WO1994009741A1

WO1994009741A1 - Burial or cremation casket

Info

Publication number: WO1994009741A1
Application number: PCT/US1993/009832
Authority: WO
Inventors: Bruce E. Elder; Stephen D. Woedl
Original assignee: Elder Davis, Inc.
Priority date: 1992-10-23
Filing date: 1993-10-14
Publication date: 1994-05-11

Abstract

A casket (8) comprising a structurally-sound inner casket box (10) with lid (11A, 11B), clad with ornamental panels (12, 14, 16, 18) of self-sustaining plastic or metal material. The panels are preferably thermo-formed to conform to the exterior of the box and to the top of the lid, and are preferably bolted (32) and, in some cases, also cemented in place.

Description

- 1 -

BURIAL OR CREMATION CASKET

Field of the Invention

This invention relates to burial or cremation caskets for burying or cremating human remains, and particularly to such caskets which are inexpensive and ligh in weight, yet attractive. The term "casket" will be used herein to designate a casket whether used for burial or cremation.

Background of the Invention It is known to provide attractive and even impressive caskets made of wood, metal or plastic. While these may be both structurally sound and aesthetically pleasing, they are typically quite expensive, and often ver heavy as well. Much less expensive, and lighter, forms of casket made of corrugated fiberboard are shown, described and claimed in U.S. Patents No. 4,730,370, issued March 15, 198 to B.E. Elder; No. 4,773,134, issued September 27, 1988 to W. Kay; No. 4,944,076, issued July 31, 1990 to W. Kay and B.E. Elder; and No. 4,967,455, issued November 6, 1990 to B.E. Elder. Such caskets, while inexpensive and light in weight, still have the structural integrity required to serve their intended purposes. To provide a pleasing 2 -

external appearance, it is known to cover the corrugated fiberboard casket with a cloth-like material. Nevertheless its appearance is not as aesthetically pleasing as is the case for certain fine wood, metal or plastic caskets. Stil other forms of caskets have also been proposed, but each ha drawbacks with respect to costs, appearance, construction integrity and/or weight.

It is an object of the present invention to provide a casket which is light in weight, structurally sound, relatively inexpensive to make, and yet aestheticall pleasing in appearance.

Summary of the Invention

In accordance with the present invention, a caske is provided which comprises an interior, structurally-sound light-weight box, with lid, for holding human remains, and which may have strips of wood or the like secured to its exterior for strength and/or ornamentation. In accordance with the invention, the exterior of the box and lid is clad with thin, self-sustaining, but non-structural, ornamental panels of metal or plastic material, shaped to conform to the exterior of the internal box and lid and providing the desired exterior ornamental appearance. Preferably, a separate individual panel is provided for each of the two long sides, the bottom, the two ends, and the top of the li of the casket. The side and end panels are preferably positioned on the exterior of the corrugated fiberboard box by means of overlapping end structures, and clamped to the interior box by appropriate bolts and nuts which also serve to mount the usual carrying handles of the caskets. According to the presently preferred embodiment o the invention, the panels are made by a thermo-forming process. Preferably, male molds are made from a suitable material such as wood or aluminum as examples, each mold having an external convex surfaces which is the image of a corresponding portion of the exterior of the casket box, preferably including the top of the lid. A thin sheet of a^' - 3 -

suitable thermoplastic material such as ABS (acrylonitrile- butadiene-styrene) or polystyrene, as examples, is heated to a pliable state and draped over the convex surface of the mold; a vacuum is applied through openings in the mold, to the inner side of the plastic sheet so that it conforms closely to the detailed topography of the mold surface. After subsequent cooling to rigidify the molded sheet, the thin but self-sustaining sheet is removed, trimmed, cleaned, placed on the corresponding exterior surface of the box, and fastened in place. In the molding process the side panels are provided at each end with right-angle end portions and the end panels are provided at each end with set-back end extensions which fit inside and overlap the end portions of said side panels to and in holding the panels in place. Alternatively, thermo-forming may be accomplished as follows. Male mold patterns are first made from a suitable material such as wood or aluminum as examples, each pattern having a surface which is like that of a portion of the exterior of the inner casket box, including the top of the lid. From each such pattern, a vacuum-forming mold is made having on a concave side thereof a surface which is the image of the desired exterior configuration of the panel. A thin sheet of a suitable thermoplastic material such as ABS (acrylonitrile-butadiene-styrene) or polystyrene, as examples, is placed over the configured concave side of the mold and heated enough so that the sheet sags inwardly toward the mold in response to a vacuum applied to the inner surface of the sheet through holes extending through the mold, so as to assume the configuration desired for the exterior of the casket. Again, after cooling, the thin but self-sustaining panel is removed from the mold, trimmed, cleaned and applied to the exterior of the box, and fastened in place. Preferably, this thermal-molding process also provides the side and end panels with overlapping end portions to aid in holding them assembled to each other on the casket. In final assembly, the panels are fastened to - 4 -

the inner box by the same bolts and nuts which secure the usual carrying handles to the casket.

In another embodiment, the cladding panels may be of a metal, for example aluminum, steel, bronze or copper, stamped to the desired configuration and secured to the exterior of the interior box.

The interior box may be of any of a variety of materials, preferably but not necessarily corrugated fiberboard. Light-weight wood, laminated paper, paper mache, particle board and foamed plastic materials such as styrofoam are examples of other suitable inner-box materials. It is also feasible to construct the assembly b making the exterior cladding first, and later flowing a plastic into the exterior box to form an inner liner constituting the interior box.

The resultant casket provides a substantial improvement in appearance compared to inexpensive caskets o the prior art, yet is substantially less expensive, easier to make, and generally lighter in weight than fine wood and/or metal caskets. It therefore fills a significant niche between the inexpensive, relatively less attractive caskets now available and the attractive but higher-priced types of caskets.

Brief Description of the Drawings These and other objects and features of the invention will be more readily understood from a consideration of the following detailed description, taken with the accompanying drawings, in which:

Figure 1 is a perspective view of a casket constructed according to a presently preferred embodiment o the present invention;

Figure 2 is an exploded view of the casket of Fig 1, less the lining fabric;

Figure 3 is a cross-sectional view of the casket of Fig. 3, taken along lines 3-3 of Fig. 1; - 5 -

Figure 4 is a longitudinal sectional view taken along lines 4-4 of Fig. 1;

Figure 5 is an enlarged fragmentary sectional view, with parts broken away, taken along lines 5-5 of Fig. 1.

Detailed Description of Preferred Embodiments

Turning now to the preferred embodiment of the invention illustrated in the drawings, and without thereby in any way limiting the scope of the invention, there is shown in Fig. 1 a completed casket 8, according to the presently-preferred embodiment of the invention, consisting of an internal structurally-sound, corrugated fiberboard bo 10 (Figs. 2 and 3) of known type, including a hinged, two- part lid 11A, 11B, all clad on the exterior with end panels 12 and 14, side panels 16 and 18, bottom panel 19 and lid top panels 20A and 2OB which in this example are all of a plastic material, for example ABS or polystyrene. Carrying handles such as 30, 31 are held to the casket by through bolts such as 32 and mating cap nuts such as 34 (Fig. 3) ; these bolt and nut assemblies also serve to hold and clamp the side and end cladding panels against the fiberboard inner box, as shown.

Further, framing strips such as 35 are secured, a by an adhesive, to the exterior of the fiberboard box, and extend around the top and bottom of its sides and ends to provide additional rigidity for the structure; other strips may also be used for ornamental effect, if desired. Framin strip 35A (Fig. 1) provides a mounting surface on its top for hinges 36 and 37 which support the lid section 11A, as well as for the corresponding hinges on which the other lid section 11B is supported (not shown) . Lid latches such as 38 are provided on the top of framing strip 35B, which latc the lid tongues such as 38A on the lids. The interiors of the casket trough and lid are completed, as usual, with appropriate fine fabric lining 38B secured to the underlyin inner box. - 6 -

Set-back end extensions such as 39 and 40 (Fig. 5 are formed, during the thermo-forming process, on both ends of the end panels 12 and 14 to aid in securing each end panel to its neighboring side panel. Thus, for example, each end panel extension such as 39 fits tightly behind a right-angle bend such as 41 provided on the end of the adjacent side panel, to assist in holding the adjacent panels in the desired positions on the fiberboard box. Thermo-forming, the preferred method of manufacture of the panels, is well known in the art for the manufacture of other molded articles, and therefore need no be set forth in great detail. A sheet of thermoplastic material, for example polystyrene, is placed on the convex exterior of a suitable male mold. The sheet is preferably quite thin, preferably about 0.070", although thickness up to about 0.100" are contemplated. The sheet is heated and draped across the male mold, and a vacuum is supplied to it inner side, between the sheet and the mold, to pull the heated sheet against the mold, after which the sheet is cooled to provide the desired rigid, ornamental panel, whic is self-sustaining, as opposed to a limp, flexible sheet of collapsible material, for example. After trimming and cleaning, it is secured as described above for the end and side panels. As mentioned above, included on the molds for the panels which are to cover the sides and ends of the casket box are portions which provide the overlapping end extensions such as 39, 40 on the finished end panels, and the right-angle bends such as 41 on the side panels.

As mentioned above, the bolts 32 and cap nuts 34 provide final permanent clamping of the panels to the caske box in the final product.

In this example there are two lid sections, a head-end lid section 11A and a foot-end lid section 11B, which may be mirror images of each other except that the interior of the foot-end lid need not be finished, since it is not normally opened for display. - 7 -

The inner side of the lid 11A, i.e. the side whic faces inwardly when the lid is closed, preferably receives rectangular frame 44, which is pressed into place in a corresponding recess in the lid, after which the usual fabric is fastened by adhesive and/or staples to the adjacent interior box.

As to the lids, each end comprises in addition to the frame 44 the fiberboard lid top 60 having pop-up sections 62, 64, 66, which are cut through along the solid lines but only weakened along the broken lines. To support the top panels such as 20A, these pop-up sections are bent upwardly so that their curved surfaces conform to and support the underside of the single-face corrugated reinforcement 68 glued to the underside of the lid cladding 20A. Small tabs such as 70 on each pop-up section are bent at right angles and glued to the reinforcement 68 to hold the pop-up section in place.

The bottom of the otherwise-complete casket box i preferably covered by the flat bottom panel 19, preferably of the same material as the rest of the cladding, and may b secured in place by a suitable adhesive or by thermal welding in the case of plastic panels.

In the manufacture of a metal-clad casket according to the invention, a stamping die may be made for each panel by conventional techniques, each die corresponding to the exterior of a portion of the fiberboar casket plus sections of the dies which are designed to produce the exterior, overlapping panel extensions describe above; using these dies, the metal panels are stamped out and thereafter secured to the exterior of the fiberboard box, as described above for the plastic panels.

The interior box need not be of corrugated fiberboard, but may constitute any of a large variety of materials so long as they provide a structurally sound box which is reasonably light in weight. Suitable inner box materials, in addition to corrugated fiberboard, include, but are not limited to, wood, particle board, styrofoam and - 8 -

other foamed plastic; when using the more frangible materials such as styrofoam, larger washers are appropriat under the nuts on the ends of the bolts which fasten the exterior covering to the interior box. There has thereby been provided a new type of casket which, while inexpensive and easy to make, still presents a very pleasing appearance.

While the invention has been described with particular reference to specific embodiments in the intere of complete definiteness, it will be understood that it ma be embodied in a variety of forms diverse from those specifically shown and described, without departing from t spirit and scope of the invention.

Claims

- 9 -WHAT IS CLAIMED IS:

1. A casket, comprising: an inner casket box having a lid, for holding a human body; and an external ornamental covering of self-sustainin panels, conforming to the exterior of said inner casket box and secured thereto.

2. The casket of claim 1, wherein said panels ar selected from the group consisting of plastic and metal.

3. The casket of claim 1,wherein said inner box is of a material from the group consisting of corrugated fiberboard, laminated paper, paper mache, wood, particle board, and foamed plastic.

4. A casket comprising: a structurally-sound casket box having a lid and made of corrugated fiberboard, for holding a human body; an an ornamental cladding made up of self-sustaining panels covering and conforming to the exterior of said casket box.

5. The casket of claim 4, wherein said panels cover at least the exterior sides and ends of said casket box, and the top of said lid thereof.

6. The casket of claim 5, wherein said panels also cover the bottom of said casket box.

7. The casket of claim 5, wherein said panels ar bolted in place.

8. The casket of claim 4 , wherein said panels comprise end panels and side panels having overlapping end portions to aid in mounting said panels on said box. - 10 -

9. The casket of claim 4, wherein said panels a made of a plastic selected from the group consisting of AB and polystyrene, and are from about 0.070 to about 0.100 inch in thickness.

10. The casket of claim 4, wherein said panels are of molded plastic material.

11. The casket of claim 4, wherein said panels a of metal.

12. The casket of claim 11, wherein said panels have a thickness of from about 0.010 to about 0.015 inch.

13. The method of making a casket having a lid, comprising: constructing a structurally-sound inner casket b with lid; constructing ornamental exterior panels for said casket box and lid to provide the ornamental configuration desired for the exterior of said casket; and securing each of said panels to the exterior of said casket box.

14. The method of claim 13, wherein said panels are molded of plastic material.

15. The method of claim 13, comprising also securing handles to the outside of said casket and panels.

16. The method of claim 14, wherein said molding comprises thermo-forming sheets of said plastic material on the surface of a vacuum mold to provide said desired ornamental exterior appearance. - 11 -

17. The method of claim 16, wherein said panels are of plastic material from about 0.070 to about 0.100 inc in thickness.

18. The method of claim 17, wherein said panels are about .070" in thickness.

19. The method of claim 14, wherein said plastic is selected from the group consisting of plastic material and metal material.

20. The method of claim 13, comprising also forming, on an end of each of at least some of said panels, an extension positioned to overlap and fit against the interior of an end of an adjacent one of said panels, to aid in holding said panels in their desired relative positions.

21. The method of claim 20, comprising applying cement to at least one of said panels to aid in holding them in position on said casket body.

22. The method of claim 13, comprising bolting said panels to said casket box.

23. A casket according to claim 1, wherein said lid comprises a frame fitting about the peripheral portions of said lid on the interior side thereof and over the edges of the part of said inner box which is in said lid.