Abstract:
A columbarium having a framework of a plurality of horizontally spaced vertical risers and a plurality of vertically spaced horizontal members defining a plurality of niches arranged in substantially horizontal rows and substantially vertical columns. Each of the horizontal members has a substantially planar web extending between a front rail and a back flange. A plurality of shutters is removably mounted over the plurality of niches by a concealed mounting system. The concealed mounting system permits the shutters to be movable about three axes of rotation as well as vertically and horizontally with respect to the horizontal members.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    For purposes of the United States, this application is a continuation-in-part of U.S. patent application Ser. No. 12/476529, filed Jun. 2, 2009. 
     
    
     BACKGROUND 
       [0002]    Stone shutters are removably secured to columbarium structures by a mounting system that is preferably substantially concealed or substantially hidden from view so as not to detract from the appearance of the stone and the reverent atmosphere of the columbarium. The concealed mounting system must resist corrosion and it must securely hold the shutters in position despite extreme temperature swings and countless freeze-thaw cycles for season-after-season and year-after-year, for decades, if not centuries. In addition, the mounting system must permit the shutters to be relatively easily removed and replaced even after years or decades of being exposed to the elements. 
         [0003]    U.S. Pat. No. 4,6108,711 to Eickhof discloses one type of concealed shutter mounting system that meets all of the foregoing challenges. Variations of the Eickhof &#39;711 concealed shutter mounting system have achieved significant commercial success in the columbarium industry. However, a simpler and more cost effective concealed fastener system is needed in view of the recent trend away from using large 24″×24″ stone panels and toward the use of 8″×8″ individual niche shutters. The terms “shutter,” “panel,” “slab” and “facing stone” are used interchangeably throughout this specification. 
         [0004]    A standard columbarium niche is 8″×8″. Until relatively recently, it was common to use 24″×24″ stone slabs with false joints cut into the finish face of the stone slab to simulate nine 8″×8″ individual niche shutters. Each of the nine 8″×8″ spaces on the large panel is typically engraved with a the name, birth year and death year of the deceased person whose urn resides behind that 8″×8″ space. Thus, each time an urn is to be placed into one of the nine niches, or each time one of the nine niches is to be engraved, the entire 24″×24″ stone panel has to be removed and then replaced. A typical 24″×24″ stone panel weighs about sixty pounds. Because of the potential for misspelling of names or errors in the birth or death dates during each time the panel is engraved, it is not uncommon to have to discard and replace an entire panel due to a single mistake made when engraving one of the nine niches. Accordingly, it should be appreciated that large panels are not only difficult to handle by a single person due to their size and weight, but the use of large panels can be expensive if the panels need to be replaced due to engraving errors. 
         [0005]    As a result of the foregoing concerns with the use of 24″×24″ panels, a relatively recent trend in the columbarium industry is to use 8″×8″ individual niche panels. These smaller panels are easier to handle during initial installation and when they need to be subsequently removed for engraving or when placing an urn within the niche. If there is ever an engraving error, only the single 8″×8″ panel needs to be replaced instead of the entire 24″×24″ panel. It should be appreciated, however, that when going from one large panel to nine smaller individual panels, all other things being equal, the amount of individual hardware pieces required to mount the panels will necessarily increase as will the amount of material costs and labor costs associated with the initial assembly of the panels and the initial mounting of the panels. 
         [0006]    Accordingly, there is a need in the industry for a universal concealed mounting system capable of use with virtually any size columbarium shutters, but which has fewer pieces and is quicker and easier to assemble and install then currently available mounting systems in order to reduce material costs and labor costs so that even the use of smaller individual 8″×8″ shutters is at least as cost effective as using larger 24″×24″ panels mounted with currently available mounting systems. 
         [0007]    Heretofore, columbaria structures have been constructed using a variety of different materials and techniques. For example, some columbarium structures have been constructed using cast-in-place or precast concrete to form the niches. Other columbarium structures have been constructed entirely from aluminum members welded or bolted together to form the niches. While each of these types of construction may serve the intended purpose, both construction types are costly and time consuming. U.S. Pat. No. 5,195,812 to Eickhof (hereinafter “the &#39;812 patent”) discloses a columbarium structure that is comprised of a framework of vertical risers and horizontal shelves secured together by brackets and tie-rods to form the niches. The &#39;812 patent discloses that the vertical risers are constructed of cement fiberboard and the plastic shelves are constructed of extruded plastic. The &#39;812 patent discloses that the back of the niches are closed off by large cement fiberboard panels secured by rivets or screws to the back flange of the extruded horizontal shelves. The framework of niches is then secured to a supporting wall or another bank of niches. The type of framework construction disclosed in the &#39;812 patent has proven to be very commercially successful due to the savings in labor, time and materials over previous construction methods because the framework is comprised of relatively light weight prefabricated members designed to easily fit together for quick assembly while still providing a durable and quality appearance. 
         [0008]    Some customers, however, viewed the use of plastic shelves as being of lesser quality and it was also found that the dimension tolerances of the extruded plastic shelves could not be satisfactorily controlled, impeding the assembly process. As a result, as disclosed in co-pending U.S. patent application Ser. No. 12/476529 to Eickhof (hereinafter “the &#39;529 application”), the extruded plastic shelves were replaced with cement fiberboard. While cement fiberboard shelves provide a more high quality appearance than plastic shelves, they are much heavier and therefore more expensive to ship and more difficult to lift and handle. Furthermore, with the use of a cement fiberboard shelf, both a front rail and a back rail are necessary to support the shelf and to provide the necessary surface area on which to secure the cement fiberboard to enclose the back of the niches and to support the stone facing at the front of the niche. Accordingly, there is a need for a columbarium construction that provides the features and advantages of the framework system disclosed in the &#39;812 patent and which provides the higher quality appearance disclosed in the &#39;529 application, but which is lighter weight for easier handling, which reduces shipping costs, and which reduces handling and labor costs for assembly. 
         [0009]    Furthermore, although the concealed mounting system disclosed in the &#39;529 application was a significant improvement over previous concealed mounting systems, the mounting system disclosed in the &#39;529 application did not permit in-and-out adjustment of the shutters or facing stones. As a result, if there was even a minor variation in thickness of the facing stones, it was difficult to adjust the stones in-and-out to provide a smooth or flush wall surface. Furthermore, with the mounting system of the &#39;529 application, when a facing stone was removed, unless it was replaced exactly in the original location the vertical gap between adjacent stones would be inconsistent and detract from the appearance of the columbarium unless time was taken to adjust the facing stone to correct the gap or spacing between the adjacent stones. Additionally, some customers prefer a columbarium structure with a relief pattern in the facing stones. Accordingly, it is desirable to provide a concealed mounting system that can accommodate different stone thicknesses and to permit in-and-out adjustment so the facing stones can be easily placed with the desired relief pattern in the wall. It is also desirable to provide a mounting system, that will allow the facing stones to be replaced in the same location so as to ensure spacing between the stones remains uniform without having to adjust the stones after they are replaced. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a perspective view of a columbarium comprising a plurality of niches, wherein some of the niches are open, some are shown with inner closure panels disposed over the front opening, and other niches are shown with shutters mounted utilizing an embodiment of a concealed mounting system cooperating with an embodiment of the horizontal member. 
           [0011]      FIG. 2  is partial side perspective view of the columbarium of  FIG. 1  showing a detailed view of the preferred embodiment of the concealed mounting system and horizontal member. 
           [0012]      FIG. 3  is a cross-sectional view of the columbarium of  FIG. 1  as viewed along lines  3 - 3  of  FIG. 1 . 
           [0013]      FIG. 4  is an enlarged view of the area circled in  FIG. 3  showing in detail the preferred embodiment of the bottom hanger and swivel socket of the concealed mounting system. 
           [0014]      FIG. 5  is an enlarged view of the other area circled in  FIG. 3  showing in detail the preferred embodiment of the upper clip and upper lock of the concealed mounting system. 
           [0015]      FIG. 6  is a rear perspective view of a shutter illustrating a portion of the preferred embodiment of the concealed mounting system secured to the back side of the shutter. 
           [0016]      FIG. 7  is an exploded perspective view of the shutter and portion of the concealed mounting system of  FIG. 6  and illustrating the slots fabricated into the back side of the shutter to receive the anchors. 
           [0017]      FIG. 8  is a perspective view of a columbarium with an example of a relief pattern to show how different size facing stones and different thicknesses of stones can be used with the concealed mounting system of the present invention to create different mosaics and relief patterns. 
       
    
    
     DESCRIPTION 
       [0018]    Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views,  FIG. 1  is a perspective view of a columbarium  10  comprising a plurality of niches  12  which may hold one or more urns  13 . Some of the niches  12  are shown open, some are shown with inner closure panels  14  disposed over the niche opening, and other niches  12  are shown with shutters or facing stones  16  secured over the closure panels  14  utilizing a concealed mounting system  100  as described in detail later. 
         [0019]    The columbarium  10  preferably comprises a framework  20  of horizontally spaced, vertical, planar risers  22  and vertically spaced, horizontal shelves  24 . As disclosed in U.S. Pat. No. 5,195,812 to Eickhof (hereinafter “the &#39;812 Patent”) and in pending U.S. application Ser. No. 12/476529 (hereinafter “the &#39;529 Application”), both of which are incorporated herein in their entirety by reference, shelf brackets  26  and tie rods  28  (best viewed in  FIG. 3 ) secure the vertical risers  22  and horizontal shelves  24  in spaced relation to define a grid of a plurality of niches  12 . However, unlike the systems disclosed in the &#39;812 patent or in the &#39;529 Application, in the embodiment of the present invention (discussed in greater detail later), the horizontal shelves  24  are preferably comprised of a single horizontal member  200  that includes a front rail  202  and a back flange  204  joined by a planar web  206  (best viewed in  FIG. 3 ). As discussed in detail later, the front rail  202  cooperates with the concealed mounting system  100  to adjustably support the shutters or facing stones  16 . The back flange  204  provides a surface to which the back wall  32  is secured by rivets or threaded connectors. It should be appreciated that the large section modulus of the horizontal member  200  (resulting from the front rail  202 , back flange  204  and web  206 ) provides substantial lateral and longitudinal stability when the framework structure  20  is tied together with the tie rods  28 . 
         [0020]    The horizontal member  200  is preferably fabricated from extruded aluminum, but may be fabricated from pultruded fiber reinforced polymer (“FRP”) or any other suitably rigid, weather resistant, and dimensionally stable, extrudable or pultrudable materials. The dimensions of the horizontal member  200  may vary depending on the desired size of the niches  12 , the span between risers  22 , any anticipated static or dynamic loading conditions, the overall dimensions of the framework  20  and the support structure (if any) to which the framework  20  is to be secured. 
         [0021]    As best illustrated in  FIGS. 2-5 , the front rail  202  of the horizontal member  200  includes a forwardly projecting flange  208  having a top surface  210  offset a distance downwardly from the top surface of the web  206 . The front rail  202  also includes a downwardly projecting flange  212 . A top channel  214  and a top slot  216  are also formed along the length forwardly projecting flange  208 . Referring to  FIG. 3 , when two horizontal members  200  are disposed in vertical spaced relation, the top slot  216  of the lower horizontal member  200  is vertically aligned with the front face of the downwardly projecting flange  212  of the upper horizontal member  200  so that the inner closure panel  14  is substantially vertical. As best viewed in  FIGS. 4 and 5 , a turn tab  218  is pivotally secured to the downwardly projecting flange  212  by a threaded connector or rivet  220  to hold the top edge of the inner closure panel  14  in position, while the bottom edge of the inner closure panel  14  is received in the top slot  216 . To remove the inner closure panel, the turn tab  218  is rotated up to free the top edge of the inner closure allowing the top edge to tilt forwardly so it can be grasped and lifted from the top slot  216  of the lower horizontal member  200 . 
         [0022]    Referring to  FIGS. 2-7 , the concealed mounting system  100  preferably includes an upper clip  102  and at least one, preferably two, lower support hangers  104  secured to the back side of the shutter  16 . The upper clip  102  preferably includes an upwardly curving hook  106  that receives and is engaged by the upper lock  150  (described in greater detail later). The lower support hangers  104  preferably comprise an L-shaped bracket  108  with threaded studs  110  threadably received through a threaded apertures  112  in the rearwardly projecting leg  114  of the L-shaped bracket  108 . The upper clip  102  and hangers  104  are preferably fabricated from extruded aluminum or other suitably rigid, weather resistant and dimensionally stable, extrudable or pultrudable material. 
         [0023]    In the preferred embodiment, as best illustrated in  FIGS. 4 ,  5  and  7 , the clip  102  and hangers  104  are secured with threaded anchors  120 . The heads  122  of the threaded anchors are received within inverted T-shaped slots  124  cut into the back side of the stone such as disclosed in U.S. Pat. No. 4,020,610, which is incorporated herein in its entirety by reference. The threaded shaft  126  of the anchors  120  project from the back face of the shutter  16  and are received through apertures  128  in the clips  102  and hangers  104 . A nut  130  is threaded onto the projecting threaded shaft  126  and are preferably tightened to approximately 95 in-pounds of torque to securely attach the clips  102  and hangers  104  in place and to prevent their rotation. 
         [0024]    The preferred concealed mounting system  100  further includes at least one hanger support  132 , preferably two, for cooperatively receiving and supporting the threaded stud  110 . The hanger support  132  preferably comprises a swivel socket with an elongated body  134  having an aperture  136  near one end and a socket or indentation  138  at an opposite end. The swivel socket  132  is slidably positioned along the front rail  202  of the horizontal member  200  by a threaded lug  140  having a head  142  received within the top channel  214  of the front rail  202 . The shaft  144  of the lug  140  extends through the top channel  214  and into the aperture  146  of the swivel socket  132  and is secured by a nut  148 . By loosening and tightening the nut  148 , the swivel socket  132  can pivot or swivel about the lug  140  and can be slidably, adjustably, fixably positioned anywhere along the length of the top channel  214  in order to align the socket  138  to receive the downwardly extending threaded stud  110 . By turning the threaded stud  110  clockwise or counterclockwise it will cause the shutter  16  to raise or lower, respectively, relative to the swivel socket  132  and front rail  202  thereby providing vertical adjustment of the shutter  16 . Likewise, by loosening and tightening the nut  148  on the lug  140 , the swivel socket  132  can pivot inwardly or outwardly relative to the front rail  202  thereby providing in-and-out or fore-and-aft adjustment at the bottom of the shutter  16 . 
         [0025]    The concealed mounting system  100  also preferably includes an upper lock  150 . The upper lock  150  includes a rearwardly projecting flange  152  having an elongated slot  154 . Similar to the swivel sockets  132 , the upper lock  150  is slidably positioned along the front rail  202  of the horizontal member  200  by a threaded lug  140  having a head  142  received within the top channel  214  of the front rail  202 . The shaft  144  of the lug  140  extends through the top channel  214  and into the elongated slot  154  of the rearwardly projecting flange  152 . By loosening and tightening the nut  148  threaded over the shaft  144  of the lug  140 , the upper lock  150  can be positioned inwardly or outwardly relative to the front rail  202  thereby providing in-and-out or fore-and-aft adjustment at the top of the shutter. Furthermore, by loosening and tightening the nut  148  on the lug  140  the upper lock can be slidably, adjustably, fixably positioned at the desired location along the channel  214 . This lug and nut configuration avoids the need to drill a hole through the front rail required for the locking screw in the &#39;529 application. Additionally, because the lugs  140  of the top lock  150  and bottom hanger supports  132  use the same channel, the front rails has a simpler cross-section and requires less material than the front rail disclosed in the &#39;529 application. 
         [0026]    The preferred upper lock  150  includes a forwardly extending channel  156 , and a downwardly extending channel  158 . Apertures  160 ,  162  extend through the forwardly extending channel  156  and downwardly extending channel  158 , respectively. A locking screw  164  passes through both apertures  160 ,  162 . The locking screw  164  includes a threaded upper shaft  166  and a rectangular lower shaft  168 . The threaded upper shaft  166  is threadably received by a nut  170  disposed within the forwardly extending channel  156 . The nut  170  is larger than the diameter of the apertures  160 ,  162  such that the locking screw  164  is vertically supported within the forwardly extending channel  156  by the nut  170 . The width of the rectangular lower shaft  168  of the locking screw is preferably only slightly less than the width between the legs of the downwardly extending channel  158  such that the rectangular lower shaft  168  prevents the locking screw  164  from rotating within the channel  158 . 
         [0027]    As best illustrated in  FIG. 2 , the nut  170  is accessible for rotation by an open end wrench  172  ( FIG. 2 ) inserted in the gap  174  between vertically adjacent shutters  16 . It should be appreciated that because the cooperation of the rectangular lower shaft  168  within the downwardly extending channel  158  prevents the locking screw  164  from rotating. Upon turning the nut  170  clockwise using the wrench  172 , the locking screw  164  is caused to move downwardly allowing the end of the rectangular lower shaft  168  to engage the upwardly curving hook  106  of the upper clip  102 . Likewise, by rotating the nut  170  counter-clockwise using the wrench  172 , the locking screw  164  is caused to move upwardly thereby disengaging the end of the rectangular lower shaft  168  from the upward hook  106  of the clip  102  and allowing the shutter  16  to be easily removed for access to the niche  12 . The end of the rectangular lower shaft  168  is preferably beveled to better mate with the upwardly curving hook  106 . 
         [0028]    The in-and-out adjustment capability at the top of the shutter when combined with the in-and-out adjustment capability at the bottom of the shutter, allows for easier and faster installation of shutters and better accommodates different shutter thicknesses, whether due to thickness tolerances or inconsistencies in the stone or whether different stone thicknesses are being used to create a relief pattern such as shown in  FIG. 8 . Furthermore, it should be appreciated that once the nut  148  is tightened down, the swivel sockets  132  and the top lock  150  are prevented from pivoting or sliding horizontally within the top channel  214 . Thus, if the facing stone or shutter  16  is ever removed, when it comes time to replace the shutter, the threaded studs  110  will be guided to seat in the bottom of the sockets  138  of the swivel socket  132  and the top lock  150  will cooperate to ensure that the shutter is returned to the exact same position before it was removed thereby avoiding the tedious task of having to readjust the shutter to ensure a uniform gap with the adjacent shutters. 
         [0029]    As shown in  FIG. 1 , It should also be appreciated that through the pivotable movement of the swivel sockets  132 , and with the centrally positioned upper lock  150 , the shutter is capable of pivoting about a vertical Y axis as indicated by arrow  180 . Furthermore, with threaded studs  110  received within the swivel sockets  132 , and with the curvature of the upper clip cooperating with the upper lock  150 , the shutter is also able to pivot about a horizontal X axis as indicated by arrow  182 . Also, with the independent vertical adjustability of the threaded studs  110  cooperating with the swivel sockets, the shutter is also able to pivot about the Z axis as indicated by arrow  184 . Thus, the shutter  16  is capable of being adjustable in three dimensions or about three axes of rotation, thereby enabling infinite adjustment of the shutters  16  to ensure uniform gaps are maintained between adjacent shutters for a more pleasing aesthetic appearance and to ensure the front of adjacent shutters are flush if desired, or as illustrated in  FIG. 8 , to allow adjacent shutters to be moved in or out to create a relief pattern if desired. 
         [0030]    As shown in  FIG. 8 , it should also be appreciated that the concealed mounting system  100  allows more versatility than current shutter mounting systems by allowing the upper clips  102  and hangers  104  on the back of the shutters  16  to have varying positions between adjacent shutters and it allows for the shutters  16  to be placed anywhere along the front rail. This versatility will permit different sized niche fronts to be used along the columbarium wall thereby avoiding the post-office-box look that is often created when an entire columbarium wall comprises a grid of 8″×8″ shutters. For example, the mounting system  100  will easily allow 8″×8″ single niche shutters to be positioned adjacent 8″ high×16″ wide shutters or vertical 16″ high×8″ wide shutters or 12″×12″ shutters or 24″×24″ panels as desired. Accordingly, the mounting system  100  will allow more versatility in the configuration of niche fronts to create embellishments and introduce more and different types of stone mosaic patterns. 
         [0031]    The foregoing hardware and components comprising the concealed locking system are preferably made of corrosion resistant material such as stainless steel, brass or aluminum or plated with a corrosion resistant finish and are preferably galvanically compatible with the other components to which they come into contact to minimize oxidation or corrosion so they remain capable of supporting the loads anticipated for the structure and withstanding extreme environmental conditions to which they may be subject. 
         [0032]    It should be appreciated that the concealed mounting system  100  and cooperating horizontal member  200  may have application outside the internment industry where a concealed mounting system is desired for security or aesthetic reasons. For example, the concealed mounting system  100  and cooperating horizontal member  200  may be used in building structures that require removable wall panels. Another application may be for removably securing protective panels over windows of buildings or houses for protection from hurricanes or high winds. The foregoing mounting system  100  is equally suitable for fixed wall panels, where, once mounted, there may never be a need to remove the panel. Other applications may include the commercial sign industry where a concealed hardware is desirable to deter vandals and allow easy change-out of signs, advertisements, tenant directories, etc. 
         [0033]    The foregoing description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the preferred embodiment of the apparatus, and the general principles and features of the system and methods described herein will be readily apparent to those of skill in the art. Thus, the present invention is not to be limited to the embodiments of the apparatus, system and methods described above and illustrated in the drawing figures, but is to be accorded the widest scope consistent with the spirit and scope of the appended claims.