Tapered Metal Cup Geometry for Stackable Separation
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Solution Overview
Problem
There is a need for a reusable and recyclable metal cup that is stackable, as existing disposable beverage cups are typically made of plastic and lack the features of being stackable and durable, and existing metallic containers do not provide the necessary tapered geometry for efficient stacking and separation.
Innovation Solution
A tapered metal cup with shallow wall angles and a constant wall thickness is designed, featuring a curled lip, multiple tapered sections with successively smaller diameters, and a domed bottom for enhanced structural stability and stackability, along with anti-sticking features to prevent cups from sticking together when nested.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal cup is made with straight walls and constant diameter, then manufacturing is simpler, but stackability is poor
Solution Approach 1:
The cup sidewall is divided into multiple tapered sections with different diameters, creating distinct segments that allow one cup to fit within another. This segmentation enables efficient nesting and stacking while maintaining manufacturing feasibility through sequential forming operations.
Solution Approach 2:
The cup transitions from a symmetric constant-diameter form to an asymmetric tapered form with varying diameters along its height. This asymmetric geometry creates the necessary clearance and orientation for stackability while preserving structural integrity through controlled wall thickness variations.
2Weight of moving object
If a metal cup is made with thin walls to reduce weight, then portability improves, but structural strength decreases
Solution Approach 1:
The cup employs varying wall thicknesses at different locations: thinner walls in upper sections for weight reduction and portability, while thicker walls at the base and rim provide localized structural strength for stability and handling. This spatial variation in material distribution optimizes both weight and strength requirements.
Solution Approach 2:
The cup incorporates curved and tapered sidewalls instead of straight cylindrical forms. These curved geometries distribute mechanical stresses more effectively throughout the structure, enhancing strength-to-weight ratio by utilizing the inherent strength of curved surfaces to resist deformation while maintaining thin wall sections.
3Ease of operation
If a metal cup is made with tapered sections for stackability, then nesting efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The tapered cup is formed as a sequence of discrete tapered sections, each with a specific diameter reduction. This segmentation allows the manufacturing process to create each section in controlled stages, simplifying the overall forming operation while achieving the nested geometry required for efficient stacking and storage.
Data Source
AI summary
A metal cup and method of forming the same is provided. Metal cups of the present disclosure comprise a plurality of thin, straight-walled sections and a tapered profile. A domed portion is provided in the bottom of the cup. The cup may comprise a disposable cup, a reusable cup, or a recyclable cup.