Tapered Metal Cup with Segmented Ribs for Lightweight Stackability
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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, as existing disposable beverage cups are typically made of plastic and lack the features of a tapered design for improved stacking.
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 bottom dome for enhanced structural stability, formed through processes involving cupping presses, bodymakers, and die expansion techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a metal cup is made with thin-walled aluminum to be lightweight, then weight is reduced and recyclability is improved, but structural strength and rigidity may be compromised
Solution Approach 1:
The cup is divided into multiple sections separated by horizontally-extending steps or ribs. These segments reinforce the thin-walled structure by creating rigid zones that prevent buckling and deformation, allowing the cup to maintain strength while using thinner material throughout.
Solution Approach 2:
A dome is provided in the bottom wall of the cup, creating a curved, dome-shaped base. This curvature distributes stresses more effectively across the thin-walled structure, enhancing structural integrity and rigidity without adding significant weight or material thickness.
2Ease of manufacture
If a straight-walled cup design is used for simplicity, then manufacturing is easier, but stackability and storage efficiency are reduced
Solution Approach 1:
The cup transitions from a straight-walled design to a tapered design where the diameter decreases from the upper end to the lower end. This asymmetric geometry allows cups to nest within each other when stacked, significantly improving storage efficiency and shipping space utilization while remaining manufacturable through standard drawing and expanding processes.
3Loss of substance
If the cup wall thickness is reduced to be thinner, then weight is reduced and material usage is decreased, but structural integrity and durability are compromised
Solution Approach 1:
The horizontally-extending steps or ribs divide the cup wall into segmented sections. These segments act as reinforcement elements that prevent the thin-walled structure from collapsing or deforming under load, maintaining structural integrity despite reduced material usage in the wall sections between ribs.
Solution Approach 2:
The dome in the bottom wall provides a curved surface that distributes mechanical stresses evenly across the thin-walled base, preventing localized failure and enhancing overall structural integrity without requiring additional material in the bottom section.
4Ease of operation
If a tapered design with shallow wall angles is implemented for stackability, then storage efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The tapered cup is manufactured by dividing the forming process into discrete stages: first forming a straight-walled cup, then creating multiple straight wall sections through drawing operations, and finally expanding each section to create the tapered profile. This segmented manufacturing approach manages complexity by breaking down the tapered shape creation into standardized, repeatable steps.
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.