Tapered Aluminum Cup Structure for Stackable Reuse
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Solution Overview
Problem
There is a need for a reusable and recyclable metal cup that is also stackable to facilitate easier shipping and storage.
Innovation Solution
The development of a tapered metal cup with shallow wall angles, made from thin-walled aluminum, which is lightweight, rigid, and durable, and features a constant wall thickness, horizontally-extending steps or ribs for added strength, and a domed bottom for enhanced stability and stackability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plastic cups are used, then lightweight and disposable characteristics are achieved, but durability and recyclability are poor
Solution Approach 1:
The patent changes the material parameter from plastic to thin-walled aluminum, transforming the cup from disposable to reusable while maintaining lightweight characteristics. The aluminum material provides superior durability and recyclability compared to plastic, while the thin-walled construction keeps the weight low.
Solution Approach 2:
The patent uses aluminum alloy material that combines lightweight properties with high strength and durability. The material selection creates a composite effect that achieves both light weight and high reliability, resolving the contradiction between these two parameters.
2Ease of operation
If straight-walled cup geometry is used, then manufacturing simplicity is maintained, but stackability is poor
Solution Approach 1:
The patent introduces asymmetric tapered geometry to the cup, with the sidewall angle varying from vertical at the top to more angled at the bottom. This asymmetric shape enables better stackability by allowing cups to nest within each other, while the gradual transition maintains manufacturing feasibility.
Solution Approach 2:
The cup geometry transitions from a static straight-walled design to a dynamic tapered profile where the sidewall angle changes continuously from top to bottom. This dynamic shape optimization achieves improved stackability while remaining compatible with existing forming processes.
3Weight of moving object
If thin-walled aluminum is used, then lightweight and recyclable characteristics are achieved, but structural strength is reduced
Solution Approach 1:
The patent applies local quality enhancement by adding horizontally-extending steps or ribs at specific locations on the cup. These localized structural features provide additional strength and rigidity to the thin-walled aluminum cup without increasing overall weight, as the reinforcement is concentrated only where needed.
Solution Approach 2:
The patent incorporates a domed bottom geometry that uses curvature to enhance structural strength. The spherical/domed shape distributes stresses more effectively than a flat bottom, providing increased structural integrity to the thin-walled cup while maintaining lightweight characteristics.
4Ease of operation
If tapered geometry with shallow wall angles is used, then stackability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses dynamic forming processes that gradually transform the blank into the tapered shape through sequential drawing and expansion operations. This dynamic approach allows the complex tapered geometry to be achieved using standard metal forming equipment without requiring specialized tooling.
Solution Approach 2:
The patent employs preliminary forming steps that prepare the metal blank and intermediate forms in advance, making the final tapered shape achievable with standard equipment. The preliminary actions include initial cupping, drawing, and shaping operations that set up the material for the final expansion to the desired tapered profile.
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.