Patent Publication Number: US-9427369-B2

Title: Foldable casket with corner supports

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to caskets, and more particularly, to lightweight caskets. 
     BACKGROUND OF THE INVENTION 
     Caskets and cremation containers are constructed from a plurality of materials, including wood, metal, and paper materials, as well as combinations of the foregoing. These caskets and cremation containers vary substantially in price. While wood and metal-based caskets can be expensive, paper-based cremation containers can provide a viable low cost option when cremation is contemplated. In fact, extremely low costs may be achieved by employing a corrugated paper cremation container, which costs a fraction of the cost of hardwood or metal caskets. Even if cost is not a major consideration, corrugated paper caskets are a popular choice for cremation, in part because they are completely consumed during the cremation process. 
     Many corrugated paper caskets can have ornamentation and other design elements that approximate decorative wood or steel caskets. Many people find such paper caskets to be suitable for presentation at a viewing and/or funerary service. These ornately designed paper caskets represent a cost savings over hardwood caskets, and are particularly advantageous in cases in which the casket is to be consumed during the cremation process. 
     While ornately designed paper caskets are less expensive than hardwood caskets, they still represent a significant cost that may not be practical in some cases. In such cases, a more inexpensive option is a simple rectangular corrugated paper container and associated simple rectangular lid that fits over the container in a manner similar to that of a common shoebox. The deceased fits within the container and then the rectangular lid is fitted over the container to close off the casket. 
     The need for such inexpensive caskets arises in situations of financial need, and also in disaster areas where many deceased are located in a relatively small area. The paper container has significant advantages over traditional caskets in this environment including the ability to transport significant numbers of the lightweight paper casket and the disposability of such caskets. 
     While cardboard cremation caskets are typically considered to be an economical approach the storage of the deceased, a significant cost nevertheless arises as a result of shipping and storage costs. Even though the caskets are fairly light, they are more or less as bulky as traditional wood and metal caskets. 
     One solution to the costs associated with storage and shipment of caskets is the implementation of paperboard caskets that can be shipped as flat paperboard blanks, or as partially constructed caskets, which can be further constructed as needed at the funeral or cremation establishment. For example, U.S. Pat. No. 8,347,467 shows a lightweight, inexpensive casket that may in large part assembled at the funeral establishment, or other retail establishment where the casket may be sold. The foldable casket of U.S. Pat. No. 8,347,467 is relatively easy to assemble, is low cost, and occupies a reduced footprint during shipping and storage. For example, in the casket shown in FIG. 6 of U.S. Pat. No. 8,347,467, the base, which requires more complex assembly, may be assembled prior to shipment, such as at the factory. The lid, which is bulkier and lighter, can be shipped flat and assembled at the funerary establishment or other retail or wholesale establishment. 
     Nevertheless, one drawback of lightweight foldable caskets is that in many cases, they cannot be stacked (in the assembled state) without damaging the lids. In particular, it is sometimes desirable for the casket retail establishment to assemble several caskets to be ready for immediate use. It is often convenient to store multiple assembled paperboard caskets by stacking the caskets. However, the lightweight lids of the caskets, when assembled, often do not have sufficient strength to support several stacked caskets. When such caskets are stacked, the lids can bend or crush under the weight. 
     Accordingly, there is a need for a lightweight foldable casket that can be stacked after assembly without damaging the lid of the casket. 
     BRIEF SUMMARY OF THE INVENTION 
     The inventions described herein have several aspects, each of which individually addresses on or more of the problems of the prior art discussed above, and/or other problems or shortcomings not specifically mentioned, but which will become readily apparent to those of ordinary skill in the art by reference to the following detailed description and accompanying drawings. 
     In a first embodiment, a casket includes a container configured to receive a deceased, the container including a bottom and sides defining at least a part of a casket interior. The casket further includes a lid disposed on the container to cover the casket interior. The lid is formed from a corrugated paperboard blank folded into a lid structure. The lid structure includes a top panel, at least two side panels and at least one end panel, and a plurality of supports extending to a height of the side panels. Each of the corner supports includes at least a first panel extending diagonally from a first location proximate one of the side panels to a second location proximate the at least one end panel. The first panel has a first length corresponding to the height of the side panels. 
     The support structures strengthen the lid sufficient to allow items, for example, other caskets, to be stacked atop the assembled lid. The lid structure in at least some embodiments may be assembled at a retail establishment due to the ease of assembly 
     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 a perspective view of an exemplary casket according to a first embodiment of the present invention; 
         FIG. 2  shows a perspective view of an exemplary lid structure according to at least one embodiment of the present invention; 
         FIG. 3  shows a fragmentary perspective view of a portion of the lid structure of  FIG. 2 ; 
         FIG. 4  shows an exemplary embodiment of a blank that may be folded into the lid structure of  FIG. 2 ; 
         FIG. 5 a    shows a fragmentary perspective view of the blank of  FIG. 4 ; 
         FIG. 5 b    shows the fragmentary perspective view of the blank of  FIG. 5 a    wherein the blank has been partially assembled into the lid structure of  FIG. 2 ; 
         FIG. 5 c    shows the fragmentary perspective view of the blank of  FIG. 5 a    wherein the blank has been further partially assembled into the lid structure of  FIG. 2 ; 
         FIG. 5 d    shows the fragmentary perspective view of the blank of  FIG. 5 a    wherein the corner support of the lid structure of  FIG. 2  has been substantially completed; 
         FIG. 5 e    shows a different fragmentary perspective view of the blank of  FIG. 4  showing two corner supports substantially completed; 
         FIG. 5 f    shows the fragmentary perspective view of the blank of  FIG. 5 e    wherein the lid structure is further assembled; and 
         FIG. 5 g    shows the fragmentary perspective view of  FIG. 5 e    wherein the lid structure is completed. 
     
    
    
     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 an embodiment of a casket  10  that includes strengthening features and a convenient assembly. The exemplary casket arrangement  10  according to the invention includes a casket body or container  12  and a one piece lid  14 . The container  12  is preferably in the form of an open-top box formed of corrugated paper. To this end, the container  12  includes a bottom panel  16 , side panels  18 , end panels  19 , and defines at least part of a casket interior, not visible in  FIG. 1 , but which disposed in the area generally between the side panels  18  and the end panels  19 . The container also includes handle holes  13 . The container  12  may suitably have the same structure as the casket body of FIG. 6 of U.S. Pat. No. 8,347,467, the disclosure of which is incorporated herein by reference. However, it will be appreciated that other casket containers designs may be used in other embodiments. 
     The lid  14  is disposed on the container  12  to cover the casket interior. The lid  14  is formed from a corrugated paperboard blank  100  (see  FIG. 4 ) folded into a lid structure  22 .  FIG. 2  shows a perspective view of the lid  14 , apart from the container  12  to reveal the bottom structure. With simultaneous reference to  FIGS. 1 and 2 , the lid structure  22  includes a top panel  24 , a first side panel  26 , a second side panel  28 , a first end panel  30 , a second end panel  32 , and four corner supports  34 ,  36 ,  38  and  40 . The four corner supports  34 ,  36 ,  38  and  40  provide the structural strength to the lid  14  to withstand stacking weight of multiple similar caskets. To this end, the corner supports  34 ,  36 ,  38  and  40  have the same height as the side panels  26 ,  28 , or in other words extend from the top panel  24  to the lower edge of the side panels  26 ,  28 . 
       FIG. 3  shows a fragmentary perspective view that illustrates the first corner support  34  in further detail. The corner support includes a first panel  42 , a second panel  44 , and a third panel  46  that are integrally formed with each other, and formed from folding paper board, as will be discussed below in connection with  FIGS. 4-5   g . The first panel  42  extends diagonally from a first location  48  proximate the first side panel  26  to a second location  50  proximate the end panel  30 . The first panel  42  has a first length corresponding to the height of the side panel  26  as well as the end panel  30 . However, it will be appreciated that in alternative embodiments, the first panel  42  may have a length that it substantially the same as the longer of either the side panel  26  or the end panel  30 . 
     The second panel  44  extends from the first panel  42  at the second location  50  to a third location  52  that is proximate an intersection  54  of the first side panel  26  and the first end panel  30 . The second panel  44  extends from and is foldably connected to the first side panel  26 . It will be appreciated that in an alternative embodiment, the second panel  44  is foldably connected to the first end panel  30  and extends from the first panel  42  at the first location  48  to the third location  52 . In any event, the second panel  44  has the same height/length as that of the first panel  42 . 
     The third panel  46  extends from the first location  48  to the third location  52 . To this end, the third panel  46  extends from and is foldably coupled to the first panel  42 . Thus, in this embodiment, the third panel  46  is coupled directly to the first panel  42 , and the second panel  44  is coupled directly to the first panel  42 . The third panel  46  has the same height/length as that of the first panel  42 . The third panel  46  also includes one or more tabs  56  (not shown in  FIG. 3 ) extending from an edge of the third panel. As will be discussed below in connection with  FIGS. 5 a -5 g   , the tab  56  is received into a corresponding slot  58  located at the intersection  54  of the first side panel  26  and the first end panel  30 . 
     As shown in  FIG. 3 , the first end panel  30  further includes a first end tab  60  extending from the edge of the first end panel  30 . In the folded lid structure  22 , the first end tab  60  is disposed in a fourth location  62  defined between the first panel  42  and the first end panel  30  and/or and the first side panel  26 . In this embodiment, the first end tab  60  is of sufficient width that it is trap fit by first panel  42  and the first side panel  26  against the first end panel  30 . The first end tab  60  thus operates in part hold the first end panel  30  in position. In other embodiments, fasteners and/or adhesive may be used. However, to facilitate assembly at funeral homes and other retail establishments, the trap fit of the embodiment described herein is especially advantageous because it eliminates the need for adhesives or coupling mechanisms. 
     Referring again to  FIGS. 1 and 2 , it will be appreciated that the corner supports  36 ,  38  and  40  have substantially the same structure and configuration as that of the first corner support  34 . Moreover, the other intersections of side panels  26 ,  28  and the end panels  30 ,  32  include slots for receiving tabs of corresponding third panels of the respective corner supports  36 ,  38  and  40 . 
     The lid structure  22  shown in  FIGS. 1-3  provides an easy to assemble lid  14  that may be shipped as a corrugated or kraft paper board blank. The lid structure  22 , when assembled onto the container  12  (or other containers), can be stacked with other like structures without damage or failure. 
       FIG. 4  shows a corrugated paperboard blank  100  from which the lid structure  22  is formed. The blank  100  includes all the elements and features of the lid structure  22  in unfolded form. Like reference numbers are used to identify similar structures on the blank  100  of  FIG. 4  and the lid structure  22  of  FIGS. 1-3 . 
     As shown in  FIG. 4 , the side panels  26 ,  28  are connected to the top panel  24  via respective fold lines  102 ,  104 . Similarly, the end panels  30 ,  32  are connected to the top panel  24  via respective fold lines  106 ,  108 . The first corner support  34  is connected to one of the short edges of the first side panel  26  via a fold line  110 . The fourth corner support  40  is connected to the opposite short edge of the first side panel  26  via a fold line  112 . The second corner support  36  is connected to one of the short edges of the second side panel  28  via a fold line  114 , and the third corner support  38  is connected to the opposite short edge of the first side panel  26  via a fold line  116 . 
     Referring specifically to the first corner support  34 , the fold line  110  connects the first side panel  26  to the second panel  44  of the first corner support  34 . The slot  58  is disposed on or about, and preferably extends parallel to, the fold line  110 . The opposite edge of the second panel  44  is coupled to the first panel  42  via a fold line  118 . The opposite edge of the first panel  42  is coupled to the third panel  46  via a fold line  120 . 
     As discussed further above, the second corner support  36  has substantially the same structure as the first corner support  34 . Accordingly, the second corner support  36  also has a first panel  42   a , second panel  44   a , and third panel  46   a  coupled in the same way. The second corner support  36  also includes a tab  56   a  on the third panel  46   a  that is configured to be received by a corresponding slot  58   a  in the fold line  114 . As discussed above in connection with  FIGS. 1-3 , the third corner support  38  an fourth corner support  40  have the same structure. 
     It will be appreciated that the blank  100  may suitably be die-cut from rectangular piece of paperboard or kraft paper. The fold lines  102 ,  104 ,  106 ,  108 ,  110 ,  112 ,  114 ,  116 ,  118  and  120  may suitably be slit scored. 
       FIGS. 5 a -5 g    show a series of fragmentary views of the blank  100  that illustrate the method of construction of the corner support  34  and the corresponding side panels  26 ,  28  and end panel  30 .  FIGS. 5 a -5 d    show the panels  42 ,  44 , and  46  of the first corner support  34  in different stages of folding/assembly.  FIGS. 5 e -5 g    show the assembly of one of the end panels  30  onto the side panels  26 ,  28 . 
     Referring to  FIG. 5 a   ,  FIG. 5 a    shows a fragmentary view of the blank  100  illustrating the panels  42 ,  44  and  46  in an unfolded state. In a first step, with the blank  100  lying flat on a surface, the third panel  46  is folded upward along fold line  120  with respect to the first panel  42 , and the first panel  42  is folded in the same way along the fold line  118  with respect to the third panel  44 , as shown in  FIG. 5 b   . As shown in  FIG. 5 c   , the panels  46  and  44  are further folded over onto themselves to form a triangular structure, and the tab  56  is inserted into the slot  58 . 
     Thereafter, the triangular structure formed by the panels  42 ,  44 , and  46  is further folded over such until the third panel  46  extends in a plane that is almost parallel to that of the side panel  26 , as shown in  FIG. 5 d   . The resulting structure in  FIG. 5 d    is the substantially complete corner structure  34 . 
       FIG. 5 e    shows a fragmentary perspective of the blank  100  with the first and second corner supports  34 ,  36  assembled, but the side panels  26 ,  28  and end panel  30  unassembled with respect to each other. To complete the assembly of the lid structure  22 , the side panels  26 ,  28  are folded up to the vertical position, the first end panel  30  is folded up to the vertical position, and then the end tabs  60  are inserted into the interiors of the corner supports  34 ,  36 . (See  FIGS. 5 f , 5 g   ). The second end panel  32 , not shown in  FIGS. 5 f , 5 g   , is constructed in an analogous way. 
     The method of construction illustrated in  FIGS. 5 a  to 5 g    may readily be carried out at a retail establishment. As a consequence, the blank  100  of  FIG. 4  may be shipped to a location, along with (or separate from) a more complex, assembled base, such as the container  12 . Because in many cases, such as the embodiment of  FIG. 1 , the container  12  has a lower profile than the lid  14 , shipping an assembled container  12  and an unassembled blank  100  can save significant space. In some embodiments, both the container  12  and the lid  14  may be shipped in unassembled state, and assembled at the retail location, thus further saving shipping costs and space. 
     The supports  34 ,  36 ,  38  and  40  provide an integral strengthening mechanism along the load bearing portion of the casket  10  that extends from the top of the lid  14  to the base or bottom of the container  12 . The supports  34 ,  36 ,  38  and  40  thereby allow for the stacking of other caskets or objects on top of the lid  14 , both on and off of the container  12 . The strengthening can occur even if fewer than all four corner supports are employed, and/or if additional strengthening measures are employed. In the exemplary embodiment described herein, the diagonal first panel  42  of the support  34  provides a strengthening bracing, and the panels  44  and  46  reinforce the corner areas of the side panel  26  and end panel  30 . 
     It will be appreciated that the above-described embodiments are merely illustrative, and that those of ordinary skill in the art may readily devise their own implementations and modifications that incorporate the principles of the present invention and fall within the spirit and scope thereof.