Abstract:
A lightweight structurally sound casket formed preferably of a sandwich construction using a core of an open cell or honeycomb patterned material and fluid resistant surface elements. The casket is comprised of a body containment portion and a lid portion, each of which has the sandwich construction as the main structural element. The open cell material is structurally enhanced by being sandwiched between first and second stabilizing surface elements in both the body containment portion and the lid portion. In addition to the stabilizing surface elements, an aesthetically pleasing material is adhered to the outer portions of the body containment section and lid so that the casket has an attractive appearance. The body containment portion is constructed from rectangular pieces of the open cell material and stabilizing surface elements by folding the same into a box-like configuration. The lid portion is formed from placing the open cell material and the stabilizing surface elements into a jig, applying adhesive between the elements and finally, applying pressure thereto for adhering the elements together. As a final touch to the casket, ornamental features such as corner pieces and handles are added to the casket for aesthetic effects. The casket is environmentally safe for cremation and interment ceremonies and is economic and lightweight.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    This invention relates to caskets or coffins used to house the remains of once living organisms. More particularly, this invention is directed toward a lightweight yet structurally strong casket highly suitable for cremation-type and interment ceremonies. The casket exhibits excellent structural integrity while being highly flammable and minimally harmful to the environment.  
           [0002]    The riddance of the bodies of the deceased can be accomplished in several ways, including burial and cremation. Because of the growing concern for the world&#39;s environment, both of these methods have been highly scrutinized. Environmental problems include the overpopulation of cemeteries and the effects of placing a corpse into the ground. In addition, environmental concerns arise from cremation, which is done in part to alleviate the concerns regarding burial, wherein harmful volatile organic compounds (VOC&#39;s) are released to the atmosphere via the burning of environmentally unsafe materials which are often used to manufacture caskets or coffins.  
           [0003]    In response to the environmental concerns surrounding cremation and in response also to the ever-rising costs of coffins and/or caskets for burial, inexpensive, lightweight and environmentally safe caskets have been developed. Most of these caskets are constructed from corrugated cardboard or the like. Corrugated cardboard tends to absorb moisture and degrades structurally when it is exposed thereto. However, because of the inadequate structural integrity of corrugated cardboard caskets, such caskets tend to twist and bend thereby threatening the security of the corpse therein and risking the stability of the mental health of friends and relatives who may unwantingly witness an unscheduled viewing of the deceased should the casket fail.  
           [0004]    In the prior art, for example, the patent to Elder, U.S. Pat. No. 4,967,455 discloses a cardboard casket and a method of manufacturing the same. The patent discloses a corrugated cardboard casket constructed from multiple blanks of cardboard which are attached and folded to create the enclosure which forms the casket. However, as can be seen from the drawing and the text, only the use of corrugated cardboard is disclosed. Corrugated cardboard, which is currently and predominantly used in making lightweight caskets, inherently lacks structural integrity and, therefore, causes things made from it to also lack structural integrity. Therefore, the casket in Elder poses the risk of structural failure.  
           [0005]    For the morbid partygoer, U.S. Pat. No. 4,891,859 to Nutting, discloses a cardboard coffin for use at parties or similar occasions which is formed from a plurality of corrugated cardboard blanks. Again, the coffin is constructed by folding the corrugated cardboard into the shape of the casket or coffin. As with Elder, the use of the corrugated cardboard fails to provide the coffin with the necessary strength and structural rigidity of a more expensive coffin constructed from stronger materials.  
           [0006]    While the foregoing patents disclose the use of cardboard for constructing a more economical and environmentally safe casket, none of the prior patents discloses the use of polymer coated cellulose fiber (PCCF) or other material arranged in an open cell pattern or other patterns exhibiting similar high strength when constructed in accordance with this invention.  
         SUMMARY OF THE INVENTION  
         [0007]    The invention disclosed herein is directed toward an economical and environmentally safe casket having excellent structural integrity for maintaining the shape of the casket and for exhibiting low torsional displacement during the carrying of the deceased. These properties are exhibited even when the casket is exposed to a high moisture environment.  
           [0008]    In accordance with the invention, the lightweight casket comprises a body containment compartment and a lid constructed from a core section of polymer coated cellulose fiber (PCCF) arranged in an open cell pattern. The core section for both the lid and for the body containment portion is comprised of a first and a second surface, wherein each surface is attached to a stabilizing surface element thereby causing a sandwich-type effect. Additionally, the core of this sandwich could be made of a solid surface structural material such as polystyrene foam.  
           [0009]    The core section may be comprised of a plurality of honeycomb cells wherein each cell is substantially a cylindrically shaped tube. The stabilizing surface elements are surface-treated planar sheets glued or otherwise attached to the open cell patterned core of PCCF. The combination of the open cell pattern core and the sandwiching effect via the stabilizing surface elements, supplies the structural rigidity of the casket. The core material provides the shear force for carrying the sandwich construction while the stabilizing surface elements carry the bending forces of the sandwich. The core material having the open cells perpendicular to the stabilizing surface elements exhibit a much stronger and stiffer structural shear carrying member than a longitudinally aligned corrugated configuration.  
           [0010]    This invention also includes the method of constructing the lightweight casket. The open cell patterned core section is first cut into a rectangular pattern suitable in size for folding into the body containment section. A first stabilizing surface element is attached to the underside of the core section, and a second stabilizing surface element comprising a plurality of sections is similarly attached to the upper portion of the core section but arranged in a pattern allowing the folding of the core section into the body containment section. During bonding of the stabilizing surface elements thereto, the core acts as a pressure transfer mechanism to assure proper bonding. Upon folding, the walls and bottom of the body containment section are established and are adhered to each other for maintaining the enclosure-type structure. Finally, a lid is formed in a similar manner from a core section and stabilizing surface elements which are caused to form a dome-like shape via use of a jig and the application of air pressure.  
           [0011]    The casket disclosed is lightweight yet structurally rigid for supporting and carrying the contents placed therein. By using PCCF in lieu of more expensive materials, economic and environmental concerns are precluded while a very strong lightweight structure is established via the use of the open cell pattern and stabilizing surface elements. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    For the purpose of illustrating the invention, there is shown in the accompanying drawings one form which is presently preferred; it being understood that the invention is not intended to be limited to the precise arrangements and instrumentalities shown.  
         [0013]    [0013]FIG. 1 is a perspective view of a lightweight casket constructed in accordance with the principles of the present invention;  
         [0014]    [0014]FIG. 2 is a partial cross sectional view taken along line  2  of FIG. 1;  
         [0015]    [0015]FIG. 3 a  discloses the use of a polystyrene based, solid surface, core in lieu of the honeycomb, open cell structure, core;  
         [0016]    [0016]FIG. 3 is a perspective view of the honeycomb core and first stabilizing surface element;  
         [0017]    [0017]FIG. 4 is a perspective view of the honeycomb core attached to the first and second stabilizing surface elements;  
         [0018]    [0018]FIG. 5 is a view similar to FIG. 4 with the addition of a second layer of core section attached to the inner bottom surface of the casket;  
         [0019]    [0019]FIG. 6 Is a perspective view of the lightweight casket during the folding stage;  
         [0020]    [0020]FIG. 7 is a perspective exploded view of the casket showing the insertion of the end inserts;  
         [0021]    [0021]FIG. 8 is a perspective view of the body containment portion of the casket prior to the addition of aesthetic features;  
         [0022]    [0022]FIG. 9 is a cross sectional view taken along line  9 - 9  of FIG. 8;  
         [0023]    [0023]FIG. 10 is an exploded view of the method of construction of the casket lid using a jig;  
         [0024]    [0024]FIG. 11 is a perspective view of the casket lid and jig with the jig cover in the open position;  
         [0025]    [0025]FIG. 12 is a perspective view of the jig cover and air pressure connector, and  
         [0026]    [0026]FIG. 13 is a cross-sectional view taken along line  13 - 13  of FIG. 12. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0027]    Referring now to the drawings in detail wherein like reference numerals have been used throughout the various figures to designate like elements, there is shown in FIG. 1 a perspective view of the lightweight casket constructed in accordance with the principles of the present invention and designated generally as  10 . The casket  10  is comprised essentially of the body containment portion  12  and the lid section  14 . As shown in FIG. 2 for the body containment portion, it is comprised largely of the open cell core section  16 , preferably a honeycomb pattern, being sandwiched between a first stabilizing surface element  18  and a second stabilizing surface element  20 , both of which are formed from a fluid resistant material. The lid  14  is constructed in a similarly layered manner.  
         [0028]    The formation of the body containment portion  12  is accomplished in part as shown in FIG. 3. The honeycomb core  16  is cut to a substantially rectangular shape and of a size adapted to be folded into the casket. In forming the body containment portion  12 , the first stabilizing surface element  18  is placed underneath the honeycomb core  16 , while the second stabilizing surface element  20  is placed on top of the honeycomb core  16 , as shown in FIG. 4. The first stabilizing surface element  18  is substantially rectangular in shape and scored with fold lines, as shown in FIG. 3, as well as being cut in four places  24   a  through  24   d.  The first stabilizing surface element  18 , as shown, is larger in length than the core section  16 . The fold lines and the cuts  24   a  through  24   d  function to facilitate the folding of the honeycomb core with the stabilizing surface elements attached thereto into the enclosure as shown in FIGS. 6, 7 and  8 . The fold lines are not shown but are merely continuations of the cuts  24   a  through  24   d  as well as being perpendicular to those cuts adjacent the edge of the core section  16 .  
         [0029]    The honeycomb core  16  is preferably formed from polymer coated cellulose fiber (PCCF) sheets but environmentally safe plastic or the like will also suffice. The core is comprised of a plurality of longitudinally extending cylindrically shaped cells interconnected and forming a honeycomb pattern. Because of their cylindrical shape, the members have strong structural rigidity along their longitudinal axes.  
         [0030]    With the first stabilizing surface element  18  being scored and cut for folding, the honeycomb core  16  is adhered to the upper surface thereof utilizing any suitable adhesive. In addition, an aesthetically pleasing material  26  is adhered to the underside of the first stabilizing surface element  18  for incorporating a pleasing texture and appearance to the casket. The second stabilizing surface element  20  is similarly adhered to the honeycomb core. However, the stabilizing surface element  20  is comprised of a plurality of separate sections  28   a  through  28   c.  The sections  28   a  through  28   c  comprise three rectangularly-shaped planer sheets which are arranged upon the honeycomb core as shown in FIG. 4. As can be seen, the separate sections are of sizes which allow spaces between the sections leaving rectangular portions  30   a  and  30   b  of exposed honeycomb.  
         [0031]    In a second embodiment, these spaces of core material left between the stabilizing elements may be cut on a forty five degree angle from the stabilizing element edges to the middle of the space. These angled cuts help to facilitate the folding of the core material and stabilizing elements into the body containment section. In a third embodiment, the core material between the stabilizing elements is removed and inserts are placed in the spaces for additional support.  
         [0032]    The purpose of the sandwiching effect of the honeycomb core between the two stabilizing sections is to provide the honeycomb core with structural rigidity by maintaining the cells of the core in a substantially perpendicular orientation to applied forces. The core acts as a pressure transfer mechanism and transfers the load to the outer stabilizing surface element  18  when a force is applied thereto. By leaving uncovered the exposed honeycomb core sections  30   a  and  30   b,  as provided for by the separate sections, the exposed honeycomb lacks the structural rigidity of the sandwiched honeycomb core. These exposed and, therefore, weaker sections of honeycomb inherently create fold lines on the core surface.  
         [0033]    In addition to the core  16 , an additional layer  32  of core, as shown in FIG. 5, is glued to the structure over the center portion  28   b  of the second stabilizing surface element  20 . The additional core  32  is of substantially the same size as the center portion  28   b  and in addition has a third stabilizing surface element  34  glued to the top thereof. The additional honeycomb core and stabilizing surface further strengthens and increases the structural rigidity of the casket bottom and provides extra structural security.  
         [0034]    Referring now to FIGS. 5 and 6, the lightweight casket is now ready for formation into the body containment portion  12 . To initiate this process, the sides of the casket  36   a  and  36   b  are folded upward along the fold lines (not shown), cut lines  24   a  through  24   d  and the rectangular and exposed honeycomb sections  30   a  and  30   b.  By following this procedure, the formation shown in FIG. 6 is the result. Upon folding the sides  36   a  and  36   b,  the corners  38   a  through  38   d  must be folded inward towards the center of the body containment portion  12 . As shown in FIG. 6, the corners  38   a  through  38   d  become part of the ends of the body container portion  12 . However, the ends are further completed by folding upward the end extensions  40   a  and  40   b  toward the folded corners  38   a  through  38   d.  Before folding the extensions  40   a  and  40   b,  adhesive is applied on the contact surfaces thereof for adherence to the outside surfaces of the folded corners  38   a  through  38   d.  This provides a double shear path and increases the strength of the enclosure.  
         [0035]    Referring now to FIG. 7, the body containment portion is ready for insert of the end inserts  42   a  and  42   b.  Each end insert is comprised of the rectangular portion of honeycomb material having a stabilizing surface element  44  adhered thereto. The stabilizing surface elements  44   a  and  44   b  are adhered to the surface of the end inserts  42   a  and  42   b  facing the inner portion of the body containment portion  12  wherein the end extensions  40   a  and  40   b  act as the other stabilizers for the inserts  42   a  and  42   b,  respectively. Accordingly, the end inserts are inserted adjacent each end of the body containment portion. The side of each end insert having no stabilizing surface element adhered thereto is placed adjacent and adhered to the inner surfaces of the folded corners  38   a  through  38   d,  the end insert  42   a  being adhered to folded corners  38   a  and  38   d,  and end insert  42   b  being adhered to folded corners  38   b  and  38   c.  At this point in the construction process, the lightweight casket resembles the configuration shown in FIG. 8 wherein the body containment portion  12  is fully constructed.  
         [0036]    The lid of the lightweight casket is fabricated as shown in FIGS.  10 - 13 . Similar to the body containment portion, the lid  14  is formed by placing a lid core section comprised of a honeycomb portion  46  between two lid stabilizing surface elements  48   a  and  48   b  as shown in FIG. 10. Due to the curved shape of the lid, the construction of it requires a somewhat different process than the construction of the body containment portion  12 . The preferred method of constructing the lid  14  is to construct a jig  50  having an outer portion resembling the shape of the lid  14 . The jig  50  is used to construct the lid  14  in a step-like manner which includes the application of a pressure source  52 .  
         [0037]    As shown in FIG. 10, the jig  50  has an outer section  51  which is substantially in the shape of the lid  14  shown in FIG. 1. To initiate the lid construction process, the first stabilizing surface element  48   a  is placed into the jig  50 . As shown in FIG. 10, the first stabilizing surface element is constructed from one to three separate elements, a center element and two triangularly-shaped end elements. These elements are placed into jig  50 . Each of the elements has an edge  54  formed into a rectangular shape and adapted to receive perimeter stabilizing bars  56   a  through  56   d.  The perimeter stabilizing bars  56   a  through  56   d  form the portion of the lid which contacts the body containment portion  12 . It is important that the edges which contact the body containment portion  12  have structural rigidity as well as the lid itself. Therefore, the perimeter bars  56   a  through  56   d  are placed into the folded edges  54   a - 54   d  and secured therein by adhering the edges  54   a - 54   d  thereto.  
         [0038]    Referring still to FIG. 10, the honeycomb portion  46 , similar to that used with the body containment portion, is now placed into the jig  50  and over the first stabilizing surface element  48   a.  Prior to the insert of the honeycomb  46 , adhesive is spread over the first stabilizing surface element  48   a  for causing the honeycomb portion  46  to adhere thereto. The honeycomb portion  46  is a substantially rectangular piece of material which is cut to a size which conforms to the lid shape and still contacts the entire surface of the entire first stabilizing surface element. It is not necessary to cut or provide fold lines in the honeycomb portion  46  in any manner due to the flexibility of the same in conforming to the general shape of the lid  14 .  
         [0039]    With the honeycomb portion  46  inserted therein, the second stabilizing surface element  48   b  is placed over the top of the inserted honeycomb portion  46 . The second stabilizing surface element  48   b  is rectangular but is comprised of an odd shaped section  58  having triangularly shaped but integral end sections  59   a  and  59   b  and having angular fold cuts as shown in FIG. 10. These sections  58  and  59   a  and  59   b  are placed on the honeycomb portion  46  as shown in FIG. 11 and conform to the jig  50 . Prior to placement onto the honeycomb portion  46 , adhesive is applied to the side of the sections which will contact the honeycomb portion  46 . With all the elements in place, a pressure source  52  is applied to the integrated sections.  
         [0040]    As shown in FIG. 11 and  12 , a flexible cover  60  is hinged to and extends from the edges of the jig  50  via a hinged door  61  and is placed over the integrated elements just discussed, forming an air tight seal. The pressure source connector  62  extends from the flexible portion  60  so as to connect the pressure source  52  thereto. Accordingly, the pressure source  52  is connected to the connector  62  and pressure is applied to the lid  16 . The pressure thereby forces the integrated sections together for adhering those which are contacting each other and forcing them into the shape of the jig  50 . In addition, an aesthetically pleasing layer  64  is applied to the lid  16  for matching the body containment portion  12 . When the air is removed and the sections are adhered together, the jig is disassembled and the lid can be removed, resembling the configuration shown in FIG. 1.  
         [0041]    The lid can also be formed in separate halves which is desirable for viewing purposes. The formation of the lid into two separate halves is performed essentially the same as just described except that each half is constructed separately in the jig such that finished edges are formed all around.  
         [0042]    For both the body containment portion  12  and the lid  14 , materials and patterns other than PCCF arranged in a honeycomb pattern can be used. As shown in FIG. 3 a,  for example, an environmentally safe polystyrene-type material  65  can be used in lieu of the honeycomb material where it is placed between two stabilizing surface elements. Polystyrene foam placed between similar stabilizing surface elements exhibits substantially the same structural rigidity as the honeycomb portions and can be used interchangeably. Additionally, PCCF and other materials can be formed into truss patterns which also exhibit high structural rigidity when sandwiched between the stabilizing surface elements.  
         [0043]    Upon completion of the body containment portion  12  and the lid  14  as substantially described, the lightweight casket is finished by attaching ornamental elements thereto which gives the casket a richer appearance. As shown in FIG. 1, preformed corner pieces  66   a  through  66   d  are placed onto the corners of the lightweight casket  10 . In addition to appearance, the corners  66   a - 66   d  provide extra strength in the body containment portion  12 . The corners  66   a  through  66   d  are comprised substantially of two triangularly-shaped elements attached perpendicularly to each other. The corners are covered with the same aesthetically pleasing material as the rest of the lightweight casket exhibits. The corners  66   a  through  66   d  are simply glued to the body containment compartment corners as shown in FIG. 1. In addition to the corners, handles  68  are securely attached to each side of the lightweight casket for the carrying of the same. The inner portion of the lightweight casket in its finished condition is also designed in an aesthetically pleasing manner having linings and pillows.  
         [0044]    The lightweight casket is used in a manner similar to any other casket. Because of the structural rigidity providing by the sandwiching of either the open cell or solid surface core materials, there are no special precautions which must be considered in handling the lightweight casket  10 . The body is simply placed in the casket as with any other casket and it can be carried similar to any other casket. For cremation purposes, the casket is highly flammable and, as discussed, is not harmful to the environment and can simply be placed into the furnace without alteration.  
         [0045]    The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and accordingly reference should be made to the appended claims rather than to the foregoing specification as indicating the scope of the invention.