Tapered cup and method for forming the same

Abstract

To provide a metal cup and a method for forming the same.SOLUTION: Metal cups 400a, 400b of the present disclosure comprise a plurality of thin straight wall portions and a tapered profile. Dome portions 404a, 404b are provided at a cup bottom. The cups may include disposable cups, reusable cups, or recyclable cups.SELECTED DRAWING: Figure 22

Description

[Technical Field]

[0001] This U.S. non-provisional patent application claims the benefit of priority from U.S. Provisional Patent Application Serial No. 63 / 108,102, filed October 30, 2020, the entire disclosure of which is incorporated herein by reference. This application is a continuation-in-part of, and claims the benefit of priority from, U.S. Patent Application Serial No. 15 / 811,032, filed November 13, 2017, related to, and claims the benefit of priority from, U.S. Provisional Patent Application Serial No. 16 / 214,477, filed February 7, 2017, the entire disclosures of which are incorporated herein by reference.

[0002] FIELD OF THE DISCLOSURE The present disclosure relates generally to metal cups and methods for forming the same. More specifically, the present disclosure relates to beverage cups formed from metal. Various embodiments of the present disclosure provide thin-walled beverage cups that are stackable with cups of similar construction. [Background technology]

[0003] Existing disposable beverage cups and containers typically comprise plastic materials. Plastic cups are manufactured from injection molding or thermoforming operations, from which many lightweight, disposable cups can be formed. Existing metal beverage containers generally comprise beverage cans that include an end closure that is secured to the top end of the filled can.

[0004] U.S. Patent No. 4,366,696 to Durgin et al., which is incorporated herein by reference in its entirety, discloses nested cans and methods for forming the same from blanks. However, Durgin et al. does not disclose various features of the present disclosure, including, for example, tapered or stepped shapes as shown and described herein and methods for forming the same.

[0005] U.S. Patent No. 4,914,937 to Bulso et al., incorporated herein by reference in its entirety, discloses a method for forming a tapered container. While Bulso et al. provides a straight-walled cup and a method for forming the same, it lacks various teachings of the present disclosure.

[0006] U.S. Patent No. 6,463,776 to Enoki et al., incorporated herein by reference in its entirety, discloses a method for manufacturing a bottle-shaped can having a neck and a shoulder. Enoki et al. does not disclose various features and methods of the present disclosure. For example, Enoki et al. does not provide a cup-shaped container having tapered, straight sidewalls. Summary of the Invention

[0007] Thus, there has been a long felt and unmet need to provide a reusable and recyclable metal cup, and there has also been a need to provide a stackable tapered metal cup to enhance shipping and storage of multiple cups.

[0008] In various embodiments, a tapered metal cup is provided that includes a shallow wall angle. Shallow wall angle, at least as used herein, includes a wall angle that is less than 30 degrees, preferably less than about 10 degrees, as measured from the vertical centerline or axis of the cup. The angled sides and shallow wall angle of the cup as shown and described herein allow for stacking of at least two cups, which provides advantages for shipping and storage. In some embodiments, a wall angle greater than 10 degrees is provided. In some embodiments, a wall angle that is between about 8 and 20 degrees is provided.

[0009] In various embodiments, a metal cup is provided that comprises thin-walled aluminum, preferably a recycled aluminum alloy. Various embodiments, including those that comprise thin-walled aluminum, are lightweight, are molded from recycled and / or recyclable materials, and provide a cup that is more rigid, usable, and durable than, for example, traditional plastic cups.

[0010] In a preferred embodiment, the metal cup has a constant wall thickness along at least a portion of the cup. The initial gauge of the cup tapers to a thinner wall thickness at the sidewalls of the cup. Horizontally extending steps or ribs, preferably extending the entire circumference of the cup, are provided to add strength to the finished cup while maintaining the cup's light weight. The steps or ribs are provided as transition points between portions of the finished cup having different diameters. Alternatively, a tapered cup without ribs is provided, the cup including a relatively smooth, straight sidewall extending from the upper end of the tapered cup to the closed lower end.

[0011] In various embodiments, a method for forming a metal cup is provided. In one embodiment, the method for forming a metal cup includes feeding an aluminum coil into a cupping press to produce a solid-walled cup from a substantially circular blank cut from the aluminum coil. The cup preferably has a consistent wall thickness approximately equal to the initial gauge of the aluminum. The cup is then fed to a bodymaker, where the metal is redrawn and ironed. The cup is further shaped by cleaning the cup and decorating and / or coating the exterior and interior of the cup. In certain embodiments, at least a portion of the exterior of the cup is decorated with a color, logo, or other visual information. After the cleaning and coating operations, the top edge of the cup is curled, partially curled, or throttled to eliminate sharp edges formed by the press. The cup is then drawn to a reduced diameter, forming multiple straight wall sections. Each straight wall section is expanded to a larger diameter using a tapered-profile die. Finally, a bottom dome is provided on the bottom wall of the cup, providing the cup with enhanced structural stability. In various embodiments, a dome is provided on the bottom of the metal cup to provide enhanced strength and stackability. However, it should be recognized that the term "dome" is not limited to any particular geometric shape and is intended to include, but is not limited to, conical and frustoconical "dome" members. The present disclosure contemplates that the central bottom of the cup be positioned vertically above the standing surface of the cup.

[0012] In various embodiments, a cup is provided that includes a non-constant wall thickness. For example, it is contemplated that the wall thickness may vary throughout the cup, and the thickness at the bottom of the cup may be different from the thickness in other regions of the cup (for example).

[0013] In another embodiment, a method is provided in which the bodymaker step is eliminated in favor of multiple re-stretching steps after the cup, where the cup maintains a consistent wall thickness throughout the container.

[0014] In one embodiment, a method for forming tapered metal cups is provided, the method including providing a stock metal material, forming at least one cup using a blank and a drawing operation, performing a re-drawing operation on the cup to provide the cup with a predetermined height and wall thickness, trimming the cup to a second height following the re-drawing operation, curling an upper edge of the trimmed cup to form a lip, drawing the cup to form one or more straight wall sections in the cup, expanding each of the one or more straight wall sections using one or more dies having a tapered profile, and forming a dome at the bottom of the cup. In various embodiments, each cup section is expanded by 15% or less, where the expansion ratio is expressed as [(final diameter - initial diameter) / initial diameter] x 100.

[0015] In another embodiment, a method for forming a tapered metal cup is provided, the method including the steps of providing a stock metal material; forming at least one cylindrical preform from the stock material; truncating the cylindrical preform to a second height; curling an upper end of the truncated cylindrical preform to form a lip; drawing the preform to provide one or more straight wall sections in the cylindrical preform to form a cup; expanding each of the one or more straight wall sections to a larger diameter using one or more dies having a tapered profile; and forming the cup by forming a dome at the bottom of the cup.

[0016] In one embodiment, a tapered metal cup is provided. The tapered metal cup has an upper end, a lower end, and a height extending between the upper end and the lower end. The upper end includes a curled, partially curled, or drawn lip and an opening. A plurality of tapered sections are provided between the upper end and the lower end, with steps provided between each tapered section. Each tapered section includes a wall thickness and a tapered profile. The wall thickness may vary within a given panel and / or across different portions of the cup. Adjacent tapered sections of the plurality of tapered sections define successively smaller diameters, and the steps provided between each tapered section include diameter transitions.

[0017] In some embodiments, the containers and cups of the present disclosure include shapes, geometries, or profiles that allow the cups to be stacked and increase the ease with which stacked cups can be separated. Specifically, in certain embodiments, at least the lower portion of the cup includes a profile as shown and described herein that reduces or prevents vacuum, suction, or taper lock / friction forces (resulting from two tapered panels, or a tapered panel and a vertical wall panel, pressing against each other) that would impede or tend to impede separation of stacked cups.

[0018] Embodiments of the present disclosure provide methods and systems for forming metal cups. In some embodiments, methods and associated tooling are provided for forming cups having features or shapes that reduce at least one of vacuum, suction, and friction forces between stacked cups when the stacked cups are pulled apart.

[0019] In some embodiments, the disclosed anti-stick configurations provide cup shapes and cup contours that allow for a gap or separation between the curls of adjacent cups, even when the adjacent cups are nested or stacked. This can substantially prevent adjacent cups from sticking together and reduce the force required to separate the adjacent cups. In certain embodiments, adjacent curls of stacked cups are provided with a gap of at least about 0.01 inches and 0.5 inches, more preferably about 0.20 inches, even when the adjacent cups are fully nested (i.e., one cup is fully inserted into the adjacent cup).

[0020] In one embodiment, a tapered metal cup is provided, having an upper end, a lower end, and a height extending between the upper and lower ends. The upper end includes a curl, and a plurality of tapered sections are provided between the upper and lower ends, with a step between each tapered section. Each tapered section includes a wall thickness and a tapered profile. The wall thickness of the cup of the present disclosure is contemplated to include a wall thickness between approximately 0.002 inches and 0.010 inches. Adjacent tapered sections of the plurality of tapered sections form successively smaller diameters, and the step between each tapered section includes a diameter transition. The lower end of the cup includes a dome-shaped portion, a first radius, an inwardly tapered sidewall, a second radius, and a third radius. The first and third radii include convex features, and the second radius is located between the first and third radii.

[0021] In one embodiment, a tapered metal cup is provided having an upper end, a lower end, and a height extending between the upper and lower ends. A plurality of tapered sections are provided between the upper and lower ends. Each of the tapered sections preferably includes a tapered profile. Adjacent tapered sections of the plurality of tapered sections include successively smaller diameters. The lower end of the cup includes a stacked configuration having a plurality of inflection points, the stacked configuration including a first radius, an inwardly tapered sidewall, a second radius, and a third radius. The first and third radii include convex features, and the second radius is located between the first and third radii.

[0022] In one embodiment, a method for forming tapered metal cups is provided, the method including providing stock material, forming at least one cup using a blank and a drawing operation, subjecting the cup to a re-drawing operation to form a predetermined height and wall thickness, trimming the cup to a second height following the re-drawing operation, curling an upper edge of the trimmed cup to form a lip, forming one or more straight wall sections in the cup by drawing the cup, expanding each of the one or more straight wall sections using one or more dies having a tapered profile, forming a dome on a bottom of the cup, and forming an anti-stick feature on the bottom of the cup by applying a compressive force to the bottom of the cup radially outward of the dome such that the lower portion of the cup includes an inward taper or bevel.

[0023] In one embodiment, a method for forming a tapered metal cup is provided, including an initial step of feeding a coil into a cupping press and blanking and drawing a portion of the material into the cup. The cup then undergoes at least one of drawing, ironing, trimming, washing, drying, decorating, topcoating, interior coating, and bottom spraying. A curl is then formed on the top edge or lip of the cup. At least one, preferably multiple, drawing steps are then performed, in which the cup is stretched to a greater height, and at least one of the drawing steps narrows the container. Following at least one of the drawing steps, at least one expansion step is performed, using an expansion die (for example), to expand the width and diameter of the cup to a desired size. A final step is contemplated to include a reverse taper step, in which a reverse taper is formed on the bottom of the cup to form an anti-stick feature that prevents or reduces nesting or sticking of the cups when provided in a stacked configuration. This final step is contemplated to be an optional step, allowing for easier removal or separation of adjacent stacked cups.

[0024] In various embodiments, methods, systems, and devices for stacking cups are provided to reduce the force required to separate the cups from the stacked arrangement. In some embodiments, the cups are shaped or feature-shaped to prevent the cups from "nesting" or extending beyond one another. Such features reduce the force required to separate the cups. In some embodiments, an outward protrusion is provided that is larger in diameter than the panel or section of the cup on which the protrusion is provided. The outward protrusion provides a resting surface or contact point that prevents the bottom of the cup from contacting or extending below the bottom panel of an adjacent cup. The outward protrusion of the present disclosure is contemplated to be provided on any one or more cup panels or segments. In some embodiments, the outward protrusion is contemplated to be provided on the top panel or segment. Preferably, the outward protrusion extends completely around the circumference of the cup and includes an annular element that includes a rotationally symmetrical feature. However, in alternative embodiments, the protrusion is contemplated to extend less than the entire circumference of the cup.

[0025] It is an object of the present disclosure to provide a stacking or nesting feature that reduces the separation force between cups without significantly increasing the "stack height," or the total amount of height provided by two stacked cups. The present disclosure contemplates providing at least one cup panel with a stacking feature or protrusion, the height of which of the cup panels containing such a feature can be varied to control or determine the stack height.

[0026] In one embodiment, a tapered metal cup is provided having an upper end, a lower end, and a height extending therebetween, the upper end including a peripheral curl, and a plurality of panels disposed between the upper end and the lower end, with a transition between each panel, adjacent panels of the plurality of panels including successively smaller diameters, the transition between each panel including a transition in diameter of the cup.

[0027] A semi-annular projection is provided extending along at least a portion of the circumference of the cup.

[0028] Stacking and anti-stick features are provided herein. In some embodiments, a reverse taper feature is provided on the lower end or bottom of the cup. In further embodiments, at least one of an outwardly and inwardly directed protrusion is provided operable to provide a diameter or bulge operable to contact an adjacent cup. It is specifically contemplated that one or more of these features may be provided within a single cup. Thus, stacking and anti-stick features are not mutually exclusive. While it is contemplated that a cup may include a single anti-stick or stacking feature as shown and described herein, it is further contemplated that a cup may include multiple features as shown and described herein, even if the specific combination is not shown in the figures.

[0029] The Abstract of the present invention is not intended to, and should not be construed as, representative of the entire scope and breadth of the present disclosure. The present disclosure is described in various levels of detail in this Abstract, as well as the accompanying Figures and Detailed Description, and no limitation as to the scope of the disclosure is intended by the inclusion or exclusion of elements, components, etc. in this Abstract. Additional aspects of the present disclosure will become more readily apparent from the Detailed Description, particularly when viewed in conjunction with the Figures. [Brief explanation of the drawings]

[0030] 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 a variety of ways to provide many different alternative embodiments. This description is made for the purpose of illustrating the general principles of the teachings of the present disclosure and is not intended to limit the inventive concepts disclosed herein.

[0031] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure and, together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosure.

[0032] It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the disclosure or that obscure other details may be omitted. Of course, it should be understood that the disclosure is not necessarily limited to the particular embodiments illustrated herein.

[0033] [Figure 1] FIG. 1 is a front elevational view of a container body in one stage of molding according to one embodiment of the present disclosure. [Figure 2] FIG. 2 is a front elevational view of a container body in one stage of molding according to one embodiment of the present disclosure. [Figure 3] FIG. 3 is a front elevational view of a metal container according to one embodiment of the present disclosure. [Figure 4] FIG. 4 is a front elevation view of a stackable metal container according to one embodiment of the present disclosure. [Figure 5] FIG. 5 is a cross-sectional elevation view of the vessel according to the embodiment of FIG. 4, taken along line AA. [Figure 6] FIG. 6 is a plan view of the container according to the embodiment of FIG. [Figure 7] FIG. 7 is a detailed elevation view of a portion of multiple containers stacked in accordance with one embodiment of the present disclosure. [Figure 8] FIG. 8 is a detailed elevation view of a portion of a container according to one embodiment of the present disclosure. [Figure 9] FIG. 9 is a detailed elevational view of a portion of the vessel according to the embodiment of FIG. [Figure 10] FIG. 10 is a flow diagram illustrating a method for forming a metal cup according to one embodiment of the present disclosure. [Figure 11] FIG. 11 is a flow diagram illustrating a method for forming a metal cup according to an embodiment of the present disclosure. [Figure 12] FIG. 12 is a flow diagram illustrating a method for forming a metal cup according to one embodiment of the present disclosure. [Figure 13] FIG. 13 is a flow diagram illustrating a method for forming a metal cup according to an embodiment of the present disclosure. [Figure 14]FIG. 14 is a flow diagram illustrating a method for forming a metal cup according to an embodiment of the present disclosure. [Figure 15A] FIG. 15A is a flow diagram illustrating a method for forming a metal cup according to one embodiment of the present disclosure. [Figure 15B] FIG. 15B is a detail of the lower part of the cup of FIG. 15A. [Figure 16A] FIG. 16A is a cross-sectional elevation view of a cup according to an alternative embodiment of the present disclosure. [Figure 16B] FIG. 16B is a detail of the lower part of the cup of FIG. 16A. [Figure 17] FIG. 17 is a cross-sectional view of multiple cups provided in a stacked or nested configuration. [Figure 18] FIG. 18 is a cross-sectional view of a tool component according to one embodiment of the present disclosure. [Figure 19] FIG. 19 is a cross-sectional view of the tool part of the embodiment of FIG. [Figure 20] FIG. 20 is a cross-sectional view of a cup of the present disclosure according to one embodiment. [Figure 21] FIG. 21 is a detailed cross-sectional view of a feature of a metal cup according to one embodiment of the present disclosure. [Figure 22] FIG. 22 is a cross-sectional view of a cup of the present disclosure according to one embodiment. [Figure 23] FIG. 23 is a detailed cross-sectional view of a feature of a metal cup according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0034] FIG. 1 is a front elevational view of a straight-walled preform 2. The preform 2 represents an initial forming stage of a metal cup according to one embodiment of the present disclosure. The straight-walled preform 2 is preferably formed by feeding a quantity of metal (e.g., aluminum) into a cupping press and forming a pre-drawn cup from a blank sheet cut from a coil of metal material. The resulting straight-walled drawn cup preferably includes a wall thickness approximately equal to the entry gauge of the metal being fed into the cupping press. For example, in some embodiments, the wall thickness at the bottom of the cup includes a thickness approximately equal to the entry gauge. The pre-drawn cup is then fed to a bodymaker, where the metal is ironed. The resulting straight-walled preform 2 includes a sidewall whose bottom includes a thickness approximately equal to the entry gauge of the metal, and in some embodiments, the sidewall includes a thinned portion and a thickened portion. In some embodiments, no thinned portion is provided. The straight-walled preform 2 includes an initial diameter Di that generally corresponds to and is approximately equal to the diameter of the punch that will form the cup. In various embodiments, the initial diameter Di is between about 2.0 and 6.0 inches. In preferred embodiments, the initial diameter Di is between about 3.0 and 4.0 inches, and more preferably about 3.290 inches.

[0035] The straight-walled preform 2 includes a height H1 between about 3.0 and 10.0 inches. In preferred embodiments, the preform 2 includes a height H1 between about 3.5 and 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. In various embodiments, this radius R is between about 0.025 and 0.250 inches, preferably about 0.059 inches.

[0036] FIG. 2 is a front elevational view of a curled preform cup 4 at a further stage of molding. The curled preform 4 of FIG. 2 includes the thin-walled preform 2 of FIG. 1 with a curl 6 at the top edge or lip of the cup. The curl 6 is provided to eliminate sharp edges, add rigidity, and provide a means for removal from stretch tooling. As shown in FIG. 2, the curled preform cup 4 includes a reduced height compared to the preform 2 of FIG. 1. Specifically, the curled preform cup 4 of FIG. 2 includes a height H2 of between about 3.5 and 5.5 inches, preferably about 4.233 inches.

[0037] Before or after forming the curl 6, the preform 4 may be cleaned, coated, and / or decorated. It is contemplated that the interior and / or exterior of the preform may be coated with an epoxy resin and / or other materials as would be recognized by one skilled in the art. The cup may be coated to protect the aluminum from oxidation and to prevent corrosion of the aluminum from the contents of the cup. It is further contemplated that the interior and / or exterior of the cup may be painted or otherwise decorated.

[0038] FIG. 3 is a front elevational view of a rectilinear cup 8 formed from the curled preform cup 4 of FIG. 2 according to one embodiment of the present disclosure. As shown, the rectilinear cup 8 includes a curl 6 at the top edge or lip of the cup. The rectilinear cup 8 further includes multiple sections 10a, 10b, 10c, 10d, and 10e, each of which includes straight-wall sections of successively smaller diameters and varying heights, as shown in FIG. 3. As with other figures of the present disclosure, dimensions are provided in FIG. 3. These dimensions are provided for illustrative purposes only and are intended to illustrate the cup and function according to a particular embodiment. It will be expressly recognized that the apparatus, invention, and function of the present disclosure are not limited to the dimensions provided in the drawings, and various modifications and proportions are contemplated. The rectilinear cup 8 of FIG. 3 includes an intermediate stage in the forming process of a cup of the present disclosure.

[0039] As shown in FIG. 3, the linearly stretched cup 8 includes multiple sections 10, each having a diameter that decreases successively from the top to the bottom of the linearly stretched cup 8, with the top section 10a having the largest diameter and the bottom section 10e having the smallest diameter. The sections include various heights, and the relative heights can be characterized as follows: 10c > 10d > 10b > 10e > 10a. As shown in FIG. 3, the linearly stretched cup 8 includes five sections and four ribs. The number of sections and ribs can vary depending on consumer needs. The height of the sections can also vary depending on consumer needs.

[0040] 4-5 show a finished tapered metallic tapered cup 20 according to one embodiment of the present disclosure. Tapered cup 20 is preferably formed from straight drawn cup 8 of FIG. 3 by expanding each of the straight walls 10 to a larger diameter (compared to that shown in FIG. 3) using a die (not shown) having a tapered profile.

[0041] As further shown in FIG. 4, the finished tapered cup 20 is expanded to a final height H3 greater than H2. Specifically, the finished tapered cup 20 includes a height H3 of approximately 4.5 to 6.50 inches, preferably approximately 5.330 inches. Final height H3 is generated by the expansion die during the final forming process. The upper end of the tapered cup 20 includes an opening 7, which is free of any closure or seal. The opening is defined at least in part by the circumference of the curled portion 6, which includes at least a portion of a user interface where a user's mouth is intended to contact the curled portion 6 during drinking.

[0042] Figure 5 is a cross-sectional elevation view of a metallic tapered cup 20 as shown in Figure 4, where the cross-section is taken along line 5-5 of Figure 4. As shown in Figure 5, the tapered cup 20 includes a tapered profile including multiple stepped sections 10a, 10b, 10c, 10d, 10e, with each successive section including a smaller diameter by a step 22. Additionally, each section includes an angled or tapered sidewall formed by a tapered expansion die.

[0043] Various inner diameters of the multiple sections 10 are provided. In some embodiments, the finished tapered cup 20 comprises multiple sections 10 including relative diameters characterized as follows: 10a > 10b > 10c > 10d > 10e. Specific diameters are provided and illustrated as measured from the top of each section 10. The multiple sections 10 comprise various heights, and the relative heights can be characterized as follows: 10c > 10d > 10b > 10e > 10a. The inner diameter of the curled section 6, including the spout interface, includes a diameter of approximately 2.0 to 5.0 inches, preferably approximately 3.290 inches. Details Y and Z are shown on FIG. 5 and in detail in FIGS. 9 and 8, respectively. Various expansion angles are illustrated in FIG. 5, with each section 10 expanding outward along its height. As shown, each section 10 includes a different expansion angle (expressed as a percentage of the diameter relative to the section's height). However, in alternative embodiments, it is contemplated that each section 10 includes the same expansion angle. In the depicted embodiment, the relative expansion angles can be expressed as follows: 10e > 10b > 10d > 10c. The top section 10a provided in Figure 5 includes a straight wall with no expansion angle.

[0044] It is contemplated that the straight-walled sections of FIG. 5 are formed by stretching the cup and providing each of the sections with an expanded or increased diameter. In some embodiments, it is contemplated that each of the sections is formed using stretching, and one or more expansion dies are provided to expand each of the sections following the initial forming of each stretched section. In other embodiments, it is contemplated that the stretching and expansion of the straight-walled sections are performed alternately, with a first section being stretched and then expanded, a second section being stretched and expanded, and so on. It is also contemplated that the number of stretching and expansion operations need not be equal. For example, multiple expansion steps can be provided for a portion formed from a single stretching operation. Furthermore, a portion can be stretched and not provided with a corresponding expansion operation.

[0045] Figure 6 is a top view of a completed tapered cup 20 according to the embodiment of Figure 4. The multiple steps 10 are shown in plan view, and the bottom of the tapered cup 20 includes a dome 24 in some embodiments.

[0046] FIG. 7 is a detailed view of two completed tapered cups 20 provided in a stacked configuration, with the respective curled portions 6 of each tapered cup 20 provided with a separation or standoff height. The standoff height includes the height or distance between successive top edges of the curled portions 6. In the depicted embodiment, the standoff height is between about 0.00 inches and about 1.0 inches. Preferably, the standoff height is about 0.28 inches. The standoff height provides a user with the ability to grasp and separate stacked cups, for example. While various embodiments contemplate a standoff height, such a standoff feature is not required, and alternative embodiments contemplate that such a standoff is not provided.

[0047] FIG. 8 is a detailed cross-sectional elevation view of the finished tapered cup 20 showing the top of the cup, including the curl 6. FIG. 8 is a detailed view of Detail Z of FIG. 5. As shown in FIG. 8, the curled portion 6 of the cup includes a radius of curvature between approximately 0.010 inches and 0.250 inches. In the depicted embodiment, a preferred radius of curvature includes a curvature of approximately 0.040 inches. FIG. 8 also provides a step 22 between adjacent sections 10a, 10b of the tapered cup 20. As shown, the step includes a first radius of curvature of approximately 0.040 inches and a second radius of curvature of approximately 0.040 inches, each of which includes a transition or departure from the adjacent sidewall of sections 10a, 10b. While only one step 22 is depicted in FIG. 8, it is contemplated that each step 22 of the tapered cup 20 may be provided to include the same dimensions as the step 22 shown in FIG. 8. The step 22 may be any dimension or combination of one or more radii.

[0048] FIG. 9 is a detailed cross-sectional elevation view of the finished tapered cup 20, showing the bottom of the tapered cup 20, including the dome 24. FIG. 9 is a detailed view of Detail Y in FIG. 5. FIG. 9 includes various dimensions and details of the tapered cup 20 according to one embodiment of the present disclosure. As shown, the tapered cup 20 includes a dome 24 located on the lower portion of the preform 20. The cup bottom 10e includes an outer diameter of 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 10e and the dome, and the radius of curvature R2 includes a radius between about 0.010 inches and 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 dome 24, and the flat surface 30 includes a resting place or support for the finished preform 20. The flat surface 30 generally comprises an annular surface having a width between about 0.0010 inches and 0.125 inches, preferably about 0.084 inches. In some embodiments, it is contemplated that the flat surface extends around only a portion of the diameter or circumference of the cup. The flat surface 30 extends into a domed portion 24 that includes multiple radii of curvature. A central portion of the domed feature 24 includes a radius of about 15.0 inches, and the domed portion 24 transitions into the flat surface 30 as shown. The domed portion 24 and its dimensions may vary in size. In further embodiments, no flat standing surface is provided.

[0049] As shown in FIG. 9, the bottom portion 10e of the cup 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 section 10e includes a section with increased gauge and therefore increased durability because the bottom section 10e is intended to contact another surface when the cup is placed on a surface, dropped, etc. In certain embodiments, the cup includes a single metal thickness.

[0050] FIG. 10 is a flowchart illustrating a method for forming a metal cup according to one embodiment of the present disclosure. As shown, the method of FIG. 10 includes a first step 50 of providing a coil of metal material from which a cup is to be formed. Preferably, the coil provided in step 50 comprises a coil of aluminum stock material. A second step 52 is provided in which at least one cup is formed from a blank cut from the coil. Preferably, the cup is formed using a blank and a drawing operation. Thereafter, a redraw step 54 is provided in which the cup undergoes at least one redraw 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.

[0051] The cup provided from the re-draw step 54 may be further subjected to shaping and finishing steps as shown and described herein. In the depicted embodiment of FIG. 10, the cup is subjected to a trimming operation, in which the upper open end of the cup is cut or trimmed to remove material in step 58. Subsequently, in step 60, the upper trimmed end of the cup is provided with at least one curl (see, e.g., FIG. 2, 6). Thereafter, referring to step 62, at least one incremental drawing operation is performed to form multiple straight wall sections into the cup (see, e.g., FIG. 3). The cup is then expanded via at least one expansion operation in step 64. In some embodiments, the expansion step 64 includes expanding each of the straight wall sections to a larger diameter using one or more dies with a tapered profile. A doming operation 66 is then performed to provide a dome at the bottom of the cup. The dome may be provided to enhance the structural integrity and stability of the cup. The series of steps described herein and referred to as sequence 56 includes steps that are contemplated to be reordered or eliminated depending on design, customer requirements, and / or machine technology. At least one embodiment contemplates performing the steps as shown in Figure 10, but it is also contemplated that one or more of the steps designated by 56 may be eliminated or reordered.

[0052] Following the sequence illustrated as 56 in Figure 10, the cup is then subjected to a cleaning step 68. After cleaning, the cup is decorated in step 70, provided with a bottom coating in step 72, and / or provided with an interior coating ("IC") spray step 74. It is contemplated that the multiple method steps indicated as 76 in Figure 10 may be reordered or eliminated depending on the design, customer requirements, and / or machine technology. For example, depending on the customer's needs and requirements, the method may end after the decoration step 70.

[0053] FIG. 11 is a flowchart illustrating a method for forming a metal cup according to another embodiment of the present disclosure. As shown, an initial step 80 is provided in which a coated coil is provided in the form of stock material. Preferably, the coil in step 80 comprises coated aluminum. However, various embodiments of the present disclosure provide and contemplate "coated" coils comprising epoxies, films, polymers, or other "paints" that are cured, laminated, or extruded onto the surface of the metal using various methods. At least one cup is formed from the coil in step 82, where the cup is formed from a blank sheet of material cut from the coil and a drawing die. The initial cup formed in step 82 is then subjected to at least one redraw operation in step 84. After forming the initial cup, the process proceeds to step 88, where an open top portion of the cup is trimmed, followed by providing a curl in step 90, performing a stepped redraw operation to form at least one straight wall portion in step 92, expanding the diameter in step 94, and performing a doming operation to provide a bottom dome in step 96. Steps 88-96 of Figure 11 are collectively referred to as sequence 86. It is contemplated that steps in sequence 86 may be reordered or eliminated depending on the design, customer requirements, and / or machinery.

[0054] Following the method steps of sequence 86 described, the cup is subjected to a rinsing or washing operation 100 and a decorating step 102. In Figure 11, the washing and decorating are depicted as the final sequence 98 in which the cup is completed. However, it is also contemplated that sequence 98 may be provided following re-draw step 84 and before sequence 86.

[0055] 12 is a flowchart illustrating a method for forming metal cups according to another embodiment of the present disclosure. As shown in FIG. 12, multiple initial cup-forming steps are provided, in which a coil 104 is provided. At least one cup is formed from the coil material in step 106, preferably by a blank and drawing operation. To further shape the cup, a re-drawing step 108 is provided in some embodiments. A body maker in step 110 is optionally used to shape the final cup height.

[0056] The top of the cup is then trimmed in step 112. The trimmed cup is then preferably subjected to a washing operation 114. Following washing, a decorating and / or coating sequence 116 is provided, which includes decorating the cup in step 118, providing a bottom coating 120, and / or providing an interior coating to the cup in step 122. One or more steps of the coating sequence 116 can be reordered, eliminated, or moved after a rinsing step 132.

[0057] Preferably, following the coating sequence 116, a final shaping step 124 is provided. The final shaping step preferably includes at least one of: providing a curl to the trimmed portion of the cup in step 126; performing at least one incremental stretching operation 128 to form one or more straight wall sections in the cup; and performing an expansion step 130 to enlarge the diameter of the straight wall sections. It is contemplated that the final shaping step 124 may be reordered or eliminated depending on the user's needs. A rinsing step 132 is provided as a finishing step. However, as previously mentioned, one or more steps in the coating sequence 116 may be reordered to occur following the rinsing step 132. The embodiment of FIG. 12 contemplates providing a dome at the bottom of the cup. It is contemplated that a doming operation 134 may be provided and occur during the bodymaker operation 110 or prior to rinsing as a final, separate operation.

[0058] FIG. 13 is a flowchart illustrating a method for forming a metal cup according to another embodiment of the present disclosure. As shown in FIG. 13, a cup is provided in step 140, preferably formed from a coil of blank aluminum material. The cup is then redrawn in step 142, where the cup is subjected to one or more redrawing operations. The cup is then fed to a bodymaker in step 144, where the final cup height and diameter are formed. The cup is then trimmed in step 146, where excess cup height resulting from the redrawing and / or bodymaker operations is trimmed. A cleaning and decorating sequence 150 is provided, where the cup is subjected to at least one of a rinsing step at 152 and a decorating step 154. The steps of the cleaning and decorating sequence 150 can be moved after the expanding step 162 or the doming step 164 provided in FIG. 13. Those skilled in the art will recognize that various cleaning and decorating steps may be performed at different points in the manufacturing process. This disclosure provides specific method steps and sequences of operations for illustrative purposes, and various alternatives are contemplated.

[0059] The cup then proceeds to a finishing sequence 156, which includes providing a curl to the trimmed portion of the cup in step 158, providing a stepwise re-stretching operation 160, providing an expansion operation 162, and providing a dome to the bottom portion of the cup in step 164. While the doming step 164 is contemplated to occur as the final step in the embodiment of Figure 13, it is also contemplated that the doming step occurs within the bodymaker in step 144 and the expansion operation 162 is the final step in the embodiment of Figure 13. The steps of the finishing sequence 156 of Figure 13 can be reordered or eliminated depending on the design, customer requirements, and / or machine technology.

[0060] FIG. 14 is a flowchart illustrating a method for forming a metal cup according to another embodiment of the present disclosure. As shown in FIG. 14, a cup is provided from a slug of blank material. As shown, there is an initial step 170 involving providing a slug of material (e.g., aluminum). The slug is impact extruded in step 172 to form a cup. The top of the cup is trimmed to a desired height in step 174, followed by brushing and cleaning in steps 176 and 178, respectively. In some embodiments, ironing the impact-extruded cup is provided after impact extrusion (step 172) and before trimming (step 174). A cleaned cup 178 is then provided and subjected to a coating and decorating sequence 180 as shown. The coating and decorating sequence 180 of FIG. 14 includes decorating cup 182, providing a bottom coating to cup 184, and providing an interior coating (e.g., a spray coating) to cup 186. The steps of the coating and decorating sequence 180 may be reordered and / or may be provided following a rinsing step 198 .

[0061] After the coating and decorating sequence 180, the method of Figure 14 proceeds to a finishing sequence 188, which includes curling the top, trimmed portion of the cup in step 190, performing a stepwise stretching operation 192, and providing an expansion operation using one or more expansion dies 194 to form a dome 196 on the bottom portion of the cup. Steps in the finishing sequence can be reordered or eliminated depending on user preference, design, customer requirements, and / or available machine technology. Following the finishing sequence 188, the cup is washed and / or rinsed in step 198.

[0062] 15A-15B depict a cup according to one embodiment of the present disclosure. As shown, cup 200 includes a rotationally symmetric profile with multiple steps or ribs 202. In the embodiment of FIGS. 15A-15B, cup 200 does not include the anti-stick features of other embodiments of the present disclosure. Thus, multiple cups of the embodiment of FIGS. 15A-15B can be stacked or nested in a compact manner. However, this compact manner, including the close contact and nesting between the outside of the bottom sidewall 204 of one cup and the inside of the sidewall 204 of a second, adjacent cup, can make it difficult for adjacent cups to separate due to friction and / or vacuum forces between the two cups. FIG. 15B is a detailed view of the underside of the cup of the embodiment of FIG. 15A.

[0063] 16A-16B illustrate a container 210 according to one embodiment of the present disclosure, including a bottom 212 with a particular shape and structure to facilitate the user in separating adjacent stacked cups. Figure 16A is an elevation view of the container 210, which includes multiple tapered sections 214 separated by steps or ribs 216. The bottom 212 includes an angled or tapered section and a bottom.

[0064] FIG. 16B is a cross-sectional elevation view of the container 210 of FIG. 16A. More specifically, the bottom section 212 of the container 210 is enlarged for clarity. As shown, the bottom section 212 includes a dome-shaped portion 226 surrounded by a first radius 224. An inwardly tapered sidewall 218 extends upward to a second radius 220, with a third radius 222 connecting the second radius 220 and the tapered portion 214. In some embodiments, a straight wall portion is provided between the second and third radii. As shown in FIG. 16B, the first and third radii 224, 222 include convex bends, and the second radius 220 includes a concave bend. Furthermore, the inwardly tapered sidewall 218 includes a slope or angle that extends inward (i.e., from bottom to top, toward the central longitudinal axis of the container), in contrast to the tapered portion 214, which includes an outward slope or angle. While a straight wall 218 is shown in Figure 16B, other embodiments of the present disclosure contemplate that the first radius 224 extends directly into the second radius 220. Various embodiments of the present disclosure contemplate that the second radius 220 is located closer to the centerline of the cup than the first radius 224 to provide the standoff functionality shown and described herein. The cup includes multiple inflection points, where the dome transitions to the first radius 224, the sidewall 218 transitions to the second radius 220, and the second radius transitions to the third radius 222.

[0065] In various embodiments, first radius 224 comprises a radius between about 0.050 inches and 0.20 inches, preferably about 0.100 inches. In various embodiments, second radius 220 comprises a radius between about 0.050 inches and 0.20 inches, and preferably about 0.100 inches. In various embodiments, third radius 222 comprises a radius between about 0.030 inches and 0.20 inches, and preferably about 0.060 inches.

[0066] In various embodiments, including but not limited to the embodiment shown in Figures 16A-16B, the convex curvature of the third radius 222 comprises a radius of curvature between about 0.020 inches and 0.060 inches, preferably about 0.050 inches. The concave curvature of the second radius 220 comprises a radius of curvature between about 0.050 inches and 1.00 inches, preferably about 0.080 inches. A substantially horizontally oriented straight wall is provided between the second radius 220 and the third radius 222.

[0067] FIG. 17 is a cross-sectional elevation view of multiple containers 210a, 210b provided in a stacked configuration. As shown, the containers 210a, 210b are of similar construction and size, and each includes anti-stick features as shown and described herein (see, for example, FIGS. 16A-16B). The first radius 224a of the first cup 210a is located inside the second radius 220b of the second cup 210b. The third radius 222b of the second cup 210b extends outward away from the first cup 210a, forming a void space 230 between the two cups 210a, 210b. The void space 230 is located between the inwardly tapered portion 218 of the first cup 210a and the outwardly tapered portion 214 of the second cup 210b. Additionally, the structure of the bottom of the cups 210a, 210b provides a spacing or standoff height 225 at the top ends of the cups, where the respective curls at the top end of each of the cups are spaced apart, allowing a user to grasp and easily separate nested or stacked cups.

[0068] 18-19 are cross-sectional elevation views of a forming tool according to one embodiment of the present disclosure. As shown, a tool pack 250 is provided that includes a die center punch 252 having a cavity 253 for receiving the domed bottom of a cup. The tool 250 also includes a re-stretch pressure pad 254, a re-stretch die 256, and a deformation tool 260. A metal cup 262 is shown relative to the forming tool. The re-stretch die 256 includes a vent feature 258 to allow air to escape from the tool during the forming operation.

[0069] FIG. 18 shows tool 250 in an initial or starting position for forming the anti-stick feature of the cup. As shown in FIG. 18, cup 262 includes a stepped or stepped profile, but does not yet have the anti-stick feature of the present disclosure. Pressure pad 254 and re-draw die 256 are brought into contact, and cup 262 is compressed between the two components. An internal gap 264 is provided to allow the bottom of cup 262 to move outward.

[0070] FIG. 19 shows the forming tool 250 and the cup 262 in the forming position. As shown in FIG. 19, the bottom of the cup 262 is provided with an anti-stick feature. During forming, the deformation tool 260 is moved downward (at least as shown in FIG. 19) and contacts the bottom portion of the cup 262. A concave void 266 in the deformation tool 260 that contacts the bottom portion of the cup 262 circumscribes the domed region of the cup 262, expanding the bottom portion. As a result, the cup assumes the shape shown in FIG. 19, with the bottommost portion of the cup 262 expanding outward relative to the remainder of the bottom, and the cup 262 tapering inward, as further shown and described in, for example, FIG. 16B. The metal of the cup moves outward at the bottom portion (corresponding to the first radius 224 in FIG. 16B) and moves inward adjacent the second radius (220 in FIG. 16B). During this movement, the dome origin is preferably kept constant.

[0071] FIG. 20 is a cross-sectional elevation view of cups 300a, 300b provided in a stacked or stacked arrangement. As shown, first and second cups 300a, 300b each include an upper portion having a peripheral curl 302a, 302b and a lower portion having a raised dome portion 304a, 304b. The cup height extends between the upper and lower portions of each cup, with multiple cup portions or panels 308, 310, 312, 314, 316, 318 provided along the height. The panels are shown and labeled with respect to second cup 300b for clarity. However, it will be appreciated that the two cups in FIG. 20 include substantially the same layout and shape. The shape of the cups, including the number of panels and panel size, may vary. In a preferred embodiment, each cup includes multiple panels where the panels decrease in diameter from top to bottom, creating a tapered profile, such as that shown in FIG. 20. As shown in FIG. 20, it is an object of the present disclosure to provide an offset and / or prevent contact between the bottoms of the cups to reduce the removal force required to remove a first cup 300a from within a second cup 300b. In the embodiment of FIG. 20, this offset is achieved by providing an outward protrusion 306. It is contemplated that the offset or gap 320 is a constant gap around the perimeter or circumference. In further embodiments, it is contemplated that the gap is a non-constant gap around the circumference of the cup. The gap between the cups is contemplated to include a variety of dimensions. In some embodiments, a gap between approximately 0.0001 inches and 0.010 inches is provided. In preferred embodiments, the gap includes a gap between approximately 0.001 inches and 0.006 inches. In even more preferred embodiments, a gap between approximately 0.001 inches and 0.00525 inches is provided, with variations based on radial position.

[0072] The protrusion 306 in FIG. 20 comprises a circular or semicircular protrusion or projection located at the intersection of adjacent cup panels 316, 318. The protrusion 306a of the first cup 300a is sized and operable to contact the upper portion 302b of the second cup 300b in FIG. 20. As shown, the protrusion 306a creates a limit to the extent to which the first cup 300a can extend or nest within the second cup 300b. As shown in FIG. 20, the protrusion 306 prevents contact between certain portions of the cups. For example, in the embodiment of FIG. 20, contact between the domed portions 304a, 304b is prevented, as is contact between the various panels of each cup 300a, 300b. Gaps are provided at various locations along the height of the cups, thereby reducing friction between the cups and reducing the required extension or removal force. A gap 320 is shown between the upper portion of the first panel 308 of the second cup 300b and the lower portion of the first cup 300a. In certain embodiments, a second contact point is provided at this location (320 in FIG. 20). This contact may be achieved, for example, by extending the height of the first panel 308 and / or lowering the height of the top panel 318. Thus, in certain embodiments, two contact points are provided between two adjacent cups, and a gap is preferably maintained between the panels of the cups.

[0073] Figure 21 is a detailed cross-sectional elevation view showing a portion of cup 300 according to the embodiment of Figure 20. As shown, the top of the cup includes a curl 302a having a top panel 318 extending therefrom. While top panel 318 is depicted as a vertical panel in Figure 21, alternative wall angles are contemplated. For example, various containers and cups of the present disclosure are contemplated as including wall angles between about 3 degrees and 20 degrees.

[0074] The top panel 318 transitions into an outward protrusion 306a, which is contemplated to comprise a semicircular annular protrusion. In a preferred embodiment, the semicircular annular protrusion 306a extends 360 degrees around the cup. In alternative embodiments, the protrusion extends along one or more portions of the cup's circumference and is not a continuous feature or a single protrusion. While various embodiments of the present disclosure contemplate a semicircular annular protrusion, alternatively shaped protrusions are contemplated. For example, protrusions having a triangular cross-section and various other shaped protrusions are contemplated to achieve the goals and objectives of the present disclosure. The protrusion 306a transitions into an adjacent panel 316. It is contemplated that various additional panels may be provided (see FIG. 20). It is contemplated that various forms and shapes of protrusions may be provided, including dimples and circular protrusions, and may be shaped by outward force or impact during manufacturing. In some embodiments, one or more vertically extending protrusions are provided on the interior or exterior of the cup to provide contact with adjacent cups and achieve offset. While various embodiments of the present disclosure contemplate molding the protrusions as part of the cup-forming process, alternative embodiments contemplate adding the protrusions or similar features as a separate process. For example, in some embodiments, protrusions, beads, or spot weld features are provided on the cup after the cup is at least partially formed from stock material.

[0075] Referring again to FIG. 21 , the protrusions 306, as defined by either consecutive protrusions or the space between two opposing protrusions, provide a first outer diameter for the cup. The top panel 318 includes an inner diameter D2 that defines the largest inner diameter panel or cup portion. In various embodiments, the inner diameter D2 includes a diameter between about 1.0 inch and about 5.0 inches. More preferably, D2 includes a diameter between 2.0 and 4.0 inches. In various embodiments, the cup has an inner diameter D2 that varies based on cup size. For example, an inner diameter D2 between 3.610 and 3.625 inches is provided for 16-, 20-, and 24-ounce cups, and an inner diameter D2 between 2.850 and 2.865 inches is provided for 9- and 12-ounce cups. These dimensions are provided to illustrate certain contemplated embodiments. Alternative embodiments and proportions are contemplated, and no limitations regarding cup size and diameter are provided. In preferred embodiments, the first diameter D1 is larger than the second diameter and provides a contact point or resting surface for the cup. In some embodiments, the first diameter is 1.001 to 1.2 times larger than the second diameter. Thus, in various embodiments, the outer diameter D1 formed by the protrusion 306 is between about 3.628 inches and 4.35 inches (e.g., for 16-, 20-, and 24-ounce cups), and between about 2.002 and 2.40 inches for smaller cup sizes. In some embodiments, the 9-ounce and 12-ounce cups have outer diameters D1 of about 2.869 inches and 3.438 inches, respectively.

[0076] The protrusion includes a radius R1 that is preferably between about 0.0050 inches and 3.0 inches. In a preferred embodiment, the protrusion includes a single constant radius. In alternative embodiments, one or more protrusions are provided that include multiple radii of curvature and / or straight segments, such as triangular cross-section protrusions or protrusions of various other shapes.

[0077] FIG. 22 is a cross-sectional elevation view of cups 400a, 400b provided in a stacked or stacked arrangement. As shown, first and second cups 400a, 400b each include an upper portion having a peripheral curl 402a, 402b and a lower portion having a raised dome portion 404a, 404b. The cup height extends between the upper and lower portions of each cup, with multiple cup portions or panels 408, 410, 412, 414, 416, 418 provided along the height. The panels are shown and labeled with respect to second cup 400b for clarity. However, it will be appreciated that the two cups in FIG. 22 include substantially the same layout and shape. The cup shapes, including the number of panels and panel sizes, may differ. In a preferred embodiment, each cup includes multiple panels where the panels decrease in diameter from top to bottom, forming a tapered profile, such as that shown in FIG. 22. As shown in FIG. 22 , it is an object of the present disclosure to provide an offset and / or prevent contact between the bottoms of the cups to reduce the removal force required to remove the first cup 400a from within the second cup 400b. In the embodiment of FIG. 22 , this offset is achieved by providing an inwardly facing protrusion 406. The protrusion 406 in FIG. 22 comprises an annular or semi-annular protrusion or projection located at the intersection or transition between the peripheral curl 402 and the top panel 418. The protrusion 406a is sized and operable to contact the outside of the adjacent cup. More specifically, and as shown in FIG. 22 , the protrusion 406b of the second cup extends inward toward the centerline of the cup 413 and is operable to contact the bottom of the top panel 418 of the first cup. As shown, the protrusion 406 creates a limit to the extent to which the first cup 400a is allowed to extend or nest within the second cup 400b. As shown in Figure 22, protrusions 406 prevent contact between the cups. For example, in the embodiment of Figure 22, contact between the domed portions is prevented, as is contact between the panels of each cup 400a, 400b. Gaps are provided at various locations along the height of the cups, thereby reducing friction between the cups and reducing the required stretching or removal force.A gap 420 is shown between the top of the first panel 408 of the second cup 400b and the bottom of the first cup 400a. In certain embodiments, a second contact point is provided at this location (420 in FIG. 22). This contact can be achieved, for example, by extending the height of the first panel 408 and / or by lowering the height of various panels (e.g., panel 418 in FIG. 22). Thus, in certain embodiments, it is preferable to provide at least two contact points between two adjacent cups and maintain a gap between the panels of the cups. The gap reduces frictional forces provided between the cups and, in certain embodiments, reduces the vacuum or suction force between the cups, allowing for easier separation and removal of the cups from the stacked configuration.

[0078] FIG. 23 is a detailed cross-sectional elevation view of a portion of the cup 400 according to the embodiment of FIG. 22. As shown, the top end of the cup includes a curl 402a having a top panel 418 extending therefrom. The top panel 418 is depicted as a vertical panel in FIG. 23, although alternative wall angles are contemplated. At the transition between the curl 402a and the top panel 418 is a protrusion 406a. The protrusion 406a includes an inward protrusion that is contemplated to comprise a semi-annular protrusion. In a preferred embodiment, the protrusion 406a extends 360 degrees around the cup. In alternative embodiments, the protrusion extends along one or more portions of the circumference of the cup and is not a continuous feature or a single protrusion. Furthermore, the protrusion can include various cross-sectional shapes and geometries. As used herein, the term "semi-annular" refers to a cross-sectional shape of a protrusion extruded around a point of rotation that is a partial circle. The extrusion and protrusion can include a 360-degree circumferential protrusion or a circumference less than 360 degrees. The protrusion 406a transitions into a top panel 418. It is contemplated that a variety of panels may be provided (see FIG. 22). The cup includes a first inner diameter D3 defined by the inner surface of the inward protrusion 402a. A second inner diameter D4 is provided that is larger than the first inner diameter D3 and constitutes the inner diameter of the cup portion formed by the top panel 418.

[0079] As discussed, protrusion 406a can be continuous around the entire circumference of the cup, or can be divided into any number of smaller, discontinuous features around the circumference. For purposes of FIG. 23, D3 is considered the diameter between consecutive 360-degree protrusions or the distance between opposing protrusions located approximately 180 degrees apart. The first inner diameter D3 in FIG. 23 includes the diameter at least partially defined by protrusion 406a. Protrusion 406a defines a radius of curvature R2. Radius of curvature is contemplated to include radii between about 0.005 inches and about 3.0 inches. The radius is preferably continuous, although protrusions having varying radii of curvature are also contemplated.

[0080] In various embodiments, the first inner diameter D3 defines a constriction at or near the top of the cup 400 that is between about 0.8 times the second inner diameter D4 and about 0.999 times the second inner diameter D4. Thus, it is contemplated that the first inner diameter D3 is a function of the second inner diameter D4. For certain cups (e.g., cups with a capacity of 16, 20, and 24 ounces), the second inner diameter D4 defines a diameter of about 3.625 inches, and the first inner diameter D3 defined by the protrusion is between about 2.90 and 3.621 inches. For smaller cups including a second inner diameter D4 of 2.0 inches, the first inner diameter D3 defined by the protrusion is between about 1.6 and 1.999 inches. In various embodiments, it is contemplated that the first inner diameter D3 is between about 1.0 and 5.0 inches. However, as discussed herein, the first inner diameter D3 is preferably a function of the associated cup feature shape. The various dimensions provided with respect to FIG. 23 and other figures and embodiments are provided for illustrative purposes only. A variety of different dimensions and proportions are contemplated as being within the scope of the various inventive features of the present disclosure. No limitations on dimensions or proportions are provided.

[0081] While the protrusions of the present disclosure are illustrated as being provided in specific locations, including, for example, the outer region of the underside of the top panel (306a in FIG. 20) and the inner region of the peripheral curl (406a in FIG. 22), it will be appreciated that the present disclosure is not limited to cups having protrusions in these specific locations. Cups without protrusions are also contemplated, as shown and described herein. Additionally, protrusions in alternative locations are contemplated. For example, some embodiments of the present disclosure contemplate providing an outward protrusion at a point along the height of the top panel where the first cup rests on the curl of the nested cup (e.g., somewhere along the height of panel 318 in FIG. 20). In additional embodiments, an inward protrusion is contemplated on the upper panel, below the peripheral curl. No limitations are provided regarding the specific or relative positioning of the protrusions. Protrusions in different locations on one or more panels can be formed, for example, by milling techniques and similar processes.

[0082] It is contemplated that protrusions as shown and described herein may be provided on a variety of different panels. For example, a protrusion may be provided on the top of panel 412 in FIG. 22 that creates the offset and gap as shown and described herein.

[0083] In various embodiments, a method for forming a cup is provided. In some embodiments, at least one protrusion is molded into the cup to provide a contact or rest point, and the protrusion is molded during the first expansion movement of the cup. The protrusion is molded by pressing against a rib or transition between cup portions (e.g., the transition between the top panel and an adjacent panel). In further embodiments, it is contemplated that the protrusions of the present disclosure are molded with a separate press that presses against the rib or transition while holding the rest of the cup. It is further contemplated that a rotating action is provided to press a roller into the rib or transition in a manner similar to the action of a spinner or dome-deforming tool. For example, a circumferential groove or feature is contemplated by rotating a roller around the outer diameter of the cup with an inward pressing force to create the bump or feature. It is also contemplated that a tool is inserted into the cup and the material is rotated outward to mold the feature. It is further contemplated that a reverse taper process is performed by holding the cup curl and pressing a punch against the rib or transition where the protrusion is desired, and then forcing the rib against a die with a spring to push the rib outward. It is further contemplated that an expansion tool may be provided that squeezes over the curl and expands the top panel to form the protrusions, and that a cam-actuated tool may be provided that presses a plurality of discrete bumps against the rib.

[0084] It is contemplated that the inwardly extending protrusions adjacent the curl, such as those shown in Figures 22-23, may be formed by one or more processes. For example, it is contemplated that the curl die may be provided with a tool that allows a portion of the curl to move inward or "bump." It is also contemplated that a cam-actuated tool may be provided that flattens or "crushes" the curl. It is also contemplated that a set of tools may be provided that hold the curl and pull on the bottom of the cup, thereby loosening or partially loosening the curl. It is also contemplated that a reverse taper operation may be provided that moves the curl inward and holds the ribs or transitions between panels in place.

[0085] Various features and embodiments of the metal cup have been provided herein. However, it will be recognized that various features are not necessarily specific to a particular embodiment and may be provided in any one or more embodiments. The embodiments disclosed and 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, drawing, or particular arrangement of features.

[0086] While various embodiments of the present disclosure have been described in detail, it will be apparent that modifications and alterations to those embodiments will occur to those skilled in the art. However, it is expressly understood that such modifications and alterations are within the scope and spirit of the present disclosure. Moreover, the invention described herein is capable of other embodiments and of being practiced or carried out in various ways. Furthermore, it is to be understood that the phrases and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "comprises," "comprises," or "in addition" and variations thereof herein is intended to encompass the items listed thereafter and equivalents thereof, as well as additional items.

Claims

1. A tapered metal cup, including an upper end, a lower end, and a height extending therebetween; The upper end includes a peripheral curl; Tapered metal cups also a plurality of panels disposed between an upper end and a lower end; A transition is provided between each panel, adjacent panels of the plurality of panels include successively smaller diameters; the transition between each panel includes a cup diameter transition; Tapered metal cups also a semi-annular projection extending along at least a portion of the circumference of the cup; Tapered metal cup.

2. The semi-annular projections include outward projections; 2. The tapered metal cup of claim 1.

3. Between about 3 inches and 7 inches in height, 2. The tapered metal cup of claim 1.

4. A semi-annular projection is provided at the transition between the top panel and the adjacent panel; 3. The tapered metal cup of claim 2.

5. The semi-annular projection includes an inward projection; 2. The tapered metal cup of claim 1.

6. a semi-annular protrusion is provided at the transition between the peripheral curl and the first panel; 6. The tapered metal cup of claim 5.

7. The minimum thickness of the plurality of panels includes a thickness of about 0.0096 inches or less; 2. The tapered metal cup of claim 1.

8. The lower end of the cup includes an upstanding surface; The dome-shaped portion is provided within the erection surface.

2. The tapered metal cup of claim 1.

9. At least some of the panels include a substantially constant wall thickness and a tapered profile; 2. The tapered metal cup of claim 1.

10. 1. A method for forming a thin-walled tapered metal cup, comprising: The method is: providing a stock material; forming a cup from a blank of stock material using a blank and drawing operation; subjecting the cup to a re-drawing operation to provide the cup with a predetermined height and wall thickness; following the re-stretching operation, trimming the cup; curling the top edge of the cup to form a lip; and performing a plurality of drawing operations to form a plurality of straight wall portions, each of the straight wall portions including successively smaller diameters; The method also Following the multiple drawing steps, expanding each of the straight wall sections using a die including a tapered profile; At least one protrusion is molded to provide a contact point for adjacent cups; At least one protrusion is formed during the first expansion step; method.

11. A protrusion is provided at the transition between adjacent straight wall portions. The method of claim 10.

12. a protrusion is provided at the transition between the lip and the straight wall portion; The method of claim 10.

13. the protrusions include outward protrusions; The method of claim 10.

14. the protrusions include inward protrusions; The method of claim 10.

15. A tapered metal cup, including an upper end, a lower end, and a height extending therebetween; The upper end includes a peripheral curl; Tapered metal cups also a plurality of panels disposed between an upper end and a lower end; A transition is provided between each panel, adjacent panels of the plurality of panels include successively smaller diameters; the transition between each panel includes a cup diameter transition; Tapered metal cups also a semi-annular protrusion provided on a top panel of a plurality of panels extending along the entire circumference of the cup; the top panel includes a first diameter and the semi-annular protrusion includes a second diameter, the first diameter being 1.001 to 1.2 times larger than the second diameter; Tapered metal cup.

16. The top panel includes a vertical panel; 16. The tapered metal cup of claim 15.

17. Between about 3 inches and 7 inches in height, 16. The tapered metal cup of claim 15.

18. A semi-annular projection is provided at the transition between the top panel and the adjacent panel; 16. The tapered metal cup of claim 15.

19. the semi-annular protrusion comprises a radius between about 0.0050 inches and 3.0 inches; 16. The tapered metal cup of claim 15.

20. a semi-annular protrusion is provided at the transition between the peripheral curl and the top panel; 20. The tapered metal cup of claim 19.

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