Sport Stacking Cup Bottom Lip Recess for Flash Management
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Solution Overview
Problem
Injection molding of sport stacking cups often results in flash at the bottom lip, which is detrimental as it catches on the stacking surface, causing impediments and balance issues during stacking competitions, and current methods for removing flash are time-consuming, labor-intensive, and costly.
Innovation Solution
A novel method involving a stripper plate with a unique profile that repositions flash away from the contact surface by incorporating a recessed lip design, where the flash is shielded within the lip's inner or outer recesses, preventing it from interfering with the stacking surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional injection molding is used, then cups are produced efficiently, but flash forms on the bottom lip surface causing stacking problems
Solution Approach 1:
The invention moves the flash problem from the critical 2D contact surface to a 3D recessed location. By designing a bottom lip with an inner recess and positioning the stripper plate joint at the outer surface, flash is directed into the recessed volume rather than onto the contact surface, effectively solving the problem through spatial dimensionality change.
Solution Approach 2:
The invention converts the harmful flash byproduct into a beneficial feature by designing the bottom lip recess to intentionally capture and contain the flash. The flash, instead of being a defect on the contact surface, becomes a controlled element housed within the recess structure, eliminating its negative impact on stacking performance.
2Manufacturing precision
If post-processing flash removal is performed, then surface quality improves, but production time and cost increase
Solution Approach 1:
The invention performs the flash management action during the molding process itself rather than as a subsequent post-processing step. The bottom lip recess is built into the mold design, so flash is captured and contained during injection molding, eliminating the need for separate trimming or removal operations after molding.
Solution Approach 2:
The mold design with the bottom lip recess makes the system self-sufficient for flash management. The recess structure automatically captures and contains flash during the molding process without requiring external post-processing interventions, making the manufacturing process self-service for quality control.
3Ease of operation
If stripper plate joint is positioned on the lip, then cup release from mold is effective, but flash forms at the joint location
Solution Approach 1:
The invention applies different functional qualities to different locations of the bottom lip. The outer surface maintains a smooth finish for stacking contact, while the inner recess provides a specialized zone for flash containment. The stripper plate joint is positioned at the outer surface where it is needed for effective cup release, while the recessed inner area handles flash management.
Solution Approach 2:
The invention resolves the conflict between stripper plate positioning and flash prevention by utilizing the third dimension. The bottom lip is designed with an inner recess that creates a vertical separation between the joint location (outer surface) and the flash accumulation zone (inner recess), allowing both functions to coexist without interference.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach minimizes the need for post-processing flash removal, maintaining a smooth surface essential for efficient stacking while reducing mold wear and maintaining the structural integrity of the cups.
Implementation Method 1
During this cooling process, the cup will necessarily contract about the core.
Data Source
AI summary
A method of making a cup that decreases the amount of flash on a bottom surface of the cup is provided. More specifically, a cup is provided that includes a thickened lip around an open surface. The lip also includes a recess for the receipt of excess material generated by the molding process. This excess material, or flashing, is detrimental to the use of cups in cup stacking competitions.