Systems and related methods for manufacturing ring pull bottle crowns

A method of manufacturing a ring pull crown for a bottle opening using a single machine having multiple die systems, the method comprising:

• using a first multi-stage die system comprising a plurality of diagonal rows of die punches, at least one of said plurality of diagonal rows comprising each stage of the multi-stages:
• forming a plurality of crown bodies from a first source material, wherein the plurality of crown bodies are formed in parallel diagonal rows with respect to a longitudinal length of the first source material, and
• forming a scoring line arrangement on each of the plurality of crown bodies, wherein forming the scoring line arrangement includes:
• forming a first scoring line extending in a substantially linear radial direction from a center area of a top of each crown body to a portion from which is formed a lower edge of a skirt of each crown body;
• and
• forming a second scoring line including:
• an upper radial segment extending in a substantially linear direction from the center area of the top of each crown body to the skirt of each crown body, and
• a lower annular segment extending circumferentially along the skirt in an annular direction and extending from a terminus of the upper radial segment, the lower annular segment defined in a second horizontal plane spaced from a first horizontal plane defined along the lower edge of the skirt;
• using a second multi-stage die system comprising a plurality of diagonal rows of die punches, at least one of said plurality of diagonal rows comprising each stage of the multi-stages, forming a plurality of pull ring and tab assemblies from a second source material simultaneously with the forming of the plurality of crown bodies using the first multi-stage die system, wherein the plurality of pull ring and tab assemblies are formed in parallel diagonal rows with respect to a longitudinal length of the second source material;
• and
• using a third multi-stage die system comprising at least one diagonal row of die punches:
• forming a plurality of ring pull crowns by simultaneously combining each crown body of a diagonal row of the plurality of crown bodies with a corresponding diagonal row of pull ring and tab assemblies of the plurality of pull ring and tab assemblies,
• forming the skirt that descends below a top of each ring pull crown, and
• removing the plurality of ring pull crowns from the first source material.