This invention relates generally to caskets, and more particularly to methods of forming sheet metal caskets.
One commonly employed process currently utilized to form sheet metal casket shells is as follows: Two side panels are blanked from a coil of sheet steel (or other suitable sheet metal), and two end panels are blanked from the coil. Next, both side panels and both end panels are stamped to form the desired cross-sectional profile of the shell side walls and end walls. Next, the four walls are loaded onto a weld fixture and welded together by welders, and finally the four welds are ground smooth with grinders. At some point along the way a bottom wall or panel is welded to the side walls and the end walls. The corners of the casket shell are typically formed as a part of the end panels. Thus, the weld lines where the side panels are welded to the end panels are located on the ends of the side panels, thus being visible when the casket shell is viewed from the front (or rear).
This current process of forming sheet metal casket shells includes a number of disadvantages. Each panel requires at least one blanking operation along with one or two stamping operations. The sheets must be loaded into a first press to be blanked, and then moved to a second press to be stamped. The panels are then moved to a new location where they are loaded onto a fixture that holds the panels in the correct assembled orientation. Each corner is then welded either manually or robotically. The corners contain intricate profiles which add complexity to the welding operation. The welded shell is then moved to a new location where each weld is manually rough ground. Because of the intricate profiles the grinding must be done at a slower pace to insure that only unwanted weld is removed. The shell is then placed on line where the corners are eventually manually finish sanded. All of these operations are labor intensive, and because of the repeated handling of the parts, the parts are susceptible to dents and dings. The welding operations require energy for the welder and consume welding wire. The grinding and sanding operations require energy, consume numerous sanding discs, and produce dust and debris.
It is desirable to improve upon this current method of forming sheet metal casket shells.
In one aspect, a method of forming a portion of a sheet metal casket shell, the casket shell having a pair of opposed side walls and a pair of opposed end walls, is provided. The portion of the casket shell is formed from a piece of sheet metal having a desired profile, opposite ends, and a length about equal to the combined length of one of the side walls and one of the end walls of the casket shell. The method comprises supporting the piece of sheet metal on one side with a female die having a center die portion and opposite end die portions configured to pivot relative to the center die portion, supporting the piece of sheet metal on the opposite side with a male die having a center die portion and opposite end die portions, and pivoting the end die portions of the female die relative to the center die portion of the female die to cause the opposite ends of the piece of sheet metal to fold around the end die portions of the male die. The resulting portion of the casket shell has a side wall, about half of one end wall at one end of the side wall, and about half of the other end wall at the other end of the side wall.
The desired profile can be roll formed into the piece of sheet metal. The end die portions of the male die can be curved. For example, the end die portions of the male die can be rollers.
In another aspect, the above method is repeated with a second piece of sheet metal to form a second substantially identical portion of the casket shell. The first and second portions of the casket shell are positioned such that the half end walls of each portion abut, and the abutting half end walls are welded together.
In another aspect, a sheet metal casket shell having a pair of opposed side walls and a pair of opposed end walls, comprises a first casket shell portion formed from a first piece of sheet metal and having a desired profile, one side wall, about a first half of one end wall at one end of the one side wall, and about a first half of the other end wall at the other end of the one side wall, a second casket shell portion formed from a second piece of sheet metal and having the desired profile, the other side wall, about a second half of the one end wall at one end of the other side wall, and about a second half of the other end wall at the other end of the other side wall. Each of the first and second casket shell portions has a curved corner between its side wall and each of its half end walls. A first weld joins the first and second halves of the one end wall and a second weld joins the first and second halves of the other end wall.
In another aspect, a sheet metal casket comprises a sheet metal casket shell of the type described above and including a bottom wall, and a sheet metal lid closeable on the casket shell.
In another aspect, a method of forming a portion of a sheet metal casket shell, the casket shell having a pair of opposed side walls and a pair of opposed end walls, is provided. The portion of the casket shell is formed from a piece of sheet metal having a desired profile and opposite ends. The method comprises supporting the piece of sheet metal on one side with a female die having a center die portion and opposite end die portions configured to pivot relative to the center die portion, supporting the piece of sheet metal on the opposite side with a male die having a center die portion and opposite end die portions, and pivoting the end die portions of the female die relative to the center die portion of the female die to cause the opposite ends of the piece of sheet metal to fold around the end die portions of the male die, the resulting portion of the casket shell having a side wall, a portion of one end wall at one end of the side wall, and a portion of the other end wall at the other end of the side wall.
This method can be repeated with a second piece of sheet metal to form a second portion of the casket shell having a side wall, a portion of one end wall at one end of the side wall, and a portion of the other end wall at the other end of the side wall. The two casket shell portions can be mated, and the respective abutting end wall portions of the two casket shell portions can be welded together.
In another aspect, the resulting portion of the casket shell formed by the method can have either a) a side wall, a portion of one end wall at one end of the side wall, and a portion of the other end wall at the other end of the side wall, or b) an end wall, a portion of one side wall at one end of the end wall, and a portion of the other side wall at the other end of the end wall.
The invention thus provides a number of advantages over and above the commonly employed process for forming a sheet metal casket shell described above. For example, only two sheets of sheet metal must be handled instead of four separate sheets of sheet metal. The welding operation occurs in only two locations versus four locations. Also, the welds can be located on less conspicuous surfaces in that they can be located on the end walls rather than on the ends of the side walls. The inventive method requires less labor, produces a stronger overall two piece (side walls and end walls) shell, reduces the chances of the shell becoming damaged since less handling is required, requires fewer consumables such as welding wire and sanding discs and consequently consumes less energy, and is cleaner.
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The various embodiments of the invention shown and described are merely for illustrative purposes only, as the drawings and the description are not intended to restrict or limit in any way the scope of the claims. Those skilled in the art will appreciate various changes, modifications, and improvements which can be made to the invention without departing from the spirit or scope thereof. The invention in its broader aspects is therefore not limited to the specific details and representative apparatus and methods shown and described. Departures may therefore be made from such details without departing from the spirit or scope of the general inventive concept. For example, the length of the piece of sheet metal 16 and/or its positioning between the female 12 and male 14 dies can be such that the two shell halves 40, 40 could be formed with less than or more than one-half of the shell end wall 44 at either end or both ends of the shell half 40. Forming the shell halves with about one-half of the shell end wall 44 at either end of the shell half 40 is convenient from a manufacturing standpoint in that a uniform length of piece of sheet metal 16 and a uniform positioning of the piece of sheet metal 16 in the apparatus can be utilized and is thus preferred, but is certainly not required. Furthermore, and as described, each shell half can also be formed so as to have one end wall 44 and a portion, for example about one half, of one side wall 42 at each end of the end wall 44. Accordingly, the scope of the invention shall be limited only by the following claims and their equivalents.
This application claims the priority benefit of U.S. Provisional Patent Application No. 61/515,515 filed Aug. 5, 2011, which is hereby incorporated by reference herein as if fully set forth in its entirety.
Number | Date | Country | |
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61515515 | Aug 2011 | US |
Number | Date | Country | |
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Parent | 13566236 | Aug 2012 | US |
Child | 14290282 | US |