Abstract:
A modular drip tray for use in a casket includes a plurality of modules and an overlapping member. The plurality of modules are placed into a casket adjacent to each other and the overlapping member creates an overlap region that spans a portion of the two modules and any gap between the modules such that liquids impinging upon the overlap region will be impaired from progressing beneath the overlap region. The overlapping member may be formed integrally with one or more modules. Each module may further comprise a plurality of discrete isolated compartments for retention of liquids.

Description:
FIELD OF THE INVENTION  
   The present invention relates generally to burial and cremation containers. 
   BACKGROUND OF THE INVENTION  
   The embalming process and natural decomposition of human remains results in the generation of viscous fluids. When these fluids are generated in while the human remains are in a burial or cremation container (e.g. casket), the fluids naturally migrate to the lower portions of the casket. This migration may result in a number of problems. Caskets are constructed from a plurality of materials, including wood, metal, and paper materials, as well as combinations of the foregoing. Thus, the caustic nature of the fluids can lead to corrosion of casket materials. Moreover, caskets are subject to leakage. 
   The problems associated with leakage can be broadly discussed as either short term or long term problems. In the short term, the casket will be subjected to movement, as the casket may be moved between the viewing environment and/or memorial service location and its final resting place, whether that be interred in the ground, cremated, or placed into a mausoleum or crypt. Thus, resolution of the leakage problem must address the fact that the casket will be subjected to movement, such as starts and stops and being tilted. In the short term, however, there is a lesser amount of fluids in the casket. In the long term, the casket is much less likely to be subjected to movement. However, more fluid will be present over the long term. 
   A variety of means have been developed to reduce the potential of leakage. U.S. Pat. No. Re. 34,846 discloses one such approach. This patent discloses a seamless, one-piece drip tray for a casket with a plurality of discrete isolated compartments for the retention of fluids. Another approach is disclosed in U.S. Pat. No. 5,615,464 wherein a one-piece drip tray designed to be retrofitted into caskets previously fabricated without a drip tray. The drip trays disclosed in these patents are very useful in reducing the potential problems associated with leakage. However, the one-piece design of the drip trays does present various difficulties associated with the fabrication and installation of the drip trays into caskets. 
   Typically, drip trays are fabricated from a thermoplastic material such as high density polyethylene. The material is generally vacuum formed in an in-line vacuum forming machine. In-line vacuum forming machines are available in a number of sizes. Obviously, as the size of the final product increases, the size of the machine needed to fabricate the product necessarily increases. By way of example, a typical casket is 82 inches long and 27 inches wide, so a one-piece construction drip tray would need to be almost that size. Accordingly, a manufacturer would be required to have an in-line vacuum forming machine with a capacity of at least those dimensions. For a variety of reasons, obtaining and maintaining such a machine capable of fabricating one-piece drip trays for caskets can be uneconomical. 
   Installation of a one-piece drip tray presents additional problems. Proper installation of the drip tray without damage to the drip tray is critical in minimizing the potential for leakage. Although the drip trays are light-weight, their large dimensions make them unwieldy. For example, a large casket sized drip tray can be difficult to manipulate in the close confines of a casket. Moreover, the drip trays are designed to be structurally sound once installed. However, they can be relatively fragile while being handled, being subject to bending. 
   There is a need, therefore, for a casket leak containment system that may be fabricated on smaller in-line vacuum machines. It would be beneficial if the leak containment system could be more easily installed into a casket than traditional drip trays. It would be further beneficial if the leak containment system were of a robust design, reducing the potential for damage to the leak containment system during installation. It is desired that the above advantages be realized in a leak containment system that is light-weight, durable, inexpensive to manufacture, and capable of preventing leakage both in short term and long term applications. 
   SUMMARY OF THE INVENTION  
   The present invention fulfills the above needs, as well as others, by providing a leak containment system constructed from multiple modules. The modules may be individually formed and installed. When installed, the modules overlap along at least one edge to provide proper leak protection between the modules. The modular design of the drip tray allows for a smaller in-line vacuum machine to be used to produce the individual modules. In the event a module is damaged, there will be less waste than in a one-piece drip tray. Moreover, the reduced size of each module results in greater structural integrity while moving the modules as well as increased ease of installation. However, it will be appreciated that variants of the invention may provide the advantage of ease of manipulation even it provides none of the advantages associated with using a smaller vacuum forming machine. Moreover, variants of the invention may provide some of the advantages associated with using a smaller vacuum forming machine without any advantages associated with ease of manipulation into a casket. 
   In some embodiments, the modules of the modular drip tray are identical in design. The use of identical modules in a modular drip tray provides a further advantage of reduced tooling and logistical costs. 
   The above described features and advantages, as well as others, 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 an exploded perspective view of an exemplary embodiment of a modular drip tray assembly in accordance with features of the present invention and a casket. 
       FIG. 2  shows an exploded view of a spring support structure, mattress, and the modular drip tray assembly of  FIG. 1 . 
       FIG. 3A  shows a perspective view of the modular drip tray assembly of  FIG. 1 . 
       FIG. 3B  shows a side elevational view of the modular drip tray assembly of  FIG. 1 . 
       FIG. 4A  shows a perspective view of an alternative embodiment of a modular drip tray assembly incorporating features of the present invention. 
       FIG. 4B  shows a side elevational view of the modular drip tray assembly of  FIG. 4B . 
       FIG. 5  shows a top elevational view of an alternative embodiment of a modular drip tray assembly incorporating features of the present invention within a casket. 
       FIG. 6  shows a cross sectional view of the modular drip tray assembly and casket of  FIG. 5 . 
       FIG. 7  shows an enlarged cross-sectional view of one end of the modular drip tray assembly and casket of  FIG. 5 . 
       FIG. 8  shows a perspective elevational view of a drip tray module that may be used with the modular drip tray assembly of  FIG. 5 . 
       FIG. 9  shows a side elevational view of an alternative embodiment of a modular drip tray assembly incorporating features of the present invention. 
       FIG. 10  shows a perspective elevational view of an alternative embodiment of a modular drip tray assembly incorporating features of the present invention. 
       FIG. 11  shows a partial cross sectional view of the modular drip tray assembly of  FIG. 10 . 
       FIG. 12  shows a perspective elevational view of an alternative embodiment of a modular drip tray assembly incorporating features of the present invention that includes a clip. 
       FIG. 13  shows a partial cross sectional view of the modular drip tray assembly of  FIG. 12 . 
       FIG. 14  shows a perspective elevational view of an alternative embodiment of a modular drip tray assembly incorporating features of the present invention that includes a clip. 
       FIG. 15  shows a partial cross sectional view of the modular drip tray assembly of  FIG. 14 . 
   

   DETAILED DESCRIPTION  
   For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and described in the following written description. It is understood that no limitation to the scope of the invention is thereby intended. It is further understood that the present invention includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the invention as would normally occur to one skilled in the art to which this invention pertains. 
     FIG. 1  shows a casket  10  with a modular drip tray assembly  12  which incorporates features of the present invention. The modular drip tray assembly  12  is configured to fit within the cavity  14  of the casket  10 . More specifically, as shown in  FIG. 2 , the casket  10  includes two bed screws  16  and  18  that are mounted on the bottom  20  of the cavity  14 . A spring support structure  22  is mounted on the bed screws  16  and  18 . The modular drip tray assembly  12  is placed on top of the spring support structure  22  and a mattress  24  is positioned on top of the modular drip tray assembly  12 . 
   With additional reference to  FIGS. 3A and 3B , the modular drip tray assembly  12  in this embodiment includes module  26  and module  28 . Module  28  includes a bottom  30  and a wall portion  32  that extends upwardly and outwardly from the bottom  30  to define a basin  34 . In this embodiment, a rim  36  extends outwardly from the upper end of the wall portion  32 , completely around the periphery of module  28 . Likewise, the module  26  includes a bottom  38  and a wall portion  40  that extends upwardly and outwardly from the bottom  38  to define a basin  42  and a rim  44  extends completely around the periphery of module  26  from the upper end of the wall portion  40 . Both of the wall portions  32  and  40  curve inwardly at one end to form concavities  46  and  48  respectively. 
   As shown in  FIG. 3B , when installed, the rim  36  of the module  28  extends over the top of the rim  44  of the module  26  where the module  28  is adjacent to the module  26 . Thus, both the rim  44  and the rim  36  are overlap members and provide an overlap area between the modules  26  and  28 . The overlap area substantially reduces the potential for leakage of fluids between the modules  26  and  28 . 
   Each of the modules  26  and  28  is preferably vacuum-formed as a single integrated unit with a thickness suitable for supporting its own form even when an amount of fluid is collected within the basins  34  and  42 . It is also preferable to ensure that the thickness is maintained thin enough to avoid excess stiffness since some flexibility is helpful when positioning the modules within a casket. Of course, the two piece construction of modular drip tray assembly  12  has reduced flexibility requirements than that of the larger prior art single piece design. In any event, one suitable embodiment of the invention has a wall thickness of between 0.004 inches and 0.02 inches, preferably about 0.040 inches and is formed from polyethylene. Of course, the necessary thickness of the walls will depend upon a variety of design choices that affect the capability of a formed object to maintain its shape when liquid is being held. Such design choices include, but are not limited to, the presence or absence of a rim, of ribs, and the inclination of the wall portion. 
   Assembly of the modular drip tray assembly  12  into the casket  10  is performed after the spring support structure  22  has been positioned within casket  10 . As shown in  FIG. 2 , the spring support structure  22  is attached to the bed screws  16  and  18 . The module  26  is then loaded into the casket such that the bottom  38  rests on top of the spring support structure  22  with the wall portion  40  extending upwardly away from the spring support structure  22 . The module  26  is then moved toward the end of the casket  10  such that one of the bed screws  16  or  18  is within the concavity  48  and the rim  44  of the module  26  is abutting the inner wall of the casket  10 . In this embodiment, the module  26  may be placed to abut either end of the casket  10 . It is preferable, however, to place the module  26  toward the end of the casket  10  expected to be exposed to less leakage since the basin  34  of module  28  is volumetrically larger than the basin  42  of the module  26 . 
   Next, the module  28  is inserted in a similar manner. However, concavity  46  is aligned closer to the end of the casket  10  away from the module  26 . Thus, the bed screw  16  or  18  that is not within the concavity  48  will be located within the concavity  46 . When the module  28  is inserted and the rim  36  is adjacent to the end of the casket  10  opposite to the end at which the module  26  was installed, the bottom  30  of the module  28  will be lying upon the spring support structure  22  and the rim  36  of the module  28  and the rim  44  of the module  26  will overlap. 
   The mattress  24  may then be installed, with the weight of the mattress  24  helping to maintain the modular drip tray assembly  12  in place. The modular drip tray assembly  12  is further maintained in position because the rims  44  and  36  abut the ends and sides of the casket, and motion of the modules  26  and  28  toward each other is limited by the rim  44  of the module  26  abutting the wall portion  32  of the module  28  as shown in  FIG. 3B . 
   If desired, the wall portion  32  adjacent the rim  44  may be formed to be completely vertical or even to slant away from the rim  44  to provide additional positional stability. Specifically, because the wall portion  32  is slanted upwardly toward the module  26 , it may, under certain circumstances, slide up the rim  44 , creating a gap between the rim  36  and the end of the casket. By changing the orientation of the rim  36  and the wall portion  32 , the opportunity for such sliding movement can be reduced. 
   In one embodiment, a retaining member is used to prevent sliding movement between modules. A modular drip tray assembly  11 , shown in  FIGS. 4A and 4B , includes two modules  13  and  15 . Each of the modules  13  and  15  include wall portions  17  and  19 , and rims  21  and  23 , respectively. The wall portion  19  includes a tab  25 . The tab  25  extends outwardly from the wall portion  19  and is spaced apart from the rim  23  such that when the module  15  is installed, the tab  25  may be pushed past the rim  21 . Once the tab  25  is pushed past the rim  21 , the rim  21  is entrapped between the rim  23  and the tab  25 . Thus, the module  15  cannot slide up onto the module  13 . 
   It is noted that, preferably, the modules  26  and  28  are identical in design. Use of identical modules provides a number of benefits. For example, with identical modules there is no need to order, stock or match two different modules to form a modular tray assembly. Moreover, if one module is damaged, there is no additional waste of a second unmatched module. In addition, only one tooling need be developed for the entire assembly  12 . 
   Referring now to  FIGS. 5 and 6 , modular drip tray assembly  12  is shown assembled into a casket  50  having a configuration different from the configuration of the casket  10 . The casket  50  includes two end walls  52  and  54 , two side walls  56  and  58 , a bottom  60 , a center support bracket  62 , two bed screws  64  and  66 , and two flanges  68  and  70 . The casket lid and mattress are not shown for ease of description. The flange  68  is generally “U” shaped in the horizontal plane, extending along the end wall  52  and about half way along both of the side walls  56  and  58 . Similarly, the flange  70  is generally “U” shaped in the horizontal plane, but extends along the end wall  54  and about half way along both of the side walls  56  and  58 . However, the flange  68  is located at a distance above the bottom  60  of the casket  50  less than the distance at which the flange  70  is located above the bottom  60  of the casket  50 . 
   The concavity  48  at one end of the module  26  allows the module  26  to be placed on the bottom  60  of the casket  50  while extending from the end wall  52  at a point just below the flange  68  to a point above the center support bracket  62 . Similarly, the concavity  46  of the module  28  allows the module  28  to be placed on the bottom  60  of the casket  50  while extending from the end wall  54  at a point just below the flange  70  to a point above center support bracket  62 . This ensures that a maximum area of the bottom  60  is protected from any fluids, and that most, if not all, fluids will impinge upon the modular drip tray assembly  12 . 
   As shown in  FIG. 6 , wherein the proportions have been exaggerated for clarity, the amount of upward and outward extension of the wall portions  32  and  40  is selected such that the modules  26  and  28  are not hindered from resting upon the bottom  60  by the center support bracket  62 . The amount of upward and outward extension of the wall portions  32  and  40  is further selected such that while the modular drip tray assembly  12  is positioned on the bottom  60  of the casket  50 , the rims  36  and  44  overlap at the adjacent ends of the modules  26  and  28  (above the center support bracket  62 ), and such that they respectively abut the end wall  52  below flange  68  and end wall  54  below flange  70 , (see e.g.  FIG. 7 ). The rims  36  and  44  are further selected so as to abut the side walls  56  and  58  at a point below the flanges  68  and  70 , respectively. The overlap is designed to present a tortuous path from above the modular drip tray assembly  12 , between the modules  26  and  28 , to below the modular drip tray assembly  12 . The tortuous path reduces the potential for leakage of fluids past the modular drip tray assembly  12 . The abutment of the rims  36  and  44 , combined with the flanges  68  and  70  which act as overhangs, improve the opportunity for capturing liquid that may be flowing down the side or end walls. 
   The positioning of the rims  36  and  44  beneath the flanges  68  and  70 , respectively, also maintains the modular drip tray assembly  12  in position even if the casket  50  is jolted. This is because the periphery of the casket  50  at the flanges  68  and  70  is less than the periphery of the casket  50  below the flanges  68  and  70 . Thus, flanges  68  and  70  form a restraint limiting upward movement of the modular drip tray assembly  12 . Of course, restraint may be fashioned in a number of alternative ways. By way of example, but not of limitation, the modular drip tray assembly  12  may also be restrained by a plurality of protuberances located about the periphery of the end walls  52  and  54  and/or the side walls  56  and  58  in the event that a flange is not provided or if it is desired to maintain the modular drip tray assembly  12  in place at a height lower than flanges  68  and  70 . 
   Installation of the modular drip tray assembly  12  into the casket is easily accomplished. As shown in  FIG. 6 , it is desired to have the rim  36  above the rim  44 . Accordingly, the module  26  is inserted into the casket  50  first. The concavity  48  is aligned with the bed screw  64  with the wall portion  40  extending upwardly, away from the bottom  60  of the casket  50 . The module  26  is then pushed downward and toward the bed screw  64 . To ease insertion, the module is given a slight angle from side to side while inserting it into the casket. The angle is useful since the module  26  is wider than the portion of the casket  50  above the flange  68 . The module  26  may also be oriented such that the end of module  26  including concavity  48  is lower than the other end of the module  26  that will overlap the module  28  for reasons set forth below. 
   When the module  26  nears the bottom  60  of the casket  50 , the module  26  is moved toward the bed screw  64  such that the bed screw  64  is positioned within the concavity  48 . At about the same time, the lowermost portion of the rim  44  is positioned underneath the flange  68  and against the end wall  52 . The module  26  is then pushed in the downward direction until it becomes level. The module  26  will flex slightly to allow the rim  44  to slide past and below the flange  69  along the side walls  56  and  58 . After the rim  44  has cleared the flange  68 , the module  26  will return to its original shape, and will be positioned on the bottom  60  of the casket  50 . If the module  26  is not abutting the end wall  52 , the module  26  is moved toward the end wall  52  such that the rim  44  abuts the end wall  52  beneath the flange  68 . 
   In a similar fashion, the module  28  is installed. Specifically, the concavity  46  is aligned with the bed screw  66  with the wall portion  32  extending upwardly, away from the bottom  60  of the casket  50 . The module  28  is then pushed downward and toward the bed screw  66 . To ease insertion, the module is given a slight angle from side to side while inserting it into the casket. The angle is useful since the module  28  is wider than the portion of the casket  50  above the flange  70 . The module  28  may also be oriented such that the end of the module  28  including concavity  46  is lower than the other end of the module  28  that will overlap the module  26 . 
   When the module  28  nears the bottom  60  of the casket  50 , the module  28  is moved toward the bed screw  66  such that the bed screw  66  is positioned within the concavity  46 . At about the same time, the lowermost portion of the rim  36  is positioned underneath the flange  70  and against the end wall  54 . The module  28  is then pushed in the downward direction until it becomes level. The module  28  will flex slightly to allow the rim  36  to slide past and below the flange  70  along the side walls  56  and  58 . After the rim  36  has cleared the flange  70 , the module  28  will return to its original shape, and will be positioned on the bottom  60  of the casket  50 . If the module  28  is not abutting the end wall  54 , the module  28  is moved toward the end wall  54  such that the rim  36  abuts the end wall  54  beneath the flange  70 . At this point, rim  36  will overlap rim  44  as shown in  FIG. 6 . 
   Referring now to  FIG. 8 , an alternative embodiment of a module that incorporates features of the present invention is shown. The module  72  includes a bottom  74 , a wall portion  76  and a rim  78 . The wall portion  76  extends upwardly and outwardly from the bottom  74  and extends completely around the periphery of the module  72 . Rim  106  extends outwardly from the wall portion  76 . The module  72  is configured to be used cooperatively with two other modules, such as the modules  26  and  28 . The module  72  may be placed between the modules  26  and  28  to provide additional length to the modular drip tray assembly  12 . When so placed, the rim  78  of the module  72  may be placed to overlap with the rim  36  of the module  28  as well as with the rim  44  of the module  26 . Thus, two overlap regions are formed. In one embodiment, the adjacent modules are identical, and the wall portion  76  of the module  72  is slightly taller than the wall portions of the adjacent modules. 
   Installation of embodiments having additional modules, wherein all of the modules have a wall portion of generally the same height is preferably accomplished by first inserting the end modules, and then inserting the central module(s). Installation is thus similar to the two module installations described above, except that the rims of the end modules will not overlap each other, and the additional module is inserted. Upon insertion of the final module, all adjacent rims will be overlapping. For installation of embodiments having additional modules, wherein the modules have wall portions of different heights, it is generally preferred to install the modules with shorter wall portion heights first. 
   The invention described above may be practiced in a number of alternative ways. By way of example, but not of limitation, the adjacent rims of two modules need not be flat. Referring to  FIG. 9 , a module  80  includes a curved rim  82 . A curved rim  84  of a module  86  is shown overlapped with the rim  82 . 
   Another example is shown in  FIGS. 10 and 11 . The rim  88  of the module  90  overlaps the rim  92  of the module  94 . The rim  88  includes several protuberances  96 . The rim  92  includes a number of corresponding wells  98  (only one is shown). Each protuberance  96  is inserted into a well  98 . Engaging adjacent modules in such a manner has the benefit of ensuring that no gap is created between the modules as the casket is moved. Any such gap could lead to undesired leakage. Additionally, when using properly sized modules, engagement verifies that the modules have been properly installed since misalignment will make engagement very difficult for most embodiments. The protuberances may be sized with a head area slightly larger than the opening to the wells to create a frictional engagement between the protuberance and the well to further protect against accidental separation of the modules. Alternatively, the protuberance may be designed to simply protrude into the well without any contact. Contact in this embodiment is initiated by relative movement between the modules. In yet another embodiment, the well is replaced by an opening in the module into which the protuberance is inserted. 
   Those of ordinary skill in the art will appreciate that adjacent modules may be engaged in a number of alternative ways. The engagement may be at one or more points of engagement, or with a single engaging member that extends along the entire sides of adjacent modules. These alternatives and others are within the scope of the present invention. 
   In another embodiment of the present invention, adjacent modules may, but need not overlap. Referring to  FIG. 12 , a module  100  and a module  102  include basins  104  and  106 , respectively, and are joined by a clip  108 . As shown in  FIG. 13 , the modules  100  and  102  are formed with notches  110  and  112  respectively. The clip  108 , which in this embodiment is made of high density polyethylene, engages the notches  110  and  112 . The clip  108  in this embodiment is sized to extend across the entire width of the basins  104  and  106  when the assembly is installed into a casket. The clip  108  thus acts as an overlap member and provides an overlap region spanning a portion of the modules  100  and  102 . 
   Referring to  FIGS. 14 and 15 , a module  114  and a module  116  include basins  118  and  120 , respectively, and are joined by a clip  122 . As shown in  FIG. 15 , the modules  114  and  116  are formed with notches  124  and  126  respectively. The clip  122  includes arms  128  and  130  that engage the notches  124  and  126  in a manner similar to that of the clip  108  shown in  FIGS. 12 and 13 . However, the clip.  122  also includes a spacer bar  132 . The spacer bar  132  is sized to ensure that the modules  114  and  116  abut the ends of a casket when installed, while the arms  130  and  132  provide stability to the final assembly. 
   It will be appreciated that the above embodiments are merely exemplary, and that those of ordinary skill in the art may readily devise their own implementations and adaptations that incorporate the principles of the present invention and fall within the spirit and scope thereof. By way of example, but not of limitation, the clips shown in  FIGS. 12–15  may be modified to extend completely across the modules, or a plurality of clips may be provided to be used to join two modules. Additionally, the clips may be made from a material different than the material used to form the modules. The salient consideration is that sufficient resiliency exists between the clip and the modules to allow the clip to be snapped into a position wherein both modules are engaged by the clip. 
   Moreover, many detailed features have been disclosed herein that provide additional advantages beyond those of the present invention, or indeed enhance the present invention. It will be appreciated that many of the advantages of the present invention may be obtained without such detailed features. Accordingly, the claims defined below are not intended to incorporate portions or details of the disclosed embodiments that are not expressly recited in the claims. The principles of the present invention have widespread applications, and may be incorporated into any number of modular drip tray assembly designs by those of ordinary skill in the art. In addition, it will be appreciated that while embodiments described herein employ two modules, other embodiments may employ three or more modules.