Close-nesting, light-weight, one-piece drinking cup and apparatus for the manufacture thereof

Claim 1

A one-piece, seamless drinking cup of nestable configuration, and of a size adapted to contain a single serving of a hot beverage, said cup comprising a sidewall tapering inwardly and downwardly over a major portion of its extent from the upper open mouth thereof, and a bottom wall formed integrally with the sidewall and extending thereacross at the lower end thereof, the sidewall and the bottom wall being formed from fused beads of an expanded thermoplastic material, which consists essentially of general purpose polystyrene whose density is not materially greater than 5 pounds per cubic foot, the sidewall gradually increasing in thickness over said major portion, as it extends downwardly thereof, said major portion extending from a first elevation near the upper open mouth of the cup to a second elevation near the lower end thereof and gradually increasing in its angle, relative to the vertical central axis of the cup, from a small acute angle at the first elevation to a larger acute angle at the second elevation to maintain adequate, but not excessive, clearances between all portions of the overlapped major portions of the sidewalls of a pair of such cups closely nested together, said cup being circular in horizontal cross-section at all elevations along said major portion, the ratio of the overall height to the outside diameter of the upper open mouth of said cup being of the order of 1.05, the thickness of said major portion of the sidewall at the second elevation being of the order of 2.0 times the thickness at the first elevation, and the inside surface of the major portion, along a vertical plane on which the vertical central axis of the cup lies, corresponding to the shape of an arc of a circle whose radius is of the order of 4.7 times greater than the outside diameter of said upper open mouth of the cup, the distance from the upper open mouth of the cup to the first elevation and the distance from the second elevation to the lower end of the cup each being equal to the desired stacking height between like cups closely nested together, the sidewall of said cup being provided with a thickened portion which extends for the length of such distance from the upper open mouth of the cup to the first elevation and which defines a horizontally outwardly projecting shoulder which is adapted to rest on the upper open mouth of a like cup when such cup is inserted in said like cup in closely nested relationship, the sidewall of the cup also being provided with a radially inwardly offset vertical section which extends for the length of the distance from the second elevation to the lower end of the cup and which defines a horizontally inwardly projecting shoulder on which the lower end of a like cup is adapted to rest when said like cup is inserted in said cup in closely nested relationship, the thickness of the sidewall at the first elevation being not materially greater than 0.045 in., the distance from the upper open mouth of the cup to the first elevation being no greater than 3/8 inch.