Tapered metal cup and method of forming same

Abstract

A metal cup and a method of forming the same are provided. The metal cup of the present disclosure includes a plurality of thin straight wall portions and a tapered profile. And the convex top part is arranged at the bottom of the cup body. The cup body can comprise a disposable cup body, a reusable cup body or a recyclable cup body.

Description

[0001] This application is a divisional application of the invention patent application with the application date of November 20, 2017, application number 201780088249.4, and invention name “Conical metal cup and method for forming the same”.

[0002] This U.S. non-provisional patent application claims priority to U.S. Provisional Patent Application No. 62 / 455,697, filed on February 7, 2017, and priority to U.S. Patent Application No. 15 / 811,032, filed on November 13, 2017, the entire disclosures of both of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present disclosure generally relates to metal cups and methods of forming the same. More particularly, the present disclosure relates to beverage cups made from metal. Various embodiments of the present disclosure provide a thin-walled beverage cup that is stackable with cups of similar construction. Background Art

[0004] Existing disposable beverage cups and drinking containers generally include plastic materials. Plastic cups are made by injection molding or thermoforming operations, from which many lightweight and disposable cup bodies can be formed. Existing metal beverage containers generally include drinking cans that include an end cap fixed to the upper end of the filling can.

[0005] U.S. Pat. No. 4,366,696 to Durgin et al., which is hereby incorporated by reference in its entirety, discloses a nestable can and a method of forming the same from a blank. However, Durgin et al. do not disclose various features of the present disclosure, including, for example, the tapered or stepped geometries shown and described herein and methods of forming the same.

[0006] U.S. Patent No. 4,914,937 to Bulso et al., which is incorporated herein by reference in its entirety, discloses a method for forming a tapered container. Bulso et al. provide a straight wall cup and a method for forming the same, but do not have the various teachings of the present invention.

[0007] U.S. Patent No. 6,463,776 to Enoki et al., which is incorporated herein by reference in its entirety, discloses a method for manufacturing a bottle-shaped jar having a neck and a shoulder. Enoki et al. do not disclose the various features and methods of the present disclosure. For example, Enoki et al. do not provide a cup-shaped container having a tapered straight sidewall. Summary of the invention

[0008] Therefore, there is a long-standing unmet need to provide a reusable and recyclable metal cup. It is also desirable to provide a stackable conical metal cup to enhance the transport and storage of multiple cups.

[0009] In various embodiments, a conical metal cup is provided that includes shallow wall angels. At least as used herein, shallow wall angles include wall angles less than 10 degrees measured from the vertical centerline or vertical axis of the cup. The angled sides and shallow wall angles of the cup as shown and described herein allow for stackability of at least two cups, which provides advantages for transportation and storage.

[0010] In various embodiments, a metal cup comprising thin-walled aluminum is provided. Preferably, a metal cup comprising a recycled aluminum alloy is provided. Various embodiments, including those comprising thin-walled aluminum to provide a lightweight cup body, are formed from recycled and / or recyclable materials, and are, for example, stronger, more useful, and more durable than conventional plastic cups.

[0011] In a preferred embodiment, the metal cup is provided with a constant wall thickness along at least a portion of the cup body. The feed specification of the cup body is reduced to a thinner wall thickness in the side wall of the cup body. The horizontally extending step or rib preferably extends around the entire circumference of the cup body and is provided to increase the strength of the finished cup body while maintaining the lightweight characteristics of the cup body. The step or rib is provided as a transition point between portions of the finished cup body having different diameters. Alternatively, a conical cup is provided without ribs, wherein the cup body includes a relatively smooth and straight side wall extending from the upper end of the conical cup to the closed lower end.

[0012] In various embodiments, a method for forming a metal cup is provided. In one embodiment, a method for forming a metal cup includes feeding an aluminum coil into a deep drawing press and manufacturing a straight-walled cup from a substantially circular blank cut from the aluminum coil. The cup body preferably has a constant wall thickness, which is approximately equal to the feed specification of the aluminum. Then, the cup body is fed into a body manufacturing machine, where the metal is ironed. The cup body is further formed by washing the cup body and decorating and / or coating the exterior and interior of the cup body. In certain embodiments, at least a portion of the exterior of the cup body is decorated with a color, logo or other visual information. After the washing and coating operations, the top edge of the cup body is curled, partially curled or throttled to eliminate the sharp edges formed by the press. The cup body diameter is then pulled down and a plurality of straight-walled portions are formed. Each straight-walled portion is expanded to a larger diameter using a mold having a tapered profile. Finally, a bottom convex top is provided in the bottom wall of the cup body, wherein the convex top provides enhanced structural stability for the cup body. In various embodiments, the convex top is disposed at the bottom of the metal cup to provide enhanced strength and stackable features. However, it should be appreciated that the term "convex top" is not limited to any particular geometry, and contemplated are "convex top" members including, but not limited to, conical and frustoconical shapes. The present disclosure contemplates a central bottom portion of the cup positioned vertically above the standing surface of the cup.

[0013] In another embodiment, a method is provided in which the canning machine step is eliminated in favor of multiple redrawing steps after the cupper. In this case, the cup body maintains a constant wall thickness through the entire container.

[0014] In one embodiment, a method for forming a conical metal cup is provided, the method comprising the following steps: providing a raw metal material; forming at least one cup body using a blanking and drawing operation; performing a re-drawing operation on the cup body to provide the cup body with a predetermined height and wall thickness; after the re-drawing operation, shearing the cup body to a second height; curling the top edge of the sheared cup body to form a lip; forming one or more straight wall portions in the cup body by drawing the cup body; using one or more dies with a conical profile to expand each of the one or more straight wall portions; and forming a convex top at the bottom of the cup body.

[0015] In another embodiment, a method for forming a conical metal cup is provided, the method comprising the following steps: providing a raw metal material; forming at least one cylindrical preform from the raw material; shearing the cylindrical preform to a second height; curling the top edge of the sheared cylindrical preform to form a lip; providing one or more straight wall portions in the cylindrical preform by drawing the preform to form a cup body; using one or more dies having a conical profile to expand each of the one or more straight wall portions to a larger diameter; and forming a convex top at the bottom of the cup body.

[0016] In one embodiment, a conical metal cup is provided. The conical metal cup includes an upper end and a lower end, and a height extending between the upper end and the lower end. The upper end includes a curled, partially curled or strung lip and an opening. A plurality of tapered portions are disposed between the upper end and the lower end, and a step is disposed between each tapered portion. Each tapered portion includes a substantially constant wall thickness and a tapered profile. Adjacent tapered portions of the plurality of tapered portions include successively decreasing diameters, and the step disposed between each tapered portion includes a diameter transition.

[0017] The Summary is neither intended nor should it be interpreted as representing the full scope and extent of the present disclosure. The present disclosure is described in various degrees of detail in the Summary and the accompanying drawings and detailed descriptions, and the scope of the present disclosure is not limited to the inclusion or exclusion of elements, components, etc. in this Summary. Figure 1 Other aspects of the disclosure will become more apparent as time goes by. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Those skilled in the art will recognize that the following description is merely illustrative of the principles of the present disclosure, which can be applied in various ways to provide many different alternative embodiments. The description is intended to illustrate the general principles of the teachings of the present disclosure and is not meant to limit the inventive concepts disclosed herein.

[0019] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the present disclosure and, together with the general description of the present disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the present disclosure.

[0020] It should be understood that the drawings are not necessarily drawn to scale. In some cases, details that are not necessary for understanding the present disclosure or that make other details difficult to understand may have been omitted. Of course, it should be understood that the present disclosure is not necessarily limited to the specific embodiments shown herein.

[0021] Figure 1 is a front view of a container body at a stage of formation according to one embodiment of the present disclosure.

[0022] Figure 2 is a front view of a container body at a stage of formation according to one embodiment of the present disclosure.

[0023] Figure 3 is a front view of a metal container according to one embodiment of the present disclosure.

[0024] Figure 4 is a front view of a stackable metal container according to one embodiment of the present disclosure.

[0025] Figure 5 is based on Figure 4 A cross-sectional view of the container of an embodiment taken at section AA.

[0026] Figure 6 is based on Figure 4 A top view of a container of an embodiment.

[0027] Figure 7 is a detailed elevation view of a portion of a plurality of containers stacked according to one embodiment of the present disclosure.

[0028] Figure 8 is a detailed front view of a portion of a container according to one embodiment of the present disclosure.

[0029] Fig. 9 is based on Figure 4 A detailed front view of a portion of a container of an embodiment.

[0030] Fig.10 is a flow chart depicting a method of forming a metal cup according to one embodiment of the present disclosure.

[0031] Fig.11 is a flow chart depicting a method of forming a metal cup according to one embodiment of the present disclosure.

[0032] Fig.12 is a flow chart depicting a method of forming a metal cup according to one embodiment of the present disclosure.

[0033] Fig.13 is a flow chart depicting a method of forming a metal cup according to one embodiment of the present disclosure.

[0034] Fig.14 is a flow chart depicting a method of forming a metal cup according to one embodiment of the present disclosure. DETAILED DESCRIPTION

[0035] Figure 1 is a front view of a straight-wall preform 2. Preform 2 represents the initial forming stage of a metal cup according to one embodiment of the present disclosure. The straight-wall preform 2 is preferably formed by feeding a certain amount of metal (e.g., aluminum) into a cupping press and forming a preliminary drawn cup from a blank sheet cut from a roll of metal material. The resulting straight-wall drawn cup preferably includes a constant wall thickness that is approximately equal to the feed specification of the metal fed into the deep drawing press. The preliminary drawn cup is then fed into the deep drawing press, where the metal is ironed. The resulting straight-wall preform 2 includes a side wall, wherein the thickness of the base is approximately equal to the feed specification of the metal, and the side wall includes a thin-wall portion and a thick-wall portion. The straight-wall preform 2 includes an initial diameter Di that generally corresponds to and is approximately equal to the diameter of the punch that forms the cup body. In various embodiments, the initial diameter Di is approximately 2.0 inches to 6.0 inches. In a preferred embodiment, the initial diameter Di is about 3.0 to 4.0 inches, and more preferably about 3.290 inches.

[0036] The height H1 of the straight wall preform 2 is about 3.0 to 10.0 inches. In a preferred embodiment, the height H1 of the preform 2 is about 3.5 to 5.5 inches, more preferably about 4.463 inches. The bottom of the preform includes a radius of curvature resulting from the shape and contact of the punch used to form the cup body. In various embodiments, this radius R is about 0.025 inches to 0.250 inches, and preferably about 0.059 inches.

[0037] Figure 2 is a front view of a curled preformed cup 4 in a further stage of formation. Figure 2 The hemming preform 4 comprises Figure 1 A thin-walled preform 2 is provided, wherein a curling edge 6 is provided on the upper edge or lip of the cup body. The curling edge 6 is provided to eliminate sharp edges, provide increased rigidity, and provide a means of removal from the drawing tool. Figure 2 As shown, Figure 1 Compared with the preform 2, the height of the curled preform cup 4 is reduced. Specifically, Figure 2 The height H2 of the curled preformed cup 4 is about 4.5 to 5.5 inches, preferably about 4.947 inches.

[0038] The preform 4 may be cleaned, coated and / or decorated before or after the curling 6 is formed. It is contemplated that at least one of the interior and exterior of the preform is coated with epoxy and / or other materials known to those of ordinary skill in the art. The cup body is coated to prevent aluminum oxidation and to prevent aluminum from leaching into the contents of the cup. It is further contemplated that the interior and / or exterior of the cup body is provided with painting or other decorative treatments.

[0039] Figure 3 is a front view of a straight drawn cup 8 according to an embodiment of the present disclosure, which is composed of Figure 2 The curled edge preformed cup 4 is formed. As shown in the figure, the straight drawn cup 8 includes a curled edge 6 located at the upper end or lip of the cup body.

[0040] The straight drawn cup 8 also includes a plurality of sections 10a, 10b, 10c, 10d, 10e, each of which includes a straight wall portion having a continuously decreasing diameter and a varying height, such as Figure 3 shown. Figure 3 Dimensions are provided in the drawings and other figures of the present disclosure. These dimensions are provided as examples only and illustrate cups and features according to certain embodiments. It should be clearly understood that the devices, inventions and features of the present disclosure are not limited to the dimensions provided in the drawings, and various modifications and proportions are conceivable. Figure 3 The straight drawn cup 8 comprises an intermediate stage in the formation process of the cup body of the present disclosure.

[0041] like Figure 3 As shown, the straight drawn cup 8 includes a plurality of sections 10, wherein each section 10 includes a continuously decreasing diameter from the upper end to the lower end of the straight drawn cup 8, wherein the uppermost section 10a includes the largest diameter and the lowermost section 10e includes the smallest diameter. These sections include different heights, wherein the relative heights may be characterized by: 10c>10d>10b>10e>10a. Figure 3 As shown, the straight drawn cup 8 includes five sections and four ribs. The number of sections and ribs can be varied according to the requirements of the consumer. The height of the sections can also be varied according to the requirements of the consumer.

[0042] Figure 4-5 FIG. 2 shows a finished conical metal cone 20 according to one embodiment of the present disclosure. Figure 3 The straight drawn cup 8 is formed by expanding each straight wall portion 10 to a larger diameter (with a diameter of 1.5 mm) by using a die (not shown) having a tapered profile. Figure 3The conical cup 20 is formed by comparing it with the one shown in FIG.

[0043] like Figure 4 As further shown in FIG. 1 , the finished cone 20 is expanded to a final height H3 that is greater than H2. Specifically, the finished cone 20 includes a height H3 that is approximately 4.5 to 6.50 inches, and preferably approximately 5.330 inches. The final height H3 is produced by the expansion die during the final forming process. An opening 7 is provided at the upper end of the cone 20, wherein the opening is free of closures, seals, etc. The opening is at least partially defined by the periphery of the curling portion 6, and wherein the curling portion 6 includes at least a portion of a user interface, wherein the user's mouth will contact the curling portion 6 during drinking.

[0044] Figure 5 Yes Figure 4 The cross-sectional elevation view of the conical metal cone 20 is shown, wherein the cross section is at Figure 4 The AA line is intercepted. Figure 5 As shown, the cone cup 20 includes a tapered profile including a plurality of stepped portions 10a, 10b, 10c, 10d, 10e, wherein each successive portion includes a smaller diameter via a step 22. Additionally, each portion includes an angled or tapered sidewall formed by a tapered expansion die.

[0045] Various inner diameters of the plurality of sections 10 are provided. In a preferred embodiment, the finished cone 20 includes a plurality of sections 10 including relative diameters characterized by: 10a>10b>10c>10d>10e. Some specific diameters are provided and shown, which are measured from the top of each respective section 10. The plurality of sections 10 include different heights, wherein the relative heights may be characterized by: 10c>10d>10b>10e>10a. The inner diameter of the crimped portion 6, which also includes the drinking port, is about 2.0 to 5.0 inches in diameter, preferably about 3.290 inches in diameter. Details Y and Z are provided and shown. Figure 5 is shown in Fig. 9 and 8 They are shown in detail in Figure 5 Various expansion angles are shown in FIG. 1 , where each portion 10 expands outwardly along the height of the portion 10. As shown, each portion 10 includes a different expansion angle (expressed as a percentage of the diameter to the height of the portion). However, in alternative embodiments, it is contemplated that each portion 10 includes the same expansion angle. In the illustrated embodiment, the relative expansion angles may be expressed as: 10e>10b>10d>10c. Figure 5 The uppermost portion 10a in the embodiment includes a straight wall portion which has no expansion angle.

[0046] expected Figure 5The straight wall portions of the cup body are formed by drawing the cup body and providing each portion with an expanded or increased diameter. In some embodiments, it is contemplated that each portion is formed using drawing and that after the initial formation of each drawn portion, one or more expansion dies are provided to expand each portion. In other embodiments, it is contemplated that the drawing and expansion of the straight wall portions are performed in an alternating manner, wherein a first portion is drawn and then expanded, a second portion is drawn and then expanded, and so on. It is also contemplated that the number of drawing and expansion operations need not be equal. For example, multiple expansion steps may be provided on a portion formed by a single drawing operation. In addition, a portion may be drawn without providing a corresponding expansion operation.

[0047] Figure 6 is based on Figure 4 FIG. 2 is a top view of a finished cone 20 of an embodiment of FIG. The plurality of stepped portions 10 are shown in plan view, and, in some embodiments, the bottom of the cone 20 includes a convex top 24 .

[0048] Figure 7 Detailed view of two completed cones 20 provided in a stacked arrangement and wherein the respective beaded portion 6 of each cone 20 is provided with a separation or stand-off height. A stand-off height is provided and comprises the height or distance between successively placed upper ends of the beaded portions 6. In the illustrated embodiment, the stand-off height is from about 0.00 inches to about 1.0 inches. Preferably, the stand-off height is about 0.28 inches. For example, the stand-off height provides a user with the ability to grip and separate the stacked cups. Although various embodiments contemplate a stand-off height, such a stand-off feature is not necessary and alternative embodiments contemplate not providing such a stand-off.

[0049] Figure 8 is a detailed cross-sectional elevation view of the completed cone cup 20 showing the upper portion of the cup including the curled edge 6 . Figure 8 yes Figure 5 A detailed view of the details of Z. Figure 8 As shown, the curled edge portion 6 of the cup body includes a radius of curvature of approximately 0.010 inches to 0.250 inches. In the illustrated embodiment, the preferred radius of curvature includes a curvature of approximately 0.040 inches. Figure 8 A step 22 is also provided between adjacent portions 10a, 10b of the cone 20. As shown, the step includes a first radius of curvature of approximately 0.040 inches and a second radius of approximately 0.040 inches, wherein the two radii of curvature each include a transition or deviation from the adjacent sidewalls of the portions 10a, 10b. Figure 8 Only one step 22 is depicted, but it is conceivable that each step 22 of the cone 20 is configured to include Figure 8The steps 22 are of the same size as shown in FIG. The steps 22 can be of any size or combination of one or more radii.

[0050] Fig. 9 is a detailed cross-sectional elevation view of the completed cone 20 showing the bottom portion of the cone 20 including the convex top 24 . Fig. 9 yes Figure 5 Detailed view of Y. Fig. 9 Various sizes and details of a conical cup 20 according to an embodiment of the present disclosure are included. As shown, the conical cup 20 includes a convex top 24 located at the lower portion of the preform 20. The outer diameter of the bottom 10e of the cup body is between about 1.50 and 3.50 inches, preferably about 2.349 inches. A radius of curvature R2 is provided as a transition between the bottom portion 10e and the convex top, wherein the radius of curvature R2 includes a radius of about 0.010 inches to about 0.250 inches. Preferably, the radius of curvature is about 0.10 inches. A flat standing surface 30 is provided between the radius R2 and the convex top 24, wherein the flat surface 30 includes a placement portion or support portion for the completed preform 20. The flat surface 30 generally includes an annular surface having a width of about 0.0010 inches to 0.125 inches, preferably about 0.084 inches. The flat surface 30 extends into the convex top portion 24 including multiple radii of curvature. The central portion of the raised top feature 24 includes a radius of approximately 15.0 inches, and the raised top portion 24 transitions to a flat surface 30, as shown. The raised top portion 24 and its dimensions may vary in size. In further embodiments, a flat standing surface is not provided.

[0051] like Fig. 9 As shown, the bottom portion 10e of the cup body includes a gauge or wall thickness of approximately 0.0090 inches and the adjacent portion 10d includes a gauge or wall thickness of approximately 0.0040 inches. The bottom portion 10e includes a portion of enhanced gauge and, therefore, enhanced durability because the bottom portion 10e is intended to contact another surface, such as when the cup is placed on a surface, dropped, etc. In certain embodiments, the cup body includes a single thickness of metal.

[0052] Fig.10 is a flow chart depicting a method for forming a metal cup according to one embodiment of the present disclosure. As shown in the figure, Fig.10 The method comprises a first step 50 of providing a coil of metal material from which the cup is to be formed. Preferably, the coil provided in step 50 comprises a coil of aluminum stock. A second step 52 is provided in which at least one cup is formed from a blank cut from the coil. The cup is preferably formed using a blanking and drawing operation. Subsequently, a redrawing step 54 is provided in which the cup is subjected to at least one redrawing operation. Method steps 50, 52 and 54 provide an initial cup that is ready for further processing according to the method of the present disclosure.

[0053] The cup body provided from the redrawing step 54 is further subjected to forming and finishing steps as shown and described herein. Fig.10 In the illustrated embodiment, the cup body is subjected to a shearing operation in which the upper open end of the cup body is cut or sheared at step 58 to remove material. Subsequently, at step 60, the upper sheared end of the cup body is provided with at least one curling edge (e.g., see Figure 2 6). Subsequently, referring now to step 62, at least one step drawing operation is performed, wherein a plurality of straight wall portions are formed in the cup body (e.g., see Figure 3 ). The cup body is then expanded in step 64 by at least one expansion operation. In some embodiments, the expansion step 64 includes expanding each straight wall portion to a larger diameter using one or more molds with a tapered profile. Then a top rounding operation 66 is performed to provide a convex top on the bottom portion of the cup body. The convex top can be provided to enhance the structural integrity and stability of the cup body. The series of steps described here and referred to as process 56 include steps that can be reordered or eliminated depending on the design, customer requirements and / or machine technology. Although at least one embodiment contemplates performing such Fig.10 The steps are shown, but it is also contemplated that one or more of the steps indicated by 56 may be eliminated or reordered.

[0054] Fig.10 After the process shown in 56 in the figure, the cup body is subjected to a washing step 68. After washing, the cup body is decorated at step 70, a bottom coating is provided at step 72, and / or an internal coating ("IC") spraying step 74. Fig.10 The multiple method steps indicated by 76 in the figure can be reordered or eliminated according to design, customer requirements and / or machine technology. For example, according to customer needs and requirements, the method can terminate after the decoration step 70.

[0055] Fig.11is a flow chart depicting a method of forming a metal cup according to another embodiment of the present disclosure. As shown, an initial step 80 is provided, wherein a coated coil is provided in the form of a raw material. Preferably, the coil in step 80 comprises coated aluminum. However, various embodiments of the present disclosure provide and contemplate a "coated" coil comprising an epoxy, film, polymer or other "paint" cured, laminated or extruded onto a metal surface using various methods. In step 82, at least one cup body is formed from the coil, the cup body being formed from a blank sheet cut from the coil and a drawing die. Then, in step 84, at least one re-drawing operation is performed on the initial cup body formed in step 82. After the initial cup body is formed, the process proceeds to step 88, wherein the cup body opening portion of the cup body is sheared in step 88, followed by providing a curling edge at step 90, performing a step re-drawing operation at step 92 to form at least one straight wall portion, which expands the diameter at step 94, and providing a bottom convex top by a top rounding operation at step 96. Fig.11 The steps 88-96 are collectively referred to as process 86. Depending on the design, customer requirements and / or machine, it is contemplated that the steps of process 86 may be reordered or eliminated.

[0056] After the method steps of the process 86 shown, the cup body is then subjected to a rinsing or washing operation 100 and a decoration step 102. Fig.11 In the embodiment, washing and decoration are shown as the final process 98, wherein the cup body is finished. However, it is also expected that process 98 can be arranged after the redrawing step 84 and before process 86.

[0057] Fig.12 FIG. 1 is a flow chart showing a method for forming a metal cup according to another embodiment of the present disclosure. Fig.12 As shown, multiple initial cup forming steps are provided, wherein a coil 104 is provided. At step 106, at least one cup is formed from the coil, preferably by blanking and drawing operations. A redrawing step 108 is provided to further form the cup, which is then placed in a deep drawing press at step 110 to form the final cup height. The upper portion of the cup is then sheared at step 112. The trimmed cup is then preferably subjected to a washing operation 114. After washing, a decorating and / or coating process 116 is provided, the decorating process including a step of decorating the cup at step 118, a step of providing a bottom coating 120, and / or a step of providing an inner coating to the cup at step 122. One or more steps of the coating process 116 may be reordered, eliminated and / or moved after the rinsing step 132.

[0058] Preferably, after the coating process 116, a final forming step 124 is provided. The final forming step preferably includes at least one of: providing a curling edge to the sheared portion of the cup body at step 126, performing at least one step drawing operation 128 to form one or more straight wall portions in the cup body, and performing an expansion step 130 to expand the diameter of the one or more straight wall portions. It is contemplated that the final forming step 124 may be reordered or eliminated based on user requirements. A rinsing step 132 is provided as a finishing step. However, as previously described, one or more steps of the coating process 116 may be reordered so that they occur after the rinsing step 132. Fig.12 An embodiment contemplates providing a convex top in the bottom portion of the cup body. A top rounding operation 134 is provided and can conceivably occur during the body manufacturing operation 110 or prior to rinsing as a final separate operation.

[0059] Fig.13 FIG. 1 is a flow chart showing a method for forming a metal cup according to another embodiment of the present disclosure. Fig.13 As shown, a cup body is provided at step 140, and the cup body is preferably formed from a blank aluminum coil. The cup body is then redrawn at step 142, wherein the cup body undergoes one or more redraw operations. The cup body is then fed into a body maker at step 144 to form the final cup body height and diameter. The cup body is then sheared at step 146, wherein excess cup body height resulting from the redrawing and / or body making operations is sheared. A cleaning and decorating process 150 is provided, wherein the cup body undergoes at least one of a rinsing step at 152 and a decorating step 154. The steps of the cleaning and decorating process 150 may be moved to Fig.13 After the expansion 162 or top circle forming step 164 is provided.

[0060] The cup then proceeds to a finishing operation 156, wherein the final processing steps include providing a hem to the sheared portion of the cup at step 158, providing a step redraw operation 160, providing an expansion operation 162 and providing a crown to the bottom portion of the cup at step 164. Although it is contemplated that Fig.13 In the embodiment of the present invention, the top rounding step 164 is the last step, but it is also conceivable that the top rounding step occurs in the body manufacturing machine at step 144, so that the expansion operation 162 becomes Fig.13 The last step of the embodiment. Depending on the design, customer requirements and / or machine technology, the Fig.13 The steps of completing process 156 are as follows.

[0061] Fig.14 FIG. 1 is a flow chart showing a method for forming a metal cup according to another embodiment of the present disclosure. Fig.14As shown, the cup body is provided from a piece of blank. As shown, the initial step 170 includes providing a piece (slug) of material (e.g., aluminum). At step 172, the block is impact extruded to form the cup body. At step 174, the upper end of the cup body is sheared to a preferred height and then brushed and cleaned at steps 176 and 178, respectively. In some embodiments, a step of ironing the impact-extruded cup body is provided after impact extrusion (step 172) and before shearing (step 174). The washed cup body 178 is then provided and subjected to a coating and decoration process 180, as shown. Fig.14 The coating and decorating process 180 includes the steps of decorating the cup 182, providing the cup body 184 with a bottom coating, and providing the cup body 186 with an inner coating (e.g., spraying). The steps of the coating and decorating process 180 may be reordered and / or may be provided after the rinsing step 198.

[0062] After the coating and decoration process 180, Fig.14 The method proceeds to a finishing operation 188, which includes the steps of curling the upper sheared portion of the cup body at step 190, performing a step drawing operation 192, providing an expansion operation using one or more expansion dies, and forming a convex top 196 in the bottom portion of the cup body. The steps of the finishing process can be reordered or eliminated based on user preferences, design, customer requirements and / or available machine technology. After the finishing operation 188, the cup body is washed and / or rinsed at step 198.

[0063] Various features and embodiments of metal cups are provided herein. However, it should be appreciated that the various features are not necessarily specific to certain embodiments and may be provided in any one or more embodiments. The present disclosure and the embodiments provided herein are not mutually exclusive and may be combined, substituted, and omitted. Therefore, the scope of the invention provided herein is not limited to any particular embodiment, drawings, or specific arrangement of features.

[0064] Although various embodiments of the present disclosure have been described in detail, it is apparent that modifications and variations of those embodiments will occur to those skilled in the art. However, it should be clearly understood that these modifications and variations are within the scope and spirit of the present disclosure. In addition, the invention described herein can have other embodiments and can be practiced or implemented in various ways. In addition, it should be understood that the wording and terminology used herein are for descriptive purposes and should not be considered as limiting. The use of "include," "comprise," or "addition" and variations thereof herein is intended to cover the items listed thereafter and their equivalents, as well as additional items.

Claims

1. A conical metal cup, comprising: an upper end and a lower end, and a height extending between the upper end and the lower end; The upper end includes a rolled, partially rolled or bound lip and an opening; a plurality of tapered portions disposed between the upper end and the lower end, with steps disposed between each tapered portion; and wherein each tapered portion comprises a substantially constant wall thickness and a tapered profile; and Wherein adjacent tapered portions of the plurality of tapered portions comprise successively decreasing diameters, and wherein a step disposed between each tapered portion comprises a diameter transition.

2. The conical metal cup according to claim 1, wherein: The lower end includes a convex top portion.

3. The conical metal cup according to claim 1, wherein: The height is from about 4.0 inches to about 7.0 feet.

4. The conical metal cup according to claim 1, wherein: The cup body includes at least three tapered parts.

5. The conical metal cup according to claim 1, wherein: The maximum inner diameter of the cup is at least about 3.0 inches in diameter.

6. The conical metal cup according to claim 1, wherein: The minimum inner diameter of the cup is no greater than about 2.50 inches in diameter.

7. The conical metal cup according to claim 1, wherein: The plurality of tapered portions have a minimum wall thickness of less than about 0.0070 inches in thickness.

8. The conical metal cup according to claim 2, wherein: The lower end of the cup body includes an annular standing surface, and wherein the convex top portion is disposed within the annular standing surface.

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