Tapered Metal Container Structure to Prevent Stacking Blockage
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Solution Overview
Problem
Tapered metal containers face issues with blocking during transportation due to vibration or impact, and the manufacturing process is complex, making it difficult to create a shape with a smooth surface suitable for printing.
Innovation Solution
A metal container design with a sidewall portion having a bulging portion and continuous tapered surfaces formed through multiple stages of diameter reduction drawing, allowing easy separation and printing, while preventing blocking during transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the sidewall portion is formed with a tapered profile using conventional manufacturing methods, then the container can be manufactured, but the manufacturing process becomes complicated and it is difficult to cope with diverse shapes
Solution Approach 1:
The manufacturing process is segmented into distinct stages: first forming a cup with vertical wall sections, then performing diameter reduction drawing to create the tapered profile. This segmentation allows each stage to be optimized independently, simplifying the overall process while enabling diverse shape creation.
Solution Approach 2:
The manufacturing method employs dynamic forming processes where the cup is redrawn multiple times with varying parameters to achieve different tapered profiles. The diameter reduction drawing process allows continuous adjustment of taper angle and wall thickness, providing versatility for diverse shapes without complicating the base manufacturing flow.
2Productivity
If the sidewall portion is formed with a tapered profile to allow stacking, then transportation efficiency improves, but a blocking phenomenon occurs during transportation making separation difficult
Solution Approach 1:
The container design incorporates asymmetric features: the sidewall portion has a tapered profile that is asymmetric relative to the opening portion, and the bottom portion has an outer diameter that is asymmetrically smaller than the opening portion's inner diameter. This asymmetry allows efficient stacking while preventing complete interlocking, enabling easy separation despite the tapered shape.
Solution Approach 2:
The tapering is applied locally to specific portions of the sidewall rather than uniformly throughout. The bottom portion maintains a smaller outer diameter than the opening portion's inner diameter, creating a controlled interference fit that allows stacking but prevents complete blocking, thus maintaining ease of separation.
3Stability of the object's composition
If the sidewall portion is formed with a tapered profile, then stacking is enabled, but the surface becomes unsuitable for printing due to lack of smoothness and sufficient size
Solution Approach 1:
The sidewall portion is segmented into distinct functional zones: an upper section with a relatively large diameter that provides a smooth, flat surface suitable for printing, and a lower section with tapered profiles that enable stacking. This segmentation allows each zone to fulfill its specific function without compromising the other.
Solution Approach 2:
Different portions of the sidewall are given different geometric qualities: the upper portion maintains a larger diameter and smoother surface characteristics ideal for printing, while the lower portion transitions to tapered profiles for stacking. This local differentiation resolves the contradiction between printing suitability and stacking capability.
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
The design effectively prevents blocking during transportation and allows for easy printing on a smooth surface, enhancing manufacturing efficiency and flexibility.
Implementation Method 1
forming a bottomed cup by drawing a plate-like metal material
Implementation Method 2
performing diameter reduction drawing on the bottom portion side with respect to the opening portion
Data Source
Figure 1
Figure 2
Figure 3(a)~3(c)
AI summary
Provided is a metal container having a shape with which it is possible to avoid a blocking phenomenon during transportation in a stacked state while being formed with a side wall portion having a sufficiently large surface on which it is easy to print, and a method for manufacturing a metal container with which such a metal container can be formed effectively. The metal container of the present invention has an opening portion, a side wall portion, and a bottom portion, and has a lower end outer diameter that is smaller than an upper end inner diameter, the metal container having a shape of a bottomed cup that is formed by subjecting a plate-shaped metal material to a drawing process and that is trimmed, wherein: the side wall portion is formed with a tapered contour by performing diameter reduction drawing on the bottom portion side of the opening portion of the bottomed cup; a bulging portion that bulges in a circumferential direction is formed in the side wall portion; and a continuous tapered surface in which tapered surfaces are continuously formed by performing diameter reduction drawing a plurality of times is formed below the bulging portion.