Abstract:
A hermetically sealed casket enclosure comprising a tray; a bottom cover adapted to be housed within the tray and having an open perimeter equipped with a first half of a zipper; a top cover adapted to fit over a casket and proportioned to mate with the bottom cover wherein the top cover has an open perimeter equipped with a second half of a zipper which corresponds with and engages the first half of the zipper so as to join the top cover to the bottom cover; and a clasp for sealing a start end and a finish end of the zipper.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a system and method for providing a hermetically sealed enclosure that completely envelopes a casket, and more particularly, the present invention relates to a system and method for providing a hermetically sealed enclosure that completely envelopes a casket where the casket will be interred in an above ground mausoleum crypt. 
     BACKGROUND OF THE INVENTION 
     Enclosing a casket within a burial vault is well known in the mortuary sciences. Enclosures for use with caskets to be interred within above ground mausoleum crypts are often constructed as two-piece assemblies having a bottom, on which sits the casket, and a top (also typically referred to as a cover or dome) which is placed around the casket. The top and bottom are then sealed (e.g., by heat sealing or use of an adhesive glue or tape) to form a hermetically sealed enclosure. Casket enclosures known in the art are generally either heavy synthetic plastic materials which are bulky and expensive or light weight plastic films or bags which, while being more cost efficient, are more easily punctured or damaged thereby destroying the hermetic seal. 
     Beyond weight and expense, current casket enclosures further suffer from a number of significant drawbacks. Chief among these drawbacks is the inability to form a truly hermetic seal between the top and bottom members. A number of systems have been designed wherein the top and bottom members are formed of plastic having a moderately high melting point where the seal is generated by applying a heat source to the overlapped members to fuse the members together. However, applying too much heat can damage one or both members leading to a hole within the enclosure, while applying too little heat can incompletely form a seal leading to a gap within the enclosure. 
     Alternative attempts to form a hermetic seal include means which employ an adhesive. Adhesives can either be glued-based or tape-based. The glue-based adhesives attempt to seal the top layer to the bottom layer by spreading a line of glue along one or both edges of the top or bottom and pressing the edges together until the glue cures. Unfortunately, the glue-based adhesives suffer significant drawbacks. First, the glues are often toxic or noxious chemicals which require special handling or personal protective gear. Second, this process is time consuming as users must first produce a safe working environment and then physically glue and hold each seam until the glue cures. And third, the seal may be incomplete for failure to apply a sufficient amount of adhesive, failure to supply a sufficient amount of pressure or failing to wait until the glue cures thereby disrupting the seal. 
     Turning now to tape-based adhesives, the top and bottom layers are overlapped with the tape being placed over the outer edge to form a seal. Tape-based adhesives suffer similar drawbacks as glue-based adhesives (incorrect application of pressure, improper application of the tape) while also suffering from eventual degradation of the adhesive material. Indeed, over time the adhesive will dry and crack leading to gaps within the seal. Furthermore, either type of adhesive prevents opening and resealing of the enclosure should the need arise to open the casket. 
     In the prior art, U.S. Pat. No. 4,922,590 describes a casket enclosure having a flexibly rigid bottom tray within which rests a casket. A Tyvek cover is then placed over the casket and sealed to the bottom tray using an adhesive tape to cover the seam. The Tyvek cover is also equipped with a one-way check valve to relieve gas pressure generated from decomposition from within the enclosure. The &#39;590 patent further provides that the bottom tray is foldable such that the tray forms a sturdy self-sustaining shipping and storage container when closed. The Tyvek cover and adhesive are housed within the tray when the unit is being stored or shipped. While this folding bottom tray may provide the benefit of producing its own shipping container, this feature also presents a flaw to this device. As the bottom tray is used to form a hermetic seal when joined with the cover, any damage, holes or cracks (particularly at the creases) would destroy the seal. Additionally, as these holes or cracks are on the bottom tray, and any fluids released during decomposition which escapes the casket will also leak out of the enclosure. This only adds to the potential release of odors or attraction of pests. The adhesive tape described by the &#39;590 patent also suffers those drawbacks as discussed previously. 
     As such, there is a need for a system and method for enclosing a casket that is light weight, compact, cost efficient and provides a long-lived hermetic seal. Additionally, there is a need for a system and method that provides a hermetically sealed enclosure which further enables containment of any leaks should the casket seal be disrupted. The present invention addresses these and other needs. 
     BRIEF SUMMARY OF THE INVENTION 
     In general, one embodiment the present invention is directed to a casket enclosure for mausoleum crypts which overcomes the problems and deficiencies in the prior art. The casket enclosure of the present invention is generally comprised of a two piece sealing system for enclosing a casket with said system being placed within a foldable tray. The two piece construction, having a top half and bottom half, provides a barrier which will contain any liquids, gasses or odors yielded during decomposition of the casket and its contents. For additional protection, a superabsorbent pad may be placed within the bottom half prior to loading of the casket within the tray so as to absorb any fluids which may be released from the sealed casket. The top piece of the two piece construction is also equipped with a one-way pressure relief valve to relieve any pressure generated from the decomposition process. The two halves of the sealing system are joined using an airtight polyethylene zipper track. A clasp and housing assembly envelops and seals the zipper ends. The foldable tray is adapted to contain the sealing system and all required hardware when the tray is folded closed during shipping or storing of the unused enclosure. 
     The casket enclosure system of the present invention is a light-weight, relatively inexpensive product which provides a hermetically sealed enclosure that completely envelops a casket to be placed into a mausoleum crypt. The casket enclosure system of the present invention allows mortuary workers to seal a casket within a short period of time (generally less than one-half hour) without exposing those workers to dangerous conditions or chemicals. The zipper enclosure also allows for the opening and resealing of the enclosure and casket should the need arise. 
     Additional objects, advantages and novel features of the present invention will be set forth in part in the description which follows, and will in part become apparent to those in the practice of the invention, when considered with the attached figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings form a part of this specification and are to be read in conjunction therewith, wherein like reference numerals are employed to indicate like parts in the various views, and wherein: 
         FIG. 1  is a perspective view of the casket enclosure system of one embodiment of the present invention; 
         FIG. 2  is a vertical cross-section of the casket enclosure system taken generally along line  2 - 2  of  FIG. 1 ; 
         FIG. 3  is a vertical cross-section of the zipper and housing assembly of the casket enclosure system taken generally along line  3 - 3  of  FIG. 1 ; 
         FIG. 4  is a perspective view of a zipper end clasp used in conjunction with the housing to seal the zipper ends of one embodiment of the casket enclosure system of the present invention; 
         FIG. 5  is a vertical cross-section of the zipper, clasp and housing assembly of the casket enclosure system taken generally along line  5 - 5  of  FIG. 4 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to the drawings in detail, and specifically to  FIGS. 1 and 2 , one embodiment of a casket enclosure  10  of the present invention is generally comprised of a tray  12 , a bottom cover  14  and a top cover  16 . Preferably, tray  12  is a fabricated, corrugated plastic member having a base  20 , a pair of side walls  21  and a pair of end walls  22 . To assist mortuary employees in sliding the casket enclosure within a mausoleum crypt, base  20  is preferably further provided with one or more slides  29 . Slides  29  may extend generally the entire longitudinal length of base  20 . Traditionally, small plastic beads are used to assist sliding of the casket within the crypt opening. However, these plastic beads may land on the mausoleum floor thereby created a slipping hazard for employees. Thus, slides  29  are constructed with integral features to reduce the coefficient of friction between the tray and the bottom surface of the crypt enabling easier installation while also preventing a dangerous work environment. For example, in one embodiment, slides  29  may include a pattern of dimples on their outer surface which reduces surface area contact and thus friction between the tray and mausoleum floor. Slides  29  also elevate tray base  20  slightly above the surface of the crypt thereby aiding in preventing damage to the enclosure and potential loss of the hermetic seal. 
     In a further embodiment, tray  12  is designed to further function as a foldable carrier by incorporating a pair of fold lines  24  such that the tray is folded in roughly two equal portions wherein one end wall fits snuggly within the second end wall. Fold lines  24  are further reinforced with sealing tape and ultrasonic welding to resist and prevent splitting or tearing of the tray. The foldable tray then further functions as a storage and/or shipping container for the remaining items which make up the enclosure. If tray  12  is equipped with fold lines  24 , slides  29  extend longitudinally generally from each end of base  20  to the closest fold line  24  so as not to impede folding of the tray. 
     Both bottom cover  14  and top cover  16  are constructed of heavy-duty flexible barrier packaging material. The covers are liquid and airtight, and further possess superior puncture and tear resistance as well as superior heat-seal strength. The bottom cover  14  and top cover  16  are joined to one another through an airtight polyethylene zipper track  17 . One half of the zipper track is hermetically sealed to its respective cover&#39;s open perimeter. During assembly, a zipper pull tab (not shown) initiates meshing of the bottom cover zipper half  30  with the top cover zipper half  40 . The zipper halves may comprise a continuous flange and groove, respectively, which may be hermetically engaged with one another using the zipper tab pull. The zipper pull tab is pulled completely around the casket so as to end proximate the start location. In a preferred embodiment, the zipper pull tab is distinct from the zipper track and is removed from the track once zippering is completed. The zipper pull tab is then housed with the casket enclosure should there be a need in the future to use the zipper pull tab to unzip the two halves. The start and end portions of the joined zipper track are then hermetically sealed using an end cap  18 , as will be discussed in more detail below with regard to  FIGS. 3-5 . 
     In a preferred embodiment, bottom cover  14  is factory-adhered to tray  12  so that the bottom cover automatically deploys (unfolds) with the unfolding of the tray. In a further embodiment, the casket enclosure is also supplied with a superabsorbent pad  28  which is placed within bottom cover  14  before the cover is loaded with casket  11 . The superabsorbent pad  28  provides additional protection should any fluids be released from the sealed casket during internment. Additionally, top cover  16  is further optionally equipped, via heat-sealing, with a one-way pressure relief valve  42  for relieving any pressure generated within the enclosure from the decomposition process. 
     Referring now to  FIG. 3 , a vertical cross-section of the casket enclosure highlighting the zipper ends and sealing cap is shown. In a preferred embodiment, bottom cover  14  is constructed to include a bottom extending tab  34  in seamless communication with the main body of bottom cover  14  but projects outwardly from the enclosure. Similarly, top cover  16  is constructed to include a top extending tab  44 . The extending tabs  34  and  44  are constructed such that the ends of the zipper halves  30  and  40  rest in a plane generally perpendicular to the end of the casket and are sufficiently distal from the end of the casket so as to provide enough clearance to hermetically seal the zipper ends using an end cap  18 . 
     As shown in  FIG. 4 , end cap  18  is generally comprised of an end clasp  50 . In one embodiment, end clasp  50  is constructed of a resilient rubber and has a chamfered channel  55  situated at the midpoint of one face. The chamfered channel  55  permits flexing of the end clasp (in the manner of a living hinge) so as to allow the inner face  58  on each side of the channel to contact one another. The resilient rubber is flexible enough to permit such flexing, but not rigid enough to split or crack as a result. End clasp  50  is further fabricated with recesses  56  which are proportioned to fit snuggly around the ends of zipper track  17 . End clasp  50  may be secured to extended tabs  34  and  44  using any suitable securing means, including but not limited to an adhesive, a clamp such as a spring clamp or c-clamp, or a physical fastener such as a bracket, snaps, clips, or screws. Indeed, while any suitable fastener may be employed, in a preferred embodiment, end cap  18  further comprises a housing  60  for securing and sealing end clasp  50  about the ends of zipper track  17 . 
     As shown in  FIG. 5 , housing  60  is proportioned to snuggly encapsulate end clasp  50  within cavity  62  once clasp  50  is positioned and folded about zippered extended tabs  34  and  44 . Housing  60  is preferably a machined or cast metal block having a pair of threaded bore holes  64  extending from one face into cavity  62 . Counterpart cap screws  66  are then threaded (e.g., with an Allen wrench supplied with the assembly) into threaded bore holes  64  with the cap screws  66  applying sealing pressure to an outer face  59  of end clasp  50  (see  FIG. 4 ). As described above with reference to  FIGS. 1 and 2 , bottom cover zipper half  30  extends along the entire open perimeter of bottom cover  14  such that the start and finish of the zipper track are located proximate one another. The start and finish of bottom cover zipper half  30  are depicted via reference numerals  30 (R) and  30 (L), noting one end is on the right when facing the end of the casket while the other is on the left. Similarly, the start and finish of top cover zipper half  40  are likewise situated on top cover  16  and have ends  40 (R) and  40  (L) terminating proximate one another on extended tab  44 . As describes above with reference to  FIG. 4 , the extending flaps, with their associated zipped ends, are positioned between the folded inner faces  58  of end clasp  50 . Cap screws  66  are threaded so as to apply pressure to an outer face  59  of end clasp  50  thereby compressing and hermetically sealing end clasp  50  (and extensions  34  and  44  with the zipped zipper track) against the distal wall of housing  60 . Use of housing  60  and cap screws  66  allows for quick and efficient sealing of the ends while also permitting unsealing and resealing of the casket enclosure should the need arise. Notably, in a further preferred embodiment, with reference again to  FIG. 4 , end clasp  50  is manufactured to further comprise two metal plates  52  insert molded within the resilient rubber such that the metal plates form outer face  59 . The interior ends of cap screws  66  then impact the metal plates rather than the resilient rubber. The metal plates prevent damage to the rubber due to the cap screws while also promoting even clamping pressure across the entire face of end clasp  50  enabling better clamping of the zippered ends. 
     Although the present invention has been described in considerable detail with reference to certain aspects thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the aspects contained herein. 
     All features disclosed in the specification, including the claims, abstract, and drawings, and all the steps in any method or process disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. Each feature disclosed in the specification, including the claims, abstract, and drawings, can be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.