Patent Grant
7434298
The present invention generally relates to a modular casket or coffin and more particularly to a modular casket or coffin having an integral image.
Caskets or coffins are typically purchased during a stressful time shortly after the unfortunate need arises due to the death of a loved one. Although caskets have been traditionally purchased through a funeral home, caskets could be more available from alternative point of sale locations such as directly from a funeral supply stores, the internet, and retail locations. The available selection of caskets, however, is mostly limited to steel or wood caskets that are expensive. The bulky steel or wood caskets are also difficult to ship and prone to damage during shipment which increases the difficulty of using alternative point of sale locations. Caskets also occupy considerable space when stored and require climate controlled storage. Consequently, a need exists for a less expensive casket. A need also exists for a modular casket that can be easily shipped and assembled and can be stored in a non-climate controlled facility.
Further, the steel or wood caskets typically have a single, mono-tone color. For example, wood caskets often have a wood-looking, brown exterior. Steel caskets often have a single steel-like color such as gray or silver. Application of exterior finishes typically occurs after the casket piece has been manufactured. Consequently, the addition of different designs to a steel or wood casket through application of a stain, primer, paint, lacquer, or other similar coating can be labor-intensive and therefore expensive to apply and such finishes are highly prone to damage during shipment and storage. Further, as the complexity of the design increases, the cost substantially increases. This is one reason that caskets typically have only single-color, monotone exteriors. Consequently, a need exists for a method of making a casket that incorporates one or more pre-made images, such as a color or design, to the casket exterior during or after the manufacturing process.
Prior art attempts have been made to decorate casket exteriors. For example, U.S. Pat. No. 1,388,426 discloses a method of decorating the surface of a casket. The method involves a time-consuming labor-intensive process.
U.S. Pat. No. 6,223,404 discloses a casket with a customized, decorative external surface and methods in which panels of an adhesive-backed substrate material with a digitally imaged design are fixed to the casket surface. This method also requires a time-consuming labor-intensive process including the steps of applying an acid-wash neutralizer to the external surface of the casket, buffing the surface, applying a primer, and finally applying the substrate material. The method also heavily emphasizes the complicated step of supplying a two-dimensional image that can be placed on a three-dimensional casket.
The proposed invention is directed towards a method of placing of an integral image on one or more modular casket parts. In one aspect, the method comprises placing a film having an image into a mold cavity, injecting the mold cavity with a molten plastic to form a casket part, applying multi-layer film to the casket part, and cooling the casket part such that the image adheres to the casket exterior. The present invention thereby provides a way to place lenticular or holographic images onto a casket. The invention also provides an inexpensive way to provide a high quality finished look such as the look for a faux stone finish to a casket. The above as well as additional features and advantages of the present invention will become apparent in the following written detailed description.
A more complete understanding of the method and apparatus of the present invention may be had by reference to the following detailed description when taken in conjunction with the accompanying drawings, wherein:
a is an exploded perspective side view depicting the connection of two side panels by a wedge member in accordance with one embodiment of the present invention.
b is an exploded perspective side view depicting the connection of two side panels by a wedge member in accordance with an alternative embodiment of the present invention.
c is an exploded perspective side view depicting the connection of two side panels by a twist lock fastener in accordance with one embodiment of the present invention.
a is a perspective view showing how the base section can be further secured to a side panel in accordance with one embodiment of the present invention.
b is a perspective view depicting a base section in accordance with an alternative embodiment of the present invention.
a is a partial cutaway exploded view of the inside of one end of the casket in accordance with one embodiment of the present invention.
b is an exploded perspective view depicting the hinge assembly in accordance with one embodiment of the present invention.
c is a partial exploded perspective view taken depicting the lid assembly in accordance with one embodiment of the present invention.
d is a partial cutaway view depicting the end of the casket from the inside in accordance with one embodiment of the present invention.
a is a partial cutaway view of the portion labeled
b is an alternative partial cutaway view depicting the locking mechanism depicted in
a is a simplified cross-sectional representation of an injection mold having a multi-layer film in accordance with one embodiment of the present invention.
b is a simplified cross-sectional representation of an injection mold having a multi-layer film disposed on the exterior of a casket side panel in accordance with one embodiment of the present invention.
c is a simplified cross-sectional representation depicting the trap forming process in accordance with one embodiment of the present invention.
d is a partial blown-up view of
a depicts an exploded perspective view of a multi-layer film having an image of the Virgin of Guadalupe and a portion of a solidified casket side panel having an exterior in accordance with one embodiment of the present invention.
b is a perspective view of a portion of a casket side panel having an image of the Virgin of Guadalupe; and
Where used in the various figures of the drawing, the same numerals designate the same or similar parts. Furthermore, when the terms “top,” “bottom,” “first,” “second,” “upper,” “lower,” “height,” “width,” “length,” “end,” “side,” “horizontal,” “vertical,” and similar terms are used herein, it should be understood that these terms have reference only to the structure shown in the drawing and are utilized only to facilitate describing the invention.
The lid can comprise one or more sections. In one embodiment, a first lid section 310 and a second lid section 320 can be attached to the sidewall 110. In one embodiment, the first lid section 310 is attached to a first side panel 120 and the second lid section 320 is attached to an adjacent second side panel 120.
The base section, side walls, end panels, and lid can comprise a plastic composition. Although the base section, side walls, end panels, and lid components and the hinge assembly can be formed from a variety of different materials using different manufacturing techniques, in one embodiment, they are injection molded from a suitable plastic containing fibers for reinforcement. Plastics that can be used include, but are not limited to ABS, polycarbonate, fiberglass, metals, and mixtures thereof Any injection molded composition can be used. As used herein, an “injection molded composition” is defined as any material, resin or composite that can be injection molded. It should be further noted that different additives can be used for different injection molded parts. Strengthening ribs and other complex structures can be provided to make the components more rigid.
As shown in
It should also be pointed out that the panels can be designed such that a side panel is sized to be slidably connected to an end panel receiving cavity (not shown). Such embodiment can occur if the end panel 140 is rounded and the side panel 120 is flat at the corner connection.
As shown in
a is an exploded perspective side view depicting the connection of two side panels 120 by a wedge member 130 in accordance with one embodiment of the present invention. Although the wedge member 130 shown depicts three pair of T-shaped female slots 132, the wedge member 130 can comprise any combination (number, shape, placement of male/female) of interlocking members. In one aspect, an interlocking member is a male member or a female member. Providing interlocking members as an integral part of the side panels, end panels, and base section allows the interlocking in as many places as is required without the need for a separate weld, nail, screw, nut, bolt, or adhesive. In one embodiment, the wedge member 130 comprises one or more female T-shaped slots. Further, the wedge member 130 can comprise one or more pairs of T-shaped male protrusions and/or one or more pairs of T-shaped female slots. Similarly, the side panels 120 can comprise one or more pairs of T-shaped male protrusions or female slots. In one embodiment the T-shaped female slots 132 and T-shaped male protrusions 134 disposed on the side panels 120 are tapered. Thus, in one embodiment, the male T-shaped protrusions 134 comprise a first distance D1 at the inner portion of the side panel 120 and a second, larger distance D2 at the outer portion of the side panel 120. Similarly, in one embodiment, the female T-shaped slots 132 comprise a first distance D1 at the inner portion of the female slot 132 and a second, larger distance D2 at the outer portion of the female slot 132. Of course, the tapering can be reversed resulting in a second, smaller distance D2. The male protrusions 134 and female T-shaped slots 132 slidably connect to adjoin the two side panels 120 in a sturdy fashion. In one embodiment, the wedge 130 and side panel are sized to maximize contact between the outer wedge periphery 131 and a portion of the inner side panel periphery 121. Male 136 and female 138 locking members can be provided to lock the wedge member 130 into place between the two side panels 120.
Although not necessary, in one embodiment, the first side panel 120 comprises a plurality of tapered or non-tapered integral alignment protrusions 182 that can be aligned with a plurality of corresponding tapered or non-tapered alignment slots 184 integral to a second side panel 120. A locking frame 135 on the wedge member 130 can be used to lock the alignment protrusions 182 and alignment slots 184 in place and help absorb any shock loads on the sidewall assembly.
The above-described configuration is beneficial for several reasons. First, the wedge member 130 permits side panels 120 to be fastened together with virtually no tools. At most, a rubber mallet may be required to force the wedge member 130 into place between the two side panels 120. Second, the configuration of the T-shaped protrusions and slots distributes any forces or tension placed on the wall joint over a larger area. Third, because the T-shaped protrusions and slots are oriented parallel to any normal forces exerted on the panels, e.g. forces that are perpendicular to the plane of the side panels, a sturdy connection can be made at the joint between the two side panels 120. Thus, the T-shaped protrusions and slots provide a resistance to forces normal to the side panel connection. Fourth, because the connection is intuitive to the user, the design facilitates assembly. Fifth, because no screws or nails are required, the connection can be made relatively quickly leading to more efficient casket assembly. Further, such connection is superior to nuts, bolts, screws, or nails because the fastening force is distributed over a larger surface area. Sixth, the connection can also be disassembled with few or no tools.
While several embodiments discussed above are directed towards T-shaped protrusions and slots, any type and number of tapered or non-tapered interlocking-shaped members can be used to slidably connect two side panels 120 together with a wedge member 130 without departing from the spirit and scope of the present invention. For example,
Further, other ways of fastening the side panels with minimal use of tools can also be provided without departing from the spirit and scope of the present invention. In one embodiment, casket components such as two or more side panels are pressure fit together. In one embodiment, two or more side panels are pressure fit together by a twist lock fastener. For example,
a is a perspective view showing how the base section can be further secured to a side panel in accordance with one embodiment of the present invention. As depicted in
First, the clips 240 permit the side panels 120 to be securely fastened to the base end 210 or middle base portion 220 with no tools. Second, because the connection is intuitive to the user, the design facilitates assembly. Third, because no screws or nails are required, the connection can be made relatively quickly leading to more efficient casket assembly.
In one embodiment, the clip 240 mouth is designed to be slightly smaller than the ribs inside a side panel 120 or end panel 140 (not shown) or the base end 210 and/or base portion 220. This enables the clip 240 to pressure-fit onto and retain the ribs of the side panel 120 and portion of the base end 210 and/or base portion 220 to better secure the connection between the side panel 120 and any base section 210220. Also depicted in
b is a perspective view depicting a base section in accordance with an alternative embodiment of the present invention. A portion 612 of the base section 610 is disposed on the side panel ledge 232. A stiffening bar 630, made of metal or plastic, can be placed into a housing 632 disposed near the side panel ledge 232. In one embodiment, the housing 632 is integral with the side panel 180. A joint protrusion 640 can be provided to help hold the base section 610 in the proper position during and after assembly.
a is a partial cutaway exploded view of the inside of one end of the casket in accordance with one embodiment of the present invention.
c is a partial exploded perspective view depicting the lid assembly in accordance with one embodiment of the present invention. Referring to
d is a partial cutaway view depicting the end of the casket from the inside in accordance with one embodiment of the present invention. Referring to
In one embodiment, a fabric covers the inside of the side panels 120 and end panels 140. The fabric can be attached to the upper side panels 120 and end panels 140 by the metal clips 344. In one embodiment, a pan 230 is placed in the bottom of the casket. A fabric material may or may not also cover the pan 230. In one embodiment an inflatable air mattress is also placed into the casket to provide the desired elevation of the body in an open casket or other ceremony. The gasket 350 can be attached by an adhesive. A simple arm assembly 360 can be attached to the lid locking arm mount 362 and the end panel locking arm mount 364 to prevent the lid from opening too widely. Each of these arm mounts 362364 can be integrally injection molded with their respective pieces. Also shown in
a is a partial cutaway view of the portion labeled
To open, a rigid, flat card (e.g. a credit-card like object) can be placed between the lid frame 330 and the side panel 120 and can be used to push the male latch 510 inward to permit the lid 310 to open. In one embodiment a resilient, rubber-like L-shaped gasket 350 is about the upper perimeter of the side panel 120 and the credit card-like object can press a portion of the gasket 350 into the male latch 510 to permit the lid 310 to open.
One skilled in the art would recognize that such feature could be reversed and in one embodiment the female latch portion 530 is attached to the lid 310320 and the male portion 510 extends from the side panel 120. Similarly, one skilled in the art would recognize that both the female latch 530 and male latch 510 can be attached to the lid 310320 or the side panel 120 by a clip or by a pressure-fit mount. The present invention should therefore be construed to include all embodiments wherein male 510 or female latch 530 is attached to a lid 310320, and wherein further said male latch 510 or said female latch 530 removably fastens the lid 310320 to the side panel 120, wherein said latch assembly is snap-fit together. Another advantage of such configuration is that no tools are required to attach the latch assembly to the side panel 120 or lid 310320.
In one embodiment, the invention is directed towards a method of placing of an integral image on one or more modular casket parts. As used herein, the tern “image” is defined as a visible design contrast as compared to the color of the molded casket piece prior to the application of a film and encompasses a single solid color in addition to patterns of varying colors. The image can be applied to a film sheet and the film sheet can then be mated to one or more casket pieces.
In one embodiment, a film sheet having an image is placed into an injection mold prior to formation of a casket piece through an injection mold process.
In one embodiment (not shown), the multi-layer film 1400 terminates not at the terminal end of the casket piece, but within the molded plastic piece by design. Such embodiment can be used, for example, to provide a two-tone color scheme—the first color can be provided by the injected plastic and the second color can be provided by the film.
In one embodiment, the film, which can comprise a multi-layer or laminate film 1400 comprises an image.
The method of placing the pre-made image onto the casket piece can be achieved in numerous ways well known in the art including, but not limited to, non-structural appliqué, vacuum thermoforming, and dipping.
a depicts an exploded perspective view of a multi-layer film 1400 having an image 1420 of the Virgin of Guadalupe and a portion of a solidified casket side panel 1520 having an exterior 1532 in accordance with one embodiment of the present invention. In one embodiment, the entire film sheet 1400 is heated so that when the sheet is subsequently delivered to a forming station (not shown), an overall temperature balance has been attained. On being heated, the sheet is conveyed to the forming station where by one of several methods it is forced over and contoured onto the casket piece 1520, as shown in
The thermoforming of the sheet onto the casket part can be performed by means of different, conventional techniques, for instance, in vacuum thermoforming, a pre-cut sheet of multi-layer film sheet 1400 having an image 1420 is heated. A vacuum can be applied to remove the air between the multi-layer film sheet 1400 and the casket piece 1520 and/or a counter mold can be used to help force the sheet onto the casket piece 1520. The residual heat on the film sheet 1400 can be removed after forming. After cooling, the end product is removed from the forming station and sent to a trim press where the end product is trimmed from the web. The adhesive layer 1430 bonds the multi-layer film onto the casket exterior 1532.
It should be pointed out that it may be advantageous for the image 1420 to be printed onto the multi-layer film in a way that adjusts for distortion that will occur when the image is contoured onto the casket piece 1520. The adjustment for distortion can be made as follows. The image is first developed as a standard flat graphic. A sheet the same size as the production sheet with a grid pattern printed on it is formed over the actual part (or representation of the part) to create a formed grid. The grid locations of the formed grid sheet are matched to the original flat graphic. The points on the flat graphic are moved using standard imaging software to a new location opposite the movement seen in the formed grid. The result is a new final graphic that when formed over the casket part shows no distortion of the graphic regardless of the graphic used. Consequently, in one embodiment, the present invention provides a way to compensate for distortion and results in a distrotionless graphic.
In one embodiment, a trap-forming process is used to apply the film to a casket part.
In one embodiment, the sheet 1400 stretches and conforms to the casket part only to the extent of the pulling of the sheet 1400 down. Next, a box 1303 having a box interior 1305 roughly the size of the exterior 1332 dimension of the casket part 1320 engages and pushes the edges of the sheet against the casket part on the casket part exterior 1332 perimeter.
Positive air pressure is applied to the box interior 1305 causing the sheet 1400 to conform even further to the casket part 1320. Simultaneously, the fixture 1313 holding the casket part 1320 draws a vacuum to the interior 1311 of the casket part 1320. This causes the sheet 1400 to curl 1480 around the terminal edge 1322 of the casket part 1320. Likewise, the vacuum applied to the casket part 1320 draws any additional air out from between the casket part 1320 and the adjacent sheet 1400. The resulting combination is positive pressure on the box interior 1305, a sheet 1400 conformed to the casket part exterior 1332, the casket part 1320, a vacuum applied to the casket part interior 1311, and a fixture 1313 for holding the casket part 1320.
Unlike a traditional thermoforming process, in trap forming, the sheet 1400 curls 1480 around the terminal edge 1322 of the casket part 1320.
As shown in
In one embodiment, the image comprises one or more patriotic symbols such as a flag, or symbols of the armed forces. In one embodiment, the image mimics a wood finish to less expensively provide the look of a wooden coffin. In one embodiment the image mimics a steel finish to less expensively provide the look of a steel casket. In one embodiment, the image comprises one or more colors to less expensively provide the look of a painted casket.
It should be pointed out that these images can be configured through properly registering the image on the film with the corresponding casket piece such that when the modular casket pieces are assembled into the casket, two or more casket pails reveal a single complementary image in a way similar to that of a jigsaw puzzle. For example, in one embodiment, the present invention can mimic the appearance of a flag-draped casket.
In one embodiment, the image comprises a holographic image. Holographic film laminates are known in the art as exemplified by U.S. Pat. Nos. 4,971,646 and 5,200,253. In one embodiment, the holographic image requires one to focus on the image before the image becomes apparent. In one embodiment, the holographic image is printed onto the thin plastic film by with a metallic ink. In one embodiment, the holographic image is printed by a metallic ink on a thin plastic film. In one embodiment, the holographic images are created by using a laser that permits light to be diffracted in multiple directions giving the viewer the ability to see two images in one location.
In one embodiment, the image comprises one or more lenticular images. As used herein, a lenticular image is defined as an image that shows depth or motion as the viewing angle changes. Lenticular film laminates are known in the art as exemplified by U.S. Pat. No. 6,373,636.
In one embodiment the image comprises one or more two-dimensional or three-dimensional religious symbols such as the Pope John Paul, the Virgin Mary, the Virgin of Guadalupe, a cross, Jesus, etc. A casket having a holographic or lenticular image can impart a special atmosphere to participants to a solemn funeral service when images such as religious images appear on the casket. The present invention thereby provides a way convey symbolic meaning in a tasteful manner during a solemn occasion.
The present invention provides numerous advantages over the prior art. First, the plastic caskets of the present invention are less expensive to fabricate than the traditional wood or steel caskets. Second, the casket can be easily shipped as a more compact set of parts than a traditional wood or steel casket, or a non-modular casket fabricated from other materials. Further, because plastic is lighter than wood or metal, the casket of the present invention is not only less expensive to ship, but easier to handle, both in unassembled and assembled form. Further, the casket can be easily moved and stored.
Third, the casket of the present invention can be quickly and easily constructed and assembled by a funeral home or by an individual with little or no assembly experience. The only tools that may be required include a rubber mallet and a screwdriver. The assembly of the snap-fit and pressure-fit pieces is intuitive in the way in which the pieces are put together. Such advantages can be useful in areas of natural disasters. Such advantage also provides the ability to direct-market the casket to consumers through a phone number or web-site without the added expense of a middle man. Further, the casket can be marketed to consumers through stores by-passing the traditional funeral home and resultant mark-up.
Fourth, the casket is made of materials that is more durable than the prior art caskets. For example, unlike wood, plastic does not swell or deform. Unlike metal, plastic does not rust or dent, Further, when the casket of the present invention is packed, it can be shipped without worry of exposure to the elements. For example, the caskets and casket kits of the present invention can be stored outside with worry of exposure to the elements including, but not limited to temperature, humidity, moisture, blowing sand, etc. Such advantage can be useful in areas of natural disasters. Wood, on the other hand, must be stored in controlled climate conditions. Similarly, metal-type caskets, if subjected to high humidity or moisture conditions, are susceptible to rust, especially if any scratches were made through the painted metal during shipment. Thus, the present invention provides a casket that is more durable under both shipping and storage conditions.
Fifth, the casket can be made to emulate the caskets of wood design or steel designs. For example, a wood grain finish can be imparted into the injection molded plastic. Further, rounded corners used in wood caskets can be provided in plastic caskets of the present invention. Further, the color of the plastic can be easily changed to emulate steel-type colors. Moreover, the casket of the present invention has the same accessories as caskets of the prior art. Consequently, the present invention provides a casket having a similar look and design as prior art caskets with lower costs. Thus, there is little or no stigma attached to using a casket made from less expensive plastic materials of the present invention.
Sixth, the present invention can provide an image that is embedded into the material from which the casket is formed. Further, the present invention can provide an affordable alternative to higher-priced steel or wooden caskets without sacrificing the outward appearance of the casket. In fact, the present invention, by providing a modular casket that looks just like stone but that weighs a tiny fraction of stone, can provide a far superior looking casket than those presently available on the market today. It will now be evident to those skilled in the art that there has been described herein a modular casket or coffin. The terms and expressions employed herein have been used as terms of description and not of limitation; and thus, there is no intent of excluding equivalents, but on the contrary it is intended to cover any and all equivalents that may be employed without departing from the spirit and scope of the invention.
In sums while this invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
This is a continuation-in-part of application Ser. No. 11/297,864, filed on Dec. 9, 2005.
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| Number | Date | Country | |
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| Number | Date | Country | |
|---|---|---|---|
| Parent | 11297864 | Dec 2005 | US |
| Child | 11608444 | US |
