Tapered Metal Cup with Domed Bottom for Stackability and Strength
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Solution Overview
Problem
There is a need for a reusable and recyclable metal cup that is also stackable, as existing disposable beverage cups are typically made of plastic and lack the features of being tapered and easily storable.
Innovation Solution
A tapered metal cup with shallow wall angles and a constant wall thickness is developed, featuring horizontally-extending steps or ribs for added strength, and a method of forming the cup involves feeding an aluminum coil into a cupping press, ironing, washing, decorating, and expanding the cup using dies with a tapered profile to create a dome for enhanced structural stability and stackability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a metal cup is made with thin walls to be lightweight, then weight is reduced, but structural strength and rigidity deteriorate
Solution Approach 1:
The patent applies spherical curvature to the bottom of the cup, creating a domed structure that distributes stress more effectively across the thin walls. This curvature provides structural strength and rigidity equivalent to thicker walls, while maintaining the lightweight advantage of thin-wall construction.
Solution Approach 2:
The patent introduces a stepped geometry with multiple diameters along the vertical axis, creating horizontal ledges or ribs that add structural reinforcement in the radial dimension. These stepped features provide additional stiffness and strength to the thin walls without significantly increasing weight, as the reinforcement is achieved through geometric complexity rather than material thickness.
2Ease of operation
If a metal cup is made with tapered geometry for stackability, then storage efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the cup wall into multiple segments with different diameters, creating a stepped profile. This segmentation allows the cup to taper for stackability while using standard drawing and expanding operations for each segment. The manufacturing process handles the complexity by processing the cup in discrete stages rather than requiring a single complex forming operation.
3Ease of manufacture
If a metal cup is made with constant wall thickness for simplicity, then manufacturing is simplified, but structural stability at the bottom deteriorates
Solution Approach 1:
The patent applies spherical curvature to the bottom of the cup, creating a domed structure that provides enhanced structural stability. This curved geometry distributes loads more effectively across the constant thickness wall, improving bottom stability without requiring variable wall thickness or additional reinforcement features.
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 solution provides a lightweight, durable, and stackable metal cup that is more rigid than conventional plastic cups, facilitating efficient shipping and storage while being reusable and recyclable.
Implementation Method 1
feeding an aluminum coil into a cupping press and producing a straight-walled cup from a substantially circular blank cut from the aluminum coil. The cup preferably has a constant wall thickness that is approximately equal to the incoming gauge of the aluminum.
Implementation Method 2
Each of the straight wall sections is expanded to a larger diameter using a die with a 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.