Paperboard container with sidewall features and method of manufacturing thereof

A disposable container constructed of paperboard that is formed into a geometric shape having a bottom wall having a central portion and an outer peripheral area bordered by a bottom radius joining the bottom wall to an upstanding sidewall that extends radially outward and upward to an upper rim portion extending radially outwardly from the top of the sidewall, wherein said sidewall has a sidewall height comprised of a lower sidewall portion adjacent the bottom wall and an upper sidewall portion adjacent said upper rim portion, comprising;

• an undulation of paperboard formed about a circumference of the sidewall immediately adjacent said bottom radius and said undulation resides within the lower portion of the sidewall, said undulation having a first curved segment extending from the bottom radius to an outwardly extending transition segment and a second curved segment extending upwardly to join the transition segment to said upper portion of the sidewall, wherein said outwardly extending transition segment has a flat upper surface.

A method of manufacturing a disposable paperboard container comprising the steps of:

• providing a paperboard blank with an outer peripheral dimension;
• applying pressure to said blank between forming dies having mating projections and recesses to form a geometric shape of a container having a bottom wall and a peripheral bottom radius, wherein said peripheral bottom radius joins the bottom wall to a sidewall portion that extends upwardly to an outwardly extending rim;
• wherein said method of forming a geometric shape of the container comprises the step of applying pressure to the paperboard between forming dies having a mating projection and recess to form a stepped configuration of the paperboard within the sidewall, said stepped configuration of paperboard comprising a first bend of paperboard joining said peripheral bottom radius to an outwardly extending transition segment which leads to a second bend of paperboard joining the stepped configuration to a smooth portion of the sidewall, and wherein said outwardly extending transition segment comprises a substantially flat upper surface.