Abstract:
A casket includes a lid and a container. The container is configured to receive the lid in a first configuration for shipping, and in a second configuration for funereal purposes. In general, the lid in the first configuration is detached and inverted with respect to the second configuration, particularly when the lid is closed in the second configuration.

Description:
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/186,941, filed Jun. 15, 2009, which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to caskets. 
     BACKGROUND OF THE INVENTION 
     Caskets can be employed for both display and interment of a deceased. Because of the display aspect, a casket must convey dignity and respect for the deceased. To accomplish the foregoing, it is known to manufacture caskets from hardwoods and metal materials, and providing them with decorative features. However, the cost of such caskets can be beyond the reach of many. 
     Accordingly, caskets formed of corrugated paperboard and/or manufactured wood products have been developed. Such products can be manufactured at a much lower cost than the hardwood and metal caskets. However, significant costs remain in both material and shipment of caskets made from lower cost materials. 
     SUMMARY OF THE INVENTION 
     Embodiments of caskets disclosed herein include several features that can lower the cost of manufacture and/or shipment of the casket. It will be appreciated that savings can be obtained even if less than all of the novel features disclosed herein are employed. 
     In general, an embodiment of a casket includes a lid and a container. The container is configured to receive the lid in a first configuration for shipping, and in a second configuration for funereal purposes. In general, the lid in the first configuration is detached and inverted with respect to the second configuration, particularly when the lid is closed in the second configuration. 
     Other inventive aspects of the embodiments disclosed herein include a latch system for a removable and invertible lid for a casket, a body construction for a lightweight casket, a lid construction for a lightweight casket, and a decorative bridge/cover for inner edge of a partial lid of a casket. Other features and advantages will become more readily apparent to those of ordinary skill in the art by reference to the following detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a perspective view of an exemplary casket that incorporates multiple features; 
         FIG. 2  shows a cutaway view of a first lid of the casket of  FIG. 1 ; 
         FIG. 3  shows a plan view of the lid of  FIG. 2 ; 
         FIG. 4  shows a plan view of exemplary modular components of a bridge assembly for a casket according to embodiments of the invention; 
         FIG. 5   a  shows a perspective view of a modular component of the bridge assembly of  FIG. 4 ; 
         FIG. 5   b  shows a perspective view of another modular component of the bridge assembly of  FIG. 4 ; 
         FIG. 6  shows a perspective view of the box structure of the casket of  FIG. 1 ; 
         FIG. 7  shows a fragmentary cutaway view of an exemplary embodiment of the casket of  FIG. 1 ; 
         FIG. 8   a  shows a plan view of the casket of  FIG. 1  readied for placement into a shipping configuration; 
         FIG. 8   b  shows a plan view of the casket of  FIG. 1  configured for end use; 
         FIGS. 9   a  and  9   b  show different views of an exemplary embodiment of a clip for use with the casket of  FIG. 1 ; 
         FIG. 10  shows a fragmentary cutaway view of a portion of the casket of  FIG. 1  with the clip of  FIG. 9   a  assembled thereon; and 
         FIG. 11  shows a fragmentary cutaway view of a portion of the casket of  FIGS. 1 and 8   b.    
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  shows a perspective view of an exemplary casket  100  that incorporates multiple inventive features. The casket  100  includes a body assembly  102  and first and second lid portions  104  and  106 , respectively. As shown in  FIG. 1 , the body assembly  102  includes a box structure  110  and a handle assembly  112 . The body assembly  102  further includes interior features not shown in  FIG. 1 . Further detail regarding such features, including side supports  610 ,  612 , is provided below in connection with  FIGS. 6 and 7 . 
     In  FIG. 1 , the first lid portion  104  is partly removed to show some of the underlying features thereof. It will be appreciated that the first lid portion  104  and the second lid portion  106  may be essentially identical in construction, although the lengths of the first and second lid portions  104 ,  106  may differ from each other as a matter of preference. 
     The box structure  110  includes a first side wall  114 , a second opposite side wall  116 , a first end wall  118 , a second opposite end wall  120 , and a bottom panel, not shown in  FIG. 1 . (See, e.g. bottom panel  119  of  FIG. 6 ). The first side wall  114  and the second side wall  116  have elongated sides compared to the end walls  118 ,  120 , thereby defining a substantially rectangular box. The bottom panel  119  ( FIG. 6 ) intersects with both side walls  114  and end walls  116  to form the open-topped box structure  110 . The side walls  114 ,  116  and end walls  118 ,  120  are preferably formed from at least two layers of kraft paper or corrugated paper. The bottom panel  119  is similarly formed at least in part by kraft or corrugated paper. However, the bottom panel may also include a plywood or particle board reinforcement. Further detail regarding an exemplary embodiment of the side wall  114  and the bottom panel  119  are shown in cross-section in  FIG. 7 . 
     The handle assembly  112  that includes a bar  142  and a plurality of rotatable hinge assemblies  144 . In general, the handle assembly  112  is configured such that the bar  142  can rotate partly upward and outward to facilitate carrying of the casket  100 . Further detail regarding the handle assembly  112  is provided below in connection with  FIG. 7 . 
     Similarly, the first and second lid portions  104 ,  106  are formed by multilayer corrugated paper having appropriate bends to provide the contoured shape shown in  FIG. 1 . The contoured shape allows for an aesthetically pleasing shape, and also allows for the shipping of the lid portion  104  and  106  in inverted position for shipment without interfering with reinforcement structures such as the side supports  610 ,  612 .  FIGS. 8   a  and  8   b , discussed further below, illustrate how the lid portions  104  and  106  may be inverted for shipment. 
     In this embodiment of the contoured lid shape, the first lid portion  104  includes two inclined side portions  122 ,  124 , a top portion  125 , an inclined end portion  126 , and an inward edge  128 . The two inclined side portions  122 ,  124  and the inclined end portion  126  extend inward and upward generally from respective the edges to the top portion  125 , forming part of a truncated pyramid structure, thereby defining the contoured shape. 
     In particular, as shown in  FIG. 2 , the inclined side portion  122  includes a top incline surface  202 , and a bottom incline surface  204 . In this embodiment the bottom incline surface  204  is slightly longer and extends in a slightly less inclined angle than the top inclined surface  202 . As a consequence, the inclined side portion  122  gets slightly thicker as it progress upward toward the top portion  125 . The other inclined side portion  124  has a similar structure, having a corresponding top incline surface  203  and a corresponding bottom incline surface  205 . 
     To achieve a cost-effective and sturdy lid having the desired shape, the exemplary construction of the first lid portion  104  shown in cross-section in  FIG. 2  may be advantageously employed. The first lid portion  104  first and second interior layers  208 ,  210 , respectively, that generally form the “backbone” of the top panel  128 . The layer  208 ,  210  may suitably be formed of corrugated paper. Positioned below the second interior layer  210  is a shaping piece  212 , formed of a single piece of corrugated paper folded into sections, including the sections  212   a - 212   e  discussed below. Another shaping piece  218  is disposed in part above the first interior layer  208 . Similar to the shaping piece  212 , the shaping piece  218  is a single piece of corrugated paper folded into sections, discussed further below. 
     In particular, the shaping piece includes a central section  212   a  that extends adjacent to, and just short of the ends of, the second interior layer  210 . The shaping piece  212  also includes a first inclined portion  212   b  that extends at first angle from horizontal from near one end of the second interior layer  210  to a first corner area  214 . The shaping piece  212  includes a vertical piece  212   c  that extends from the first corner area  214  to a second corner area  216 . Extending from the end of the vertical piece  212   c  is second inclined portion  212   d  that extends at a second angle from the horizontal, less than the first angle, to a point adjacent the central section  212   a  that is inward of, but close to, the end of the central section  212   a  at which the first inclined portion  212   b  begins. Extending from the resulting end of the second inclined portion  212   d  is a short horizontal run  212   e  that extends adjacent to and below a portion of the central section  212   a . In this structure, it can be seen that the second inclined portion  212   d  defines the shape of the bottom incline side surface  205  of the inclined side portion  124  of the first lid  104 . 
     The shaping piece  212  further includes symmetrical structures to the structures  212   b - 212   e  on the opposing side forming the other incline portion  122  of the first lid. Such structures have a substantially identical, but minor image construction as that of the structures  212   b - 212   e . These structures similarly define the bottom incline surface  204  of the other incline side portion  122  of the first lid  104 . 
     The upper shaping piece  218  includes a central section  218   a  that extends adjacent to, and substantially coextensively with, the first interior layer  208 . The shaping piece  218  also includes a first inclined portion  218   b  that extends at a third angle from horizontal from the end of the first interior layer  210  to the first corner area  214 . The third angle is greater than both the first and second angles of inclination of sections  212   b  and  212   d . The shaping piece  218  includes a vertical piece  218   c  that extends from the first corner area  214  to the second corner area  216 . The vertical piece  218   c  runs coextensively with and adjacent to the vertical piece  212   c  of the other shaping piece  212 . Extending from the end of the vertical piece  218   c  is second inclined portion  218   d  that extends at a second angle from the horizontal, and adjacent to the second inclined portion  212   d  of the shaping piece  212 . The second inclined portion  218   d  only extends less than half of the overall extent of the second inclined portion  212   d , and then terminates. In this structure, it can be seen that the first inclined portion  218   b  defines the shape of the top incline side surface  203  of the inclined side portion  124  of the first lid  104 . 
     The shaping piece  218  further includes symmetrical structures to the structures  218   b - 218   d  on the opposing side forming the other incline portion  122  of the first lid  104 . Such structures have a substantially identical, but minor image construction as that of the structures  218   b - 218   d . These structures similarly define the top incline surface  202  of the other incline side portion  122  of the first lid  104 . 
     It can thus be appreciated that that the shaping pieces  212  and  218  effectively define the shape of the first lid  104 , with the exception of the end inclined portion  126 . The end inclined portion  126  may suitably be formed with similar structures as those of the inclined portions  122  and  124 . In such a case, the first and second interior layers  208  and  212  may be formed to have ends that fold similar to the shaping pieces  212  and  218 . These folded ends, not shown, create shaping pieces for the end inclined portion  126 , similar to pieces  212  and  218 . 
     The first lid  104  also includes a first fabric wrap  224  that covers, is adjacent to, and extends substantially completely around the upper surface of the support structure  218 . A second, thinner fabric piece  226  covers otherwise uncovered portions of the lower support structure  212  such that the fabric  224 ,  226  cooperate to extend around the entire cross section of the first lid  104  as shown in  FIG. 2 . 
     Referring again to  FIG. 1 , the inward edge  128  of the first lid  104 , which has a planar face, includes a bridge assembly  130 . The bridge assembly  130  extends over exposed edges of the corrugated paper that form the pieces  208 ,  210 ,  212  and  218  of the first lid  104 . While the other edges are covered by the fabric  224  and  226 , the inward edge  128  of the first lid  104  is covered by the bridge assembly  130 . The corresponding inward edge of the second lid  106  is covered by a similar assembly. 
       FIG. 3  shows an end plan view of the first lid  104  facing the inward edge  128 , which shows the bridge assembly  130  in further detail. In general, the cover assembly is configured to adapt to the cutaway profile of the first lid  104 , as illustrated in  FIG. 2 . Such a configuration both adequately covers the exposed edges of the paper (or other material) pieces  208 ,  210 ,  212  and  218  without compromising the vertical clearance available for the midsection of the deceased. 
     Accordingly, the bridge assembly  130  includes, analogous to the first lid  104  itself, a first inclined portion  322 , a second inclined portion  324  and a top portion  325 . The first inclined portion  322  includes an upper inclined edge  326  and a lower inclined edge  328 . The upper incline edge  326  has a greater angle of inclination from the horizontal dimension of the top portion  325 . A short vertical edge  330  defines the outer horizontal edge of the bridge assembly  130  and extends from the end of the upper inclined edge  326  to the end of the lower inclined edge  328 . The second inclined portion  324  includes an upper inclined edge  332  and a lower inclined edge  334 . As with the edges  326 ,  328 , the upper incline edge  332  has a greater angle of inclination from the horizontal than does the lower inclined edge  334 . A short vertical edge  336  defines the outer horizontal edge of the bridge assembly  130  and extends from the end of the upper inclined edge  332  to the end of the lower inclined edge  334 . 
     The top portion  325  of the bridge assembly  130  includes an upper edge  337  and a lower edge  338 , each of which extend between the respective upper and interior ends of the inclined portions  322  and  324 . In this embodiment, the edges  337 ,  338  are horizontal. However, it will be appreciated that other shapes may be used, so long as the edges of the structural pieces (e.g. corrugated pieces  208 ,  210  etc. in the embodiment of  FIG. 2 ) are covered. 
     In the embodiment described herein, the bridge assembly  130  includes the additional feature of having a modular construction. For example, in  FIG. 3 , the modular cover assembly includes two end pieces  340 ,  342  and a center piece  344  that may be assembled in to the structure of the bridge assembly  130  shown in  FIG. 3 . The end piece  340  includes the first inclined portion  322  and a small horizontal end extension  360  that forms a part of the top portion  325 . Similarly, the end piece  340  includes the second inclined portion  324  and a small horizontal end extension  362  that forms an opposite end of the top portion  325 . The center piece  344  defines a central portion of the top portion  325 , and is configured to connect or meet with the end extensions  360 ,  362 . 
     The modular construction of the bridge assembly  130  facilitates molding, and in addition, the use of multiple casket widths. In particular, it is sometimes advantageous to provide caskets of different widths to accommodate deceased of different sizes. In the embodiment described here, the bridge assembly  130  is configured such that the center piece  344  may be replaced by a similar center piece of different length to accommodate different casket widths. Referring to  FIG. 4 , the pieces  340 ,  342  and  344  are shown in disassembled fashion, along with two alternative center pieces  346  and  348 . The center pieces  344 ,  346  and  348  have different lengths. When a casket is constructed, a suitable one of the center pieces  344 ,  346  and  348  is chosen and connected to the end pieces  340 ,  342  to form the bridge assembly  130 . The resulting bridge assembly  130  is then attached to the end of the corresponding lid (e.g. lid  104 ) using adhesive. 
     To construct the assembly  130 , each of the center pieces  344 ,  346  and  348  includes opposing end tabs  350   a ,  350   b  that are configured to be received into suitable receptacles in the respective extensions  360 ,  362  of the end pieces  340 ,  342 . In particular,  FIGS. 5   a  and  5   b  show, respectively, a fragmentary perspective view of the outer surface  502  of the center piece  344  and a fragmentary perspective view of the underside  504  of the end piece  340 . Both the center piece  344  and the end piece have a generally C-shaped cross-section. The tab  350   a  also has a C-shaped cross section, but also has a slightly reduced outer surface size as compared to the remainder the center piece  344 . Conversely, an end section forming a socket or receptacle  506  of the end piece  340  has a cutout portion on the inside, such that the inner surface of the receptacle  506  is slightly larger than the inner surface of the remainder of the interior of the end piece  504 . In addition, the receptacle  506  is sized to receive the tab  350   a  in a friction fit. Due to the reduced nature of the outer surface of the tab  350   a , the outer surface  502  of the center piece  344  is substantially flush with the corresponding outer surface of the end piece  340  when the tab  350   a  is inserted into the receptacle  506 . 
     It will be appreciated that the other end piece  342  and the other center pieces  346  and  348  have corresponding structures for assembly into corresponding finished bridges. One of the advantages of the modular nature of the bridge assembly  130  is the reduced inconvenience that otherwise would result from stocking and molding the entire integral bridge assembly  130  in three sizes. The modular design provides convenience in that it is more cost effective to mold and stock three different sizes of center pieces  344 ,  346  and  348  as opposed to three different sizes of entire integral bridge assemblies. It will be readily apparent that more or fewer sizes of center pieces may be employed. 
     Another feature in the exemplary casket  100  is the main body structure.  FIG. 6  shows a perspective view of the structure of the body structure  102  apart from the lids  104 ,  106 . As discussed further above, the body structure  102  includes a box  110  having two elongate side walls  114 ,  116 , two end walls  118 ,  120  and a bottom wall  119 . As also shown in  FIG. 6 , the body structure  102  includes a pair of side supports  610 ,  612  formed preferably of folded-over corrugated paper. Each of the side supports  610 ,  612  is preferably in the form of a triangular tube having a length that extends along substantially the entire interior length of a corresponding side wall  114 ,  116 . Each tube  610  has a height that is approximate one-half of the height of the side walls  114 ,  116 , and a similar width. As such, side supports  610 ,  612  form a sort of fillet that provides support to the overall structure and facilitates the movement of interior elements of the handle assembly  112 , not shown in  FIG. 6 . 
       FIG. 7  shows a cross section of a fragmentary portion of the sidewall  114 , the side support  610 , the handle assembly  112 , and the bottom wall  119  as illustrated in  FIG. 1  (although the bottom wall  119  is not visible in  FIG. 1 ). As shown in  FIG. 7 , the side wall  114  includes multiple layers of corrugated paperboard. The three layers  614 ,  616  and  618  form the outermost layers of both the side wall  114  and the bottom wall  119  (and the opposing side wall  116 , not shown in  FIG. 7 ). The top two layers  620 ,  622  of the bottom wall  119  may also be folded at the ends to form, at least in part, the end walls  118  and  120 , also not shown in  FIG. 7 . 
     In the particular orthogonal slice shown in  FIG. 7 , parts of the layers  614 ,  616 ,  618 ,  620  and  622  have been removed to form voids (e.g. void  638 ) to accommodate interior portions of the handle assembly  112 . In other orthogonal slices, where the handle hinge assembly  144  is not present, the layers  614 ,  616  and  618  will extend continuously down the side wall  114  and across the bottom panel  119 . 
     In any event, it will be appreciated that additional layers exclusive to the side wall  114  and/or bottom panel  119  may be employed. 
     As shown in  FIG. 7 , the side support  610  is formed a single piece of folded corrugated folded three times at fold points  630 ,  632  and  634  to form a triangular cross section with one overlapping leg  636 . The bottom of the side support  610  rests on the panel  119 , and thereby forms a top wall of the void  638  formed by the cutouts in the layers  614 ,  616 ,  618 ,  620  and  622 . 
     The hinge assembly  144  includes an arm  650  having a handle receptacle  652 , a hinge portion  654 , first anchor assembly  656 , a sliding arm  658  and second anchor assembly  660 . The general construction and operation of the first anchor assembly  656 , the second anchor assembly  660 , the hinge portion  654  and the sliding arm  658  is described in detail in U.S. patent application Ser. No. 12/383,121, which is incorporated herein by reference. In particular, FIGS. 17 and 18 of U.S. patent application Ser. No. 12/383,121 show a similar construction, with the main difference being the arm  650  (and handle receptacle  652 ) of the instant  FIG. 7 , which is integrally formed with the first anchor assembly  656 , the hinge portion  654 , the sliding arm  658  and the second anchor assembly  660 . Another difference is the hinge portion  654 , which includes an outward facing C-shaped structure  660  that accommodates upward rotational movement of the arm  650 . Otherwise, the construction and theory of operation of the hinge assembly  144  would be readily apparent from the above description,  FIG. 7  and the application Ser. No. 12/383,121. 
     One of the features of at least some embodiments of the invention is that empty caskets  100  may be shipped in a second configuration that is not used when a deceased is disposed within the casket. In particular, for shipment the lids  104 ,  106  may be inverted and place substantially entirely or at least mostly within the interior of the box  110 , oro in other words, mostly below the highest level of the side walls  114 ,  116  and end walls  118 ,  120 .  FIG. 8   a  shows the lids  104 ,  106  inverted and aligned to be placed downward into the interior of the body structure  102 . Shipment in this configuration is cost-effective because the space consumed by the casket  110  during shipment is reduced. 
     To accommodate the inverted lids  104 ,  106  within the body structure  102 , the width of each lid  104 ,  106 , from side to side, must be slightly less than the interior distance between the side walls  114  and  116 . Similarly, the combined lengths of the lids  104 ,  106  must slightly less than the interior distance between the end walls  118 ,  120 . With such dimensions, the lids  104 ,  106  of  FIG. 8   a  may be lowered into the interior of the body structure  102 . Moreover, the angled nature of the side supports  160 ,  162  (see  FIGS. 6 ,  7 ) accommodates the inclined portions  122 ,  124  of the lid  104  (see  FIGS. 1 ,  2 ) and corresponding inclined portions of the lid  106 . 
     When the casket  100  is used to house a deceased, the lids  104  and  106  are configured in the first configuration, shown in  FIG. 8   b . In the first configuration, the lids  104  and  106  are placed in the upright position over the body structure  102 . 
     It can therefore be seen that the combination of the shape of the lids  104 ,  106 , the size of the lids  104 ,  106  and the height of the body structure  102  allow for more cost effective shipping of a casket that also has an attractive, aesthetically pleasing appearance when used. 
     Referring to  FIGS. 1 and 8   b . The casket  100  further includes a plurality of clips  148  that are configured to secure the lids  104 ,  106  in the upright position shown in  FIG. 8   b . In particular, because the lids  104 ,  106  are sized to fit within the interior of the body structure  102  in the shipping configuration, the clips  148  are necessary to hold the lids  104 ,  106  from advancing significantly into the interior of the body  102 . Specifically, the clips  148  are configured to hold the lids  104 ,  106  in a predetermined position with respect to the body structure  102 . 
       FIGS. 9   a  and  9   b  show different views of an exemplary clip  148  that may be employed. The clip  148  includes a casket seating structure  902  and a lid retaining structure  904 . The casket seating structure  902  includes an inverted U-shaped plastic element designed to fit over the top of either of the sidewalls  114 ,  116 . The lid retaining structure  904  includes an upright U-shaped element configured to receive a portion of the lid  104  (or  106 ), and is integrally formed with the casket seating structure  902 . 
     In further detail, The U-shaped element of the casket seating structure  902  includes a main arm  906 , a top  908  extending in a perpendicular fashion from the top of the main arm  906 , and a retainer  910  extending downward from the top  908  in a manner that is substantially parallel to and spaced apart from the main arm  906 . The lid retaining structure  904  includes an arm  912  that extends in a perpendicular manner from a location between the ends of the main arm  906 , and in a direction opposite that from which the top  908  extends. The lid retaining structure  904  includes an upright  914  that extends upward from the arm  912  in a manner that is substantially parallel to and spaced apart from the main arm  906 . The lid retaining structure  904  further includes a small barb that extends from the end of the upright  914  back toward the main arm  906 . The clip  148  may further include a support rib  916  that extends from the bottom of the main arm  906  outward an upward to the at least the arm  912   
       FIG. 10  illustrates how the casket seating structure  902  of the clip  148  of  FIGS. 9   a  and  9   b  is inserted onto the side wall  114  of the casket body structure  102 .  FIG. 11  shows how the lid  104  is inserted into the lid retaining structure  904  of the clip  148 . It is noted that the lower  212  preferably includes a cutout  920  for receiving the barb  915  of the clip  148  to hold the lid  104  in place. 
     It will be appreciate that the above-described embodiments are merely illustrative, and that those of ordinary skill in the art may readily devise their own modifications and implementations that incorporate the principles of the present invention and fall within the spirit and scope thereof. For example, it will be appreciated that the bridge assembly  130  may employ a different connection scheme between the modular components than that shown in  FIGS. 4 ,  5   a ,  5   b . In another example, the contour of the lids  104 ,  106  may vary to have different designs. Preferably, however, such alternative lids would have a shape that ascends in some manner from the edges near the side walls  114 ,  116  toward the middle, thereby providing clearance for the deceased while nevertheless accommodating some form of the side supports  160 ,  162  when such lids are inverted and stowed within the casket. 
     It will further be appreciated that at least some of the advantages of the embodiments described herein may be obtained in alternative embodiments that do not have others of the advantageous features. For example, a casket with a single lid design may not require the bridge assembly  130 , but may incorporate any of the other features such as the side supports, general lid design, and nesting features. Similarly, a non-nesting lid having two separate lid portions may still obtain the advantages of a modular bridge. Any casket using a handle may enjoy the advantages of the side supports, which serve to allow movement of handle elements without interference with the remains in the body  102 . Such side supports also provide structural support to the casket and postural support to the deceased for viewing. 
     Accordingly, multiple independent features are disclosed herein. In many cases, synergistic combinations of features aid in facilitating a casket that is cost-effective, light weight, strong, and efficient for shipping.