Lightweight casket lid and casket lid assembly

A casket lid includes a lid body and a bridge formed from a folded corrugated paper blank. The lid body extends partially over a casket body configured to receive a human body in supine position, the lid body having a first side configured to extend along a portion of a first casket body side, a second side configured to extend along a portion of a second casket body side, a first end configured to extend along a first casket body end, and an open end. Edges of at least two of the first side, second side, and first end define a lid body bottom plane. The bridge extends downward from the lid body near or at the open end, and defines a concave opening extending above the lid body bottom plane.

FIELD OF THE INVENTION

The present invention relates to caskets.

BACKGROUND OF THE INVENTION

Caskets can be employed for display, interment and cremation of a deceased. Because of the display aspect, a casket ideally conveys 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, and can be aesthetically pleasing. However, significant costs remain in both material and shipment of caskets made from lower cost materials.

To address such concerns, prior developments have resulted in corrugated caskets that include lids that can nested into the casket body for shipment. U.S. Pat. No. 8,595,908 discloses, among other things. a casket assembly that employs a domed casket lid, formed of corrugated cardboard, that may be inverted and shipped within the casket body to reduce shipment volume.

There is nevertheless always a need to further reduce costs, for example, in material, assembly and/or shipping costs.

SUMMARY OF THE INVENTION

The embodiments described herein address at least some of the above-stated needs, as well as others, by providing a lightweight casket lid that has employs a paper bridge formed from a folded corrugated paper blank.

DETAILED DESCRIPTION

FIG.1shows a perspective view of an exemplary casket100that incorporates inventive features. The casket100includes a body assembly102and first and second lids104and106, respectively. As shown inFIG.1, the body assembly102in this embodiment includes a casket body110and a handle assembly112. The body assembly102further includes interior features not shown inFIG.1.

InFIG.1, the first lid104is removed to reveal a portion of the interior111of the casket body110. It will be appreciated that the first lid104and the second lid106may be essentially identical in construction. In some cases, the first lid104and second lid106can be essentially identical in construction except for their respective lengths, which may differ from each other as a matter of preference.FIG.2shows a side plan view of the casket100with both the first lid104and the second lid106in the closed position.

With reference toFIGS.1and2, the casket body110includes a first side wall114, a second opposite side wall116, a first end wall118, a second opposite end wall120, and a bottom panel. The bottom panel is not shown inFIG.1, but is generally located at the bottom of casket body110. The first side wall114and the second side wall116have elongated sides compared to the end walls118,120, such that the side walls114,116and end walls118,120define, respectively the sides and ends of a substantially rectangular box. The bottom panel extends between and intersects with both side walls114and end walls116to form the open-topped box structure110. The side walls114,116and end walls118,120are preferably formed from at least two layers of kraft paper or corrugated paper, but could have other construction. The bottom panel 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.

The first side wall114, the second side wall116, the first end wall118, the second opposite end wall120, and the bottom panel, are sized and configured to reasonably fit or contain a human body in supine position. It will be appreciated that the height of the walls114,116,118and120define a casket body top level130such that a portion of a deceased may extend above the casket body top level130. As will be discussed below, the reduced height reduces shipping costs, and allows for better viewing of the face of the deceased during funereal events. As also discussed below, the lids104,106are constructed to extend above the top level130to contain any portion of the deceased that extends above the casket body top level130.

To this end, the lids104,106have a smaller horizontal footprint than the casket body110, and can be inverted and placed within the casket body110for shipment or storage. When the stored body110and lids104,106are ready for use to contain a deceased, the lids104,106are removed from within the casket body110. During use, the lids104,106are supported at least in part above the top level130by a series of clips148. The clips148hook onto the walls114,116, and have a receptacle for receiving the bottom edges of the lids104,106, thereby supporting the lids104,106.

The handle assembly112in this embodiment includes a bar142and a plurality of rotatable hinge assemblies144. In general, the handle assembly112is configured such that the bar142can rotate partly upward and outward to facilitate carrying of the casket100. Further details regarding a suitable embodiment of the handle assembly112and the clips148are provided in U.S. Pat. No. 8,595,908, which is incorporated herein by reference in its entirety. It will be appreciated that some embodiments can employ no handle at all, or a different handle configuration, and still obtain advantages described herein. Other configurations can include cutout holes in the side of the walls114,116, similar to those shown in U.S. Pat. No. 10,500,117.

In general, each of the first and second lids104,106is formed primarily from corrugated paper or Kraft paper. In this embodiment each of the first and second lids104,106is formed from a folded corrugated blank. In further detail,FIG.3shows a perspective view of the underside of the first lid104, andFIG.4shows a bottom plan view of the first lid104.FIG.5shows a corrugated paper blank300from which the first lid104(and second lid106) may be constructed.

It will be appreciated that unless otherwise stated, references to directional terms, including but not limited to, vertical, horizontal, upward, downward, top, and bottom, are made with respect to the condition that the first lid104and second lid106are disposed on the casket in closed position, as shown inFIG.2, with the casket body110placed horizontally in its normal use position.

As discussed above, the first lid104is configured to extend partially over the interior of the casket body110, as shown inFIG.2. The second lid106complementarily extends over the rest of the interior of the casket body as shown inFIGS.1and2. With specific reference toFIGS.3and4, the first lid104includes a lid body200and a bridge201. In this embodiment the lid body200and bridge201are both formed from the corrugated paper blank300.

The lid body200includes a first side202, a second side204, a first end206and an open end208. The first side202is a panel or wall configured to extend along a portion of the first side wall114of the casket body110when the first lid104is assembled onto the casket body110in closed position (FIG.2). The second side204is likewise a panel or wall of the lid body200configured to extend along a portion of the second side wall116in closed position. The first end206is a panel or wall configured to extend along the first end wall118in closed position, and the open end208is sized to extend over an intermediate portion of the casket body110disposed between the first end118and the second end120in the closed position.

As will be discussed below in further details, the bottom edges209of at least two of the first side202, second side204, and first end206define a lid body bottom plane210. Although the bottom edges209of the first side202, second side204, and the first end206all lie in the lid body bottom plane210in this embodiment, it will be appreciated that the bottom edges209at least two of the first side202, second side204, and first end206can define the lid body bottom plane210even if the bottom edges in other embodiments have discontinuities such that portions of the bottom edges do not lie in the plane210.

As discussed above, the bridge201is formed from the folded corrugated paper blank300(seeFIG.5). In the assembled first lid104, the bridge201extends downward from the lid body200intermediate of the first end206and the open end208. In other embodiments the bridge201extends down at the open end208. In any event, the bridge201defines a concave opening212extending above the lid body bottom plane210. The concave opening212provides room for the torso of the deceased, not shown, when in the closed position, while also providing the structural reinforcement of a cross-bracing or rib.

In this embodiment, the lid body200further includes a top panel220, a first inclined panel222, a second inclined panel224, and a third or end inclined panel226. Each of the first side202, the second side204, and the first end206extend vertically, and the top panel220extends horizontally. As best shown inFIG.4, the top panel220is rectangular, and includes peripheral edges220a,220b,220cand220d.

With continued reference to bothFIG.3andFIG.5, the first inclined panel222extends between, and is foldably connected to, the first side202and a first edge220aof the top panel220. The first inclined panel222inclines inward and upward from the top of the first side202and to the first edge220a. Similarly, the second inclined panel224extends between, and is foldably connected to, the second side204and a second edge220bof the top panel220. The second inclined panel224inclines inward and upward from the top of the second side204and to the second edge220b. Analogously, the third or end inclined panel226extends between, and is foldably connected to, the first end206and the third edge220cof the top panel220. The fourth edge220dof the top panel220extends between the second edge220band third edge220c.

The bridge201is disposed and extends between the first side202and the second side204, and is disposed near or at the open end208, or another point between the first end206and the open end208. At least a part of the bridge201extends from the top panel220to a point above the lid body bottom plane210.

In this embodiment, the bridge201includes a first flap232, a second flap234, and a third flap236. The first flap232extends down from an underside220eof the top panel220to a location above the lid bottom plane210. To this end, the first flap232is foldably coupled to the lid body200via an intermediate first folded portion238. The intermediate first folded portion238in this embodiment is foldably connected on one side to the top panel220, and on the other side to the first flap232. The intermediate first folded portion238extends in a planar-parallel manner with, and abutting, the top panel220, such that the fold between the portion238and the top panel220is substantially 180°. The first flap232extends downward at a 90° angle from the intermediate first folded portion238toward the casket body interior. The first flap232thus has an upper edge232adefined by the fold line between itself and the intermediate first folded portion238, and a lower edge232bdefining at least a portion of the concave opening212. The lower edge232bextends to a point above the casket lid bottom plane210such that when in the closed position, there is additional room above the top of the casket body110and below the lower edge232bfor the torso of the deceased.

The second flap234is foldably coupled to the lid body200via an intermediate second folded portion240. The intermediate second folded portion240in this embodiment is foldably connected on one side to the first inclined panel222, and on the other side to the second flap234. The intermediate second folded portion240extends in a planar-parallel manner with, and abutting, the first inclined panel222, such that the fold between the portion240and the panel222is substantially 180°. The second flap234extends at a 90° angle from the intermediate second folded portion240angularly downward (toward the casket body interior). The second flap234thus has an upper edge234adefined by the fold line between the second flap234and the intermediate second folded portion240, and a lower edge234bdefining a portion of the concave opening212. In this embodiment, the second flap234is further foldably connected to an end tab248that extends from outer edge of the second flap234. (See alsoFIG.5). The end tab248extends along and is secured to the interior surface of the first side panel202. The end tab248may be secured to the first side panel202by hot melt adhesive, double sided tape, and/or other coupling mechanisms. At least a part of the second flap234overlaps a portion of the first flap232, and is preferably affixed thereto, for example, by hot melt adhesive, double-sided tape, mechanical fasteners or other suitable means.

The third flap236is not visible inFIG.3, but is shown inFIGS.4and5. With reference toFIGS.3,4and5, the third flap236is foldably coupled to the lid body200via an intermediate third folded portion242. The intermediate third folded portion242in this embodiment is foldably connected on one side to the second inclined panel224, and on the other side to the third flap236. The intermediate third folded portion242extends in a planar-parallel manner with, and abutting, the second inclined panel224, such that the fold between the portion242and the panel224is substantially 180°. The third flap236extends in a 90° angle from the intermediate third folded portion242downward (toward the casket body interior111). The third flap236thus has an upper edge236adefined by the fold line between the third flap236and the intermediate third folded portion242, and a lower edge236bdefining a portion of the concave opening212. (See alsoFIG.1). In this embodiment, the third flap236is further foldably connected to an end tab250that extends from outer edge of the third flap236. The end tab250extends along and is secured to the interior surface of the second side panel204. The end tab250may be secured by hot melt adhesive, double sided tape, and/or other coupling mechanisms. At least a part of the third flap236overlaps a portion of the first flap232, and is preferably affixed thereto, for example, by hot melt adhesive, double-sided tape, mechanical fasteners or other suitable means.

It will be appreciated that the lower edges232b,234b, and236bin this embodiment define the concave opening212. The lower edge234bextends upward and inward from the first side panel202and intersects with the lower edge232b. The lower edge232bof the first flap232extends across to intersect the lower edge236bof the third flap236b. While the edges232b,234b, and236bcomprise straight lines in this embodiment, it will be appreciated that in other embodiments, one or more of the lower edges232b,234b, and236bcan be curved, and/or have other shaped features.

As discussed above, the first lid104is formed from the corrugated blank300ofFIG.5. With reference toFIG.5, the edges220a,220b,220cand220dof the top panel200defined fold lines connecting the top panel220to, respectively, the first inclined panel222, the second inclined panel224, the third inclined panel226, and the intermediate first folded portion238. The edge220dof the top panel220near the open end208is part of a fold line302that extends also through the first side202, the first inclined panel222, the second side204, and the second inclined panel224. The fold line302couples the first side202to a first overlap304, and the second side to a second overlap306. Each of the first and second overlaps304,306, respectively, have the roughly the same width as the intermediate folded portions238,240,242. The first overlap304is adjacent to and may suitably be foldably coupled the intermediate second folded portion240, and the second overlap306is adjacent to and may suitably be foldably coupled the intermediate third folded portion242. The fold line302further couples the intermediate second folded portion240to the first inclined portion222, and the intermediate third folded portion242to the second inclined portion224.

The top edge232aof the flap232forms the fold line between the flap232and the intermediate first folded portion238. The top edge234aof the flap234forms the fold line between the second flap234and the intermediate second folded portion240. The top edge236aof the third flap236forms the fold line between the third flap236and the intermediate third folded portion242. In this embodiment, the first flap232, the second flap234and third flap236are formed from a continuous strip of the blank300. However, the intersection between the first flap232and the second flap234is slit to allow relative independent movement therebetween. Likewise, the intersection between the second flap234and the third flap236is slit to allow relative independent movement therebetween.

The blank300further includes a fold line310between the first inclined panel222and the first side202, and a fold line312between the second inclined panel224and the second side204. The end panel206is foldably connected to the third inclined panel226via a fold line314. The inclined panel226includes two connecting tabs316,318foldably connected to ends thereof, adjacent to the first inclined panel222and the second inclined panel224, respectively. The end panel206also includes two connecting tabs320,322foldably connected to corresponding opposite ends thereof.

The assembly of the blank300into the lid104is typically done with the lid104inverted or upside-down. Accordingly, in the discussion of the assembly of the lid104from the blank300, the directions upward and downward will have the opposite meaning than they do in the remainder of this description. To assemble the lid from the blank300, the blank300is folded 180° inward at the fold line302. The flaps232,234and236are then folded upward from adjacent the top panel220via fold lines (edges)232a,234aand236a.

Then, the inclined panels222,224and226are folded in an angle upward from the top panel220, and the sides202,204and206are folded in an angle upward from respectively, inclined panels222,224and226to produce the shape shown inFIG.3. As shown inFIG.3, the tab316overlaps, is secured to, and abuts, a portion of the inclined panel222. The tab318is similarly secured to the second inclined panel224. As shown inFIG.3, the tab320overlaps, is secured to, and abuts, a portion of the first side202. The tab322is similarly secured to the second side204. The end tab248overlaps, is secured to, and abuts, a portion of the first side202. The end tab250is similarly secured to the second side204. The fold line318between the end tab248and the second flap234is angled such that the fold line318defines an edge of the second flap234that engages the side wall202. Similarly, the fold line320between the end tab250and the third flap236is angled to define an edge of the third flap236that engages the side wall204. As a result, the first flap232, the second flap234and the third flap236collectively form the bridge201, which forms a brace or rib from the first side202to the second side204to strengthen the structure of the lid, while leaving room for the torso of the deceased in use.

In some embodiments, it can be desirable to add a modesty skirt to reduce the portion of the deceased that may be viewed during funereal events.FIG.6shows an end plan view of a skirt assembly500assembled onto the first lid104. In use, the skirt assembly500is assembled onto whichever of the first lid104,106is placed over the legs and lower torso of the deceased. As discussed above, the first lid104and second lid106may suitably have substantially identical structures, and thus the skirt assembly500will assemble on to the second lid500in the same manner as will be discussed below with respect to the first lid104.

FIG.7shows a rear plan view of the skirt assembly500apart from the second lid106. As shown inFIG.7, the skirt assembly500includes shaped substrate502and a draped cloth504affixed thereto.FIG.8shows a plan view of the shaped substrate502and the draped cloth504of the skirt assembly500in unassembled or partially assembled state. Referring toFIGS.6,7and8, the shaped substrate502includes an upper edge508that is complementary in shape to the underside of the first lid104or second lid106, and a lower edge510that is concave.

Each of the upper edge508and lower edge510extend from a first end512of the shaped substrate502to an opposing second end514of the shaped substrate502. The upper edge508is sized and configured to engage the underside and or inward facing surfaces of the first side202, the first inclined panel222, the top panel220, the second inclined panel224and the second side204. Preferably the upper edge508is sized and configured to provide a friction fit with the underside of the first lid104, but may also be held in place by adhesive, double-sided tape, or other fastening means, not shown. The lower edge510is configured to have a shape that does not reduce (or at least only minimally reduce) the torso clearance provided by concave opening212of the bridge201. The upper and lower edges508,510, respectively roughly define a trapezoidal body, but with the long edge or side of the trapezoid being concave instead of a straight line.

More specifically, the upper edge508includes five segments508a,508b,508c,508dand508e. When installed, the first segment508aengages the first side202, the second segment508bengages surfaces of the first inclined panel222, the third segment508cengages the top panel220, the fourth segment508dengages surfaces of the second inclined panel224and fifth segment508eengages the second side204.

The draped cloth504is affixed to, covers, and drapes downward from, the shaped substrate502. As a result, as shown inFIG.6, the draped cloth504conceals the substrate502, the bridge201, and any portion of the deceased under the first lid104beyond the bridge201.

Referring toFIG.8, a method of making the skirt assembly500includes placing the draped cloth504under the substrate502, such that the draped cloth504rests against a first side (not visible) of the substrate502, and the opposing second side518of the substrate502is exposed. The draped cloth504has a width that extends beyond the first end512and the second end514, and a length that is many times the distance between the upper and lower edges508,510. The draped cloth504is placed relative to the substrate502such that the length of cloth that extends from the lower edge510is equal to or greater than the distance between the uppermost part of the lower edge510and the lid body lower plane210when installed onto the lid104, as shown inFIG.6. The draped cloth504is also placed relative to the substrate502to provide at least a foldover portion516that extends from the upper edge510sufficiently for folding over the substrate502in the manner discussed below.

In the next step, the foldover portion516is folded over and affixed to a part of the second side518of the substrate502, as shown inFIG.9. The foldover portion516is folded along a line defined by the segment508c, and such that the foldover portion516extends over the substrate502from the segment508cto the lower edge510. As such the foldover portion516also covers a portion of the segments508band508dof the upper edge508. Because the draped cloth504has a width that extends beyond the first end512and the second end514, the result of the first foldover described above define corners520,522that in part have two layers of cloth.

In a next step, as shown inFIG.10, the two corners520,522are folded inward along diagonal fold lines defined by the segments508b,508d, respectively. The folded corners520,522are affixed to the substrate502and/or the covered area foldover portion516. The folded corners520,522cover respective portions of the second side518of the substrate502between the segments508b,508dand the lower edge510. Thereafter, as shown inFIG.7, two opposing sides of the cloth504are folded along fold lines defined by the segments508a,508e, and secured to the substrate502and/or underlying portions of the cloth504. The cloth504thus is folded sequentially inward over the edge segment508c, over edge segments508b,508d, and finally over edge segments508a,508e.

The completed skirt assembly500may there after be installed in the first lid104(or second lid106). It will be appreciated that the skirt assembly500is preferably shipped uninstalled onto either of the lids104,106, and installed at the end user location. As discussed below, the lids104,106are shipped within the casket body110to save space, and the skirt assembly500may be shipped within the casket body110as well.

In particular, because the lids104,106have a footprint similar to lids shown in U.S. Pat. No. 8,595,908, the lids104,106may be shipped within the casket body110in a manner analogous to that discussed in U.S. Pat. No. 8,595,908, which is incorporated herein by reference. As shown inFIG.2, the lids104,106may use clips148to support the lids104,106on the casket body110, such as those discussed in U.S. Pat. No. 8,595,908. The clips148allow the lids104,106to be supported over the casket body110even though the lids104,106otherwise fit (without the clips148) within the casket body110for shipment.

It will be appreciated that the above-described embodiments are merely exemplary, and that those of ordinary skill in the art may readily devise their own modifications and implementations the incorporate the principles of the present invention and fall within the spirit and scope thereof.