Tapered Metal Cup Geometry for Stackable Reusable Nesting
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Solution Overview
Problem
There is a need for a reusable and recyclable metal cup that is also stackable to enhance shipping and storage efficiency.
Innovation Solution
A method of forming a stackable tapered metallic cup with a tapered profile and stepped geometry, allowing for efficient stacking and nesting, using a series of forming steps including drawing, expanding, and doming operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal cup is made with straight-walled sections and tapered profile, then the cup achieves structural integrity and stackability, but the manufacturing process becomes complex requiring multiple forming steps
Solution Approach 1:
The cup is divided into multiple straight-walled sections (first section, second section, third section) with different diameters, where each section can be formed independently through separate drawing operations. This segmentation allows the complex tapered profile to be achieved through modular forming steps while maintaining structural integrity of each section.
Solution Approach 2:
The cup is formed through a sequence of preliminary drawing operations where each drawing step creates a specific straight-walled section with predetermined diameter. The first drawing operation creates the first section, the second drawing operation creates the second section, and so on, allowing complex geometry to be built up systematically through pre-planned forming steps.
2Productivity
If a tapered profile with multiple straight-walled sections is used, then the cup becomes stackable for efficient shipping and storage, but the manufacturing precision requirements increase
Solution Approach 1:
Each straight-walled section has a specific local quality with a predetermined diameter that is optimized for its position in the stack. The first section has a first diameter, the second section has a second diameter, and the third section has a third diameter, allowing each section to contribute differently to the overall stackability while maintaining precise dimensional control locally.
Solution Approach 2:
The cup design transitions from a simple cylindrical form to a multi-dimensional tapered profile with varying diameters along the height. By introducing dimensional variation through multiple straight-walled sections with different diameters, the cup achieves stackability in the vertical dimension while maintaining manufacturing precision through controlled forming operations.
3Weight of moving object
If thin-walled construction is used, then the cup becomes lightweight and disposable-friendly, but the cup may lack durability for reusable applications
Solution Approach 1:
The cup is constructed with thin-walled metal sections that provide sufficient structural strength through the tapered geometry and multiple drawn sections. The thin walls reduce weight while the multi-section design with varying diameters provides structural reinforcement where needed, enabling the cup to be lightweight yet durable enough for reusable applications.
Solution Approach 2:
The domed bottom section introduces curvature to the cup design, which enhances structural strength and durability. The curved surface distributes stress more effectively than flat surfaces, allowing thin-walled construction to maintain both lightweight properties and sufficient durability for reusable applications.
Data Source
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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.