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BR-112021010450-B1 - tapered metal cup

BR112021010450B1BR 112021010450 B1BR112021010450 B1BR 112021010450B1BR-112021010450-B1

Abstract

TAPERED METAL CUP AND METHOD OF FORMING THE SAME. The present invention relates to a metal cup and a method of forming the same. The metal cups of the present invention comprise a plurality of sections with straight, thin walls and a tapered profile. A concave part is provided at the bottom of the cup. The cup may comprise a disposable cup, a reusable cup, or a recyclable cup.

Inventors

  • ANTHONY J. SCOTT

Assignees

  • BALL CORPORATION

Dates

Publication Date
20260310
Application Date
20191206
Priority Date
20181210

Claims (12)

  1. 1. Tapered metal cup (20), comprising: an upper end and a lower end, and a height (H2) extending between them; the upper end comprising a peripheral corrugation; a plurality of tapered sections (214) proportioned between the upper end and the lower end, with a step (50) proportioned between all tapered sections; and wherein all tapered sections (214) comprise a constant wall thickness and a tapered profile; wherein the adjacent tapered sections (214) of the plurality of tapered sections comprise successively smaller diameters, and wherein the step (50), proportioned between all tapered sections, comprises a diameter transition; wherein the tapered sections (214) comprise thin-walled aluminum with a wall thickness between 0.010 and 0.022 cm (0.0040 and 0.0090 inch); the lower end of the cup comprising a concave part (24) with a concave wall thickness, wherein the concave wall thickness is greater than the wall thickness of a tapered section adjacent to the concave part; characterized in that the concave part (24) transitions into a first convex fold comprising a first radius (224) between 0.13 and 0.51 cm (0.050 and 0.20 inch), and wherein the first convex fold transitions into an inwardly tapered side wall (218) comprising a slope extending inward toward a central longitudinal axis of the container such that an upper end of the inwardly tapered side wall (218) is closer to a centerline of the cup than a lower end of the inwardly tapered side wall; wherein the inwardly tapered side wall transitions into a first concave fold comprising a second radius (220) between 0.13 and 0.51 cm (0.050 and 0.20 inch); where the first concave fold transitions into a second convex fold, the second convex fold comprising a third radius (222) between 0.07 and 0.51 cm (0.030 and 0.20 inch).
  2. 2. Tapered metal cup (20), according to claim 1, characterized in that the height (H2) is between 10.16 centimeters (4.0 inches) and 17.78 centimeters (7.0 inches).
  3. 3. Tapered metal cup (20), according to claim 1, characterized in that the cup (20) comprises at least three tapered sections (214).
  4. 4. Tapered metal cup (20), according to claim 1, characterized in that a maximum inner diameter of the cup comprises a diameter of at least 7.62 centimeters (3.0 inches).
  5. 5. Tapered metal cup (20), according to claim 1, characterized in that a minimum inner diameter of the cup comprises a diameter of not more than 6.35 centimeters (2.50 inches).
  6. 6. Tapered metal cup (20), according to claim 1, characterized in that the lower end of the cup comprises an annular support surface (30), and in that the concave part (24) is provided within the annular support surface.
  7. 7. Tapered metal cup (20), according to claim 9, characterized in that the thickness of the concavity wall is 0.022 cm (0.0090 inches).
  8. 8. Tapered metal cup (20) with a geometric profile adapted to allow stacking with a second metal cup, comprising: an upper end and a lower end, and a height (H2) extending between the upper end and the lower end; a plurality of tapered sections (214) proportioned between the upper end and the lower end; wherein all tapered sections comprise a constant wall thickness and a tapered profile; wherein the wall thickness comprises a thickness between 0.010 and 0.022 cm (0.0040 and 0.0090 inch); wherein the adjacent tapered sections (214) of the plurality of tapered sections (214) comprise successively smaller diameters; the lower end of the cup comprising a stacking feature with a plurality of inflection points, characterized in that the stacking feature comprises a first radius (224) between 0.13 and 0.51 cm (0.050 and 0.20 inch) positioned adjacent to a concavity (24) at the lower end of the tapered cup, with an inwardly tapered side wall (218) extending upwards from it, a first concave part having a second radius (220) between 0.13 and 0.51 cm (0.050 and 0.20 inch), and a second convex part comprising a third radius (222) between 0.07 and 0.51 cm (0.030 and 0.20 inch) with a horizontally oriented step (50) extending between the first concave part and the second convex part; wherein the concavity (24) comprises a wall thickness larger than an adjacent tapered section (214) to provide increased strength; wherein the first convex part of a metal cup is operable to rest on a convex inner surface of a first concave part of a second metal cup, such that at least one of the upper ends and the lower ends of the metal cups are separated vertically when the metal cups are stacked or fitted together.
  9. 9. Tapered metal cup (20), according to claim 8, characterized in that the first convex part transitions to an inwardly tapered side wall, the inwardly tapered side wall transitions to the first concave part, and the first concave part transitions to the second convex part.
  10. 10. Tapered metal cup (20), according to claim 8, characterized in that the height (H2) is between 10.16 centimeters (4.0 inches) and 17.78 centimeters (7.0 inches).
  11. 11. Tapered metal cup (20), according to claim 8, characterized in that the lower end of the cup comprises an annular bearing surface (30) in a lower part of the first radius, and in that the concave part (24) is provided within the annular bearing surface.
  12. 12. Tapered metal cup (20), according to claim 8, characterized in that the concavity (24) comprises a wall thickness of 0.022 cm (0.0090 inches).

Description

[0001] This patent application claims priority to and benefit of U.S. Provisional Patent Application No. 16/214,477, which is a partial continuation thereof, and claims the benefit of benefit of U.S. Provisional Patent Application No. 15/811,032, filed November 13, 2017, and claims the benefit of benefit of U.S. Provisional Patent Application No. 62/455,697, filed February 7, 2017, the descriptions of which are incorporated herein by reference in their entirety. FIELD [0002] The present invention relates generally to metal cups and methods of forming them. More specifically, the present invention relates to beverage cups formed from a metal. Various embodiments of the present invention provide a thin-walled beverage cup that is stackable with cups of similar construction. BACKGROUND [0003] Beverage cups and beverage containers typically comprise a plastic material. Plastic cups are manufactured by injection molding or thermoforming operations, which can form lightweight, disposable cups. Existing metal beverage containers comprise beverage cans, including an end closure attached to the top end of a filled can. [0004] U.S. Patent 4,366,696 to Durgin et al., which is hereby incorporated by reference in its entirety, describes a snap-fit can and the method of forming the same from a metal blank. Durgin et al., however, fail to describe the various features of the present invention, including, for example, a tapered or stepped geometry, as shown and described in this descriptive report, and the methods of forming the same. [0005] U.S. Patent 4,914,937 to Bulso et al., which is hereby incorporated by reference in its entirety, describes a method for forming a tapered vessel. Bulso et al. provide a straight-walled cup and a method for forming it, but it lacks several teachings of the present invention. [0006] U.S. Patent 6,463,776 to Enoki et al., which is hereby incorporated by reference in its entirety, describes a method of manufacturing bottle-shaped cans with a neck and shoulder portion. Enoki et al. fail to describe several features and methods of the present invention. For example, Enoki et al. fail to provide a cup-shaped container with tapered, straight side walls. SUMMARY [0007] Consequently, there is a long-standing and unmet need to provide a metal cup that is reusable and recyclable. There is also a need to provide a tapered metal cup that is stackable to improve the transport and storage of multiple cups. [0008] In various embodiments, a tapered metal cup is provided, comprising shallow wall angles. The shallow wall angles, at least as used in this descriptive report, comprise wall angles that are less than 10 degrees, measured from a vertical centerline or vertical axis of the cup. The angled sides and shallow wall angles of the cups, as shown and described in this descriptive report, provide the ability to stack at least two cups, which provides advantages for transport and storage. [0009] In various embodiments, the metal cups are provided comprising thin-walled aluminum. Preferably, the metal cups are provided comprising a recycled aluminum alloy. Various embodiments, including those comprising thin-walled aluminum, provide cups that are lightweight, are formed from a recycled and/or recyclable material, and are, for example, more rigid, useful, and durable than conventional plastic cups. [0010] In preferred embodiments, a metal cup is provided with a constant wall thickness along at least part of the cup. An inlet gauge of the cup is reduced to a thinner wall thickness in the side walls of the cup. Steps or ribs extending horizontally preferably extend throughout a circumference of the cup, and are provided to incorporate mechanical strength into the finished cup while maintaining a lightweight characteristic for the cup. The steps or ribs are provided as transition points between sections of the finished cup having different diameters. Alternatively, a tapered cup is provided without ribs, wherein the cup comprises a relatively smooth and linear side wall, extending from the upper end of the tapered cup to the closed lower end. [0011] In several embodiments, a method for forming a metal cup is provided. In one embodiment, a method for forming a metal cup comprises feeding an aluminum coil into a deep drawing press and producing a straight-walled cup from a substantially circular metal blank cut from the aluminum coil. The cup preferably has a constant wall thickness, which is approximately equal to the aluminum feed gauge. The cup is then fed into a body-making device, in which the metal is smoothed. The cup is further formed by washing it and by decorating and/or coating an external and an internal part thereof. In certain embodiments, at least part of the external part of the cup is decorated with a color, a logo, or other visual information. After the washing and coating operations, a top edge of the cup is corrugated, partially corrugated, or strangulated to eliminate the sharp edge that i