Double-Walled Paperboard Cup Stacking Stopper for Easy De-Stacking
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Solution Overview
Problem
Existing stackable paperboard cups suffer from poor stacking and de-stacking properties, particularly when under axial pressure, leading to cups becoming stuck together, especially when a large number are stacked, due to insufficient stiffness in the rolling process and design limitations.
Innovation Solution
A shoulder-shaped stacking stopper is integrated into the outer sleeve below the drinking lip, providing stability and directing axial forces normally onto the drinking lip, preventing deformation and allowing for increased stackability without material weakness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rolled groove is applied to the inner sleeve to enable stacking, then stacking properties are improved for approximately 20 cups, but the cups become stuck when more than 20 cups are stacked due to insufficient stiffness of the groove
Solution Approach 1:
The invention divides the stacking function into two separate components: the rolled groove on the inner sleeve for initial stacking engagement, and the additional rolled lip on the outer sleeve for enhanced stability. This segmentation allows each component to perform its specific function without compromising the other, enabling stable stacking of large numbers of cups while maintaining ease of operation.
Solution Approach 2:
The rolled lip on the outer sleeve acts as an intermediary element that mediates between the stacked cup weight and the inner sleeve groove. It provides an additional contact point that distributes the axial load, preventing the groove from deforming under high pressure while maintaining the stacking functionality.
2Ease of manufacture
If the rolling process is used to form the groove, then the cup is easy to manufacture, but the material strength is reduced due to weakness introduced by the rolling process
Solution Approach 1:
The invention combines two rolled features (the groove on the inner sleeve and the lip on the outer sleeve) to achieve the stacking function. By merging these two elements, the design compensates for the strength reduction in one feature through the presence of the other, maintaining both ease of manufacture through rolling and sufficient material strength for heavy stacking.
Solution Approach 2:
The invention changes the parameters of the stacking system by adding a second rolled feature (the lip on the outer sleeve) with different geometric parameters. This allows the system to maintain the manufacturing simplicity of rolling while achieving the required strength through the combined effect of both rolled features with optimized parameters.
3Force
If a stacking stopper is applied to support axial pressure, then the cups can withstand high pressure, but the design complexity increases
Solution Approach 1:
The rolled lip on the outer sleeve serves a dual function: it provides the stacking stopper function to support axial pressure, and simultaneously maintains the structural integrity of the outer sleeve. This self-service approach allows the same element to perform multiple functions without increasing overall design complexity.
Solution Approach 2:
The rolled lip on the outer sleeve is designed to perform multiple functions: it acts as a stacking stopper to support axial pressure from stacked cups, provides additional structural reinforcement, and maintains the outer sleeve's integrity. This multi-functionality reduces the need for separate components, thereby limiting the increase in design complexity.
Data Source
AI summary
Described is a double-walled heat-insulating paperboard cup which stacks with the aid of an upper stacking stopper. A particularly stable design is achieved by means of the embodiment of the upper stacking stopper, which results in good stackability and de-stackability of the cups. Furthermore a process is described which is applied for the manufacture of a cup of this type.