Tapered Metal Cup with Segmented Geometry for Stackable Storage
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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, which existing technologies have not adequately addressed.
Innovation Solution
A method of forming a tapered metal cup with a tapered or stepped geometry, allowing for stackability, involving a process that starts with a straight-walled preform, which is then curled, expanded using a die, and finished with a dome to create sections of varying diameters and heights, enabling efficient stacking and use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a straight-walled cup geometry is used, then manufacturing is simpler, but stackability and storage efficiency are poor
Solution Approach 1:
The cup is divided into multiple sections (first section, second section, third section) with different diameters along the vertical axis. This segmentation creates a tapered geometry where the upper section has a larger diameter than the lower section, enabling efficient nesting and stacking while maintaining manufacturing feasibility through sequential forming operations.
Solution Approach 2:
The invention transitions from a two-dimensional straight-walled cylinder to a three-dimensional tapered form by varying the diameter along the height dimension. This dimensional change creates radial steps and offsets that enable vertical stacking and nesting, significantly improving storage space utilization without complicating the basic forming process.
2Volume of moving object
If a tapered geometry with varying diameters is implemented, then stackability is improved, but manufacturing complexity increases
Solution Approach 1:
The cup is formed with a pre-determined tapered geometry and radial steps during the initial forming process. The offset between sections is built into the cup structure during manufacturing, eliminating the need for complex post-forming operations or assembly steps. This preliminary action simplifies the overall manufacturing complexity while achieving the desired stackability.
Solution Approach 2:
The invention varies the diameter parameter along the height of the cup, creating a tapered profile where the upper section has a larger diameter than the lower section. This parameter change is implemented through controlled forming operations that create radial steps, enabling stackability without requiring complex multi-step processes or additional components.
3Loss of substance
If thin-walled construction is used, then material usage and weight are reduced, but structural strength decreases
Solution Approach 1:
The cup employs thin-walled construction throughout, but the tapered geometry with radial steps creates local variations in wall orientation and thickness distribution. The upper section with larger diameter provides enhanced rigidity where needed, while the lower section maintains thin-walled efficiency. This local quality variation allows the cup to achieve adequate structural integrity for beverage containment while minimizing overall material consumption.
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 reusable, recyclable, and stackable metal cup that optimizes storage and shipping by allowing cups to be easily stacked and separated, while maintaining structural integrity and user convenience.
Implementation Method 1
a first expansion die to expand each of the straight wall sections to a larger diameter
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.