of the image can then be prepared.
k. Relate tracing to standards in effort to determine
cause of crimp failure.
Preparation time for a sample is approximately 30
minutes, and it takes an elapsed time of approximately
24 hours from start of the test until the sample can be
inspected. Thus this method will, the developers
believe, be limited to crimp study projects or production
troubleshooting studies, and is not adapted to routine
production application.
Most crimp failures are the result, not of a single out-
of-specification dimension, but of two or three which
reinforce each other — acting in concert. Thus, a
slightly low crimp depth of 0.192 " (4.88 mm), will not
ordinarily cause any problems—unless the crimp diam-
eter is less than about 1.060 ", or the can curl thickness is
less than about 0.123 ", and so forth. Many crimp prob-
lems seemingly solve themselves when a new lot of cans
or valves is brought in. But actually, the new compo-
nent may simply have dimensional attributes that act to
correct the deviation of some other factor.
TABLEXIV
Crimping Dimensions for "Sepro-Cans" and Effects Thereof
Crimp
Can No. Diameter Crimp Depth Can Condition
1. 1.075 " 0.150 " Depth too shallow so bag is almost
severed. Can curl is deformed. No
immediate leakage.
2. 1.070 " 1.175 " Good crimp. No tendency to cut the
bag or deform curl. No immediate
leakage.
3. 1.060 " 0.190 " Depth too deep. Giving very loose
crimp which immediately leaked.
Crimp failures with glass and plastic-coated bottles
often give rise to latent leakers through the rubber-glass
interface. In one major instance of such leakage, 0%
showed leakage up to ten days, 17% showed leakage
between ten and fourteen days, and about 2% showed
leakage between fourteen days and three months. Non-
leaking samples of this lot were easily forced to leak by
cycling from -2O0F to 13O0F to -2O0F in as little as three
cycles.
By means of a new method for crimp evaluation,
originated by Edmund Budzilek* and now an official
CSMA method written into the Aerosol Guide, it has
become possible to define a good crimp depth in terms
of the dimensions of the valve components and bottle
finish. Latent leakers may be eliminated if this proce-
dure is followed. It is described more fully in the chapter
on Glass Aerosols.
The crimp depth on ferrule type valves can be deter-
mined by means of an optical comparator, by vernier
calipers, or by means of a "ball-and-anviT' gauge simi-
lar to that described for the determination of contact
height. These dial gauges have so far been made to
order by two or more large marketers who specialize in
glass and plastic coated glass aerosols. They are not a
commercial item. The Kroplin S-2002 "ball-and-
anvil" gauge for contact height can be used for the
determination, with only slight modifications and
insertion of a correction factor.
Ferrule crimps made on small aluminum tubes must
be considered using the same parameters as for glass
bottles. The tube end will be either curled or waved.
Trigonometry can be used to derive clincher settings,
based upon the metal of the tube protruding at least
35% into the large rubber sealing gasket of the valve.
It is necessary to press down rather forcibly upon
valve ferrules to help get the penetration into the rubber
needed to create a hermetic seal between the valve and
the glass or aluminum container. The use of proper
hold-down devices or' 'nests'' is valuable in minimizing
valve distortion. The nest should be contoured for each
valve used.
The "Sepro-can" carries a dome with slightly
enlarged plug diameter and smaller curl size. Based
upon known variations occurring with "Sepro-can"
dimensions because of the extra variable due to the
"Conoloy" or polyethylene bag, these specifications
should be used only as a general guide for set-up
purposes.
*E. Budzilek is a world authority on glass aerosol technology and is currently a con-
sultant for the Wheaton Aerosol Company.