Patent Application
20110252612
The present invention relates in general to the field of coffins and caskets, and in particular, to modular caskets built from prefabricated components and/or caskets made of lightweight materials.
Lightweight caskets, and particularly modular caskets, may be built from prefabricated component parts of lightweight materials such as injection molded plastics or the like. Such caskets typically exhibit relatively low rigidity, which can result in undesirable flexing of a casket when it is lifted from a support surface. Typically, such caskets are most susceptible to torsional flexion about the longitudinal axis and/or flexion about the lateral axis. In addition to the general undesirability of a casket flexing or twisting upon lifting, such flexing can lead to sealing problems between the individual components of the casket.
The present invention provides a structurally reinforced casket that includes strategically-placed reinforcing members and/or a casket liner, such as a sprayed-in liner, that significantly increase its torsional and flexural rigidity. The invention may be particularly well-suited for use with a modular casket that is constructed from lightweight prefabricated components made of resinous plastic or the like. The structural reinforcing members may include elongate rods arranged longitudinally along the length of the casket, and reinforcing members that span laterally across the casket to reinforce both a bottom or base panel of the casket and the side panels of the casket. Optionally, a two-part liner is applied to the casket interior in a liquid or semi-liquid state, which cures to a solidified or hardened state to both seal and rigidize the casket. The reinforced casket is consequently stiffened or rigidized against flexion or torsional bending, while remaining relatively inexpensive and lightweight.
According to one form of the present invention, a structurally reinforced casket includes a base panel having left and right edge portions, and left and right side panels coupled to the base panel in a generally upstanding manner at its left and right edge portions to define a cavity. A structural sealant applied to the inwardly-facing surfaces of the base panel and the left and right side panels. The sealant is cured to a hardened state to rigidize and seal the base panel and the left and right side panels.
In one aspect, the structural sealant has two layers: (i) a lower-density panel-lining first layer and (ii) a higher-density second layer that substantially covers the first layer and is generally spaced from the base panel and the left and right side panels by the first layer. Optionally, the first layer of the structural sealant is a urethane foam, and the second layer of the structural sealant is an acrylic or urethane material. Optionally, the first layer is a spray-applied thermoset urethane foam and the second layer is a spray-applied thermoset acrylic or urethane material.
In another aspect, the inwardly-facing surface of at least one of the base panel and the left and right side panels includes a plurality of stiffening ribs defining a plurality of voids therebetween. The structural sealant substantially fills these voids.
In yet another aspect, the casket includes at least one chosen from (i) at least one longitudinal reinforcing member arranged near at least one of the left and right edge portions of the base panel, and (ii) a lateral reinforcing member arranged transversely between the left and right side panels.
According to another form of the present invention, a method is provided for manufacturing a structurally reinforced casket. The method includes providing a base panel and left and right side panels, the base panel having left and right edge portions, coupling the left side panel and the right side panel to the base panel in a generally upstanding manner at the left edge portion and the right edge portion of the base panel, respectively, to define a cavity between respective inwardly-facing surfaces of the base panel and of the left and right side panels, applying at least one layer of liquid or semi-liquid structural sealant to the inwardly-facing surfaces of the base panel and the left and right side panels, and curing the layer of structural sealant to a hardened state to rigidize and seal the base panel and the left and right side panels.
In one aspect, the method further includes applying a second layer of liquid or semi-liquid structural sealant to the first layer of structural sealant, and curing the second layer of structural sealant to a hardened state to further rigidize and seal the first layer of structural sealant, the base panel, and the left and right side panels.
In another aspect, the first layer of structural sealant forms a relatively low-density foam in its hardened state, and the second layer of the structural sealant forms a substantially rigid polymeric layer in its hardened state.
Optionally, the step of applying the first layer of structural sealant involves spraying the first layer of structural sealant along the inwardly-facing surfaces of the base panel and the left and right side panels, and the step of applying the second layer of structural sealant involves spraying the second layer of structural sealant along the first layer of structural sealant.
In yet another aspect, the step of spraying the second layer of structural sealant is performed after the first layer of structural sealant is at least partially cured.
In still another aspect, the first layer of structural sealant is a urethane foam and the second layer of structural sealant is an acrylic or urethane. Optionally, the urethane foam and the acrylic are both thermoset materials that give off heat during the curing process.
According to another form of the present invention, a structurally reinforced casket includes a base panel, left and right side panels, and at least one chosen from (i) a longitudinal reinforcing member arranged near at least one of the left and right edge portions of the base panel, (ii) a lateral reinforcing member arranged transversely between the left and right side panels, and (iii) a sealant applied to inner surfaces of the casket and cured to a hardened state. The base panel includes head and foot end portions and left and right edge portions defining a perimeter region, with the left side panel and right side panel disposed at the left edge portion and the right edge portion of the base panel, respectively. The left side panel and the right side panel are coupled to the base panel in a generally upstanding manner to define a cavity between the panels.
In one aspect, each of the left and right side panels is made up of adjacent first and second panel portions, which are coupled to one another via at least one fastener.
In another aspect, in which the casket includes a longitudinal reinforcing member arranged along each of the left and right edge portions of the base panel, the longitudinal reinforcing members are formed from hollow tubes.
In a further aspect, the casket further includes a lateral reinforcing member in the form of at least one chosen from (i) a U-section bar, (ii) a square tube, and (iii) a round tube. Optionally, the lateral reinforcing member includes left and right upstanding leg portions arranged along respective ones of the left and right side panels, and further includes a horizontal portion spanning substantially between the left and right edge portions of the base panel and arranged transversely between the left and right side panels
In a still further aspect, the casket further includes a two-layer sealant applied to respective inner surfaces of the left side panel, the right side panel, and the base panel casket. The two-layer sealant includes a lower-density panel-lining first layer and a higher-density second layer applied to the first layer. The first and second layers are both cured to a hardened state.
Thus, the structurally reinforced casket provides a lightweight, low-cost, rigidized and stiffened and sealed or more readily-sealable container, such as a modular casket, for supporting a deceased person. The reinforced casket may be lifted from a support surface substantially without flexion or twisting, and may be sealed against leakage.
These and other objects, advantages, purposes, and features of the present invention will become apparent upon review of the following specification in conjunction with the drawings.
The present invention is directed to a structurally reinforced casket, and more specifically, to a structurally reinforced modular casket made of prefabricated components, and particularly one that is made of lightweight materials, such as injection molded plastics or the like. While the present invention is described with reference to a modular rectangular casket made of injection molded plastic material, it should be understood that the same or similar principals may be used with substantially any casket in which structural reinforcement and/or stiffening is desired. As will be more fully described below, the structural reinforcements include longitudinal reinforcing rods or members arranged along the sides of the casket, and lateral reinforcing members such as generally U-shaped cross-members arranged transversely along the walls or panels of the casket. In other embodiments, the structural reinforcements include liner materials that are applied to the interior surfaces of the casket in a liquid or semi-liquid uncured state, and which cure to a hardened state that rigidizes and seals the casket. The structural reinforcements are substantially hidden from view by upholstery or other materials when the casket is fully assembled.
Referring now to
In the illustrated embodiment, each of the left and right side panels 16, 18 is made up of a pair of panel portions 16a-b, 18a-b that are joined together halfway between head end panel 14 and foot end panel 12. The end panels 12, 14; side panels 16, 18; base panel 20; and movable hinged lid 22 may be joined together via interlocking components and/or fasteners, for example. Base panel 20 has a perimeter region defined by a left edge portion 20a, a right edge portion 20b, a foot end portion 20c, and a head end portion 20d (
In addition, modular casket 10 may include interior reinforcements 28 (
Longitudinal reinforcing members 24 are arranged and disposed along respective corner regions defined between or near the respective intersections of left and right side panels 16, 18 with base panel 20. It will be appreciated that the longitudinal reinforcing member 24 along the right side panel 18 is substantially identical or formed as a “mirror image” relative to the longitudinal reinforcing member 24 along left side panel 16. Left and right side panels 16, 18 each include a plurality of spaced ribs or flanges 32 along a lower portion of the respective side panel near where it meets and joins to base panel 20. Each spaced flange 32 includes an aperture or through-hole 34 for receiving one of the longitudinal reinforcing members 24. The through-holes 34 of a given side panel are substantially co-axial and sized and shaped to receive longitudinal reinforcing member 24 (
In the illustrated embodiment of
Lateral or U-shaped reinforcing member 26 includes a horizontal portion 36 and upstanding leg portions 38 that are substantially perpendicular to horizontal portion 36 (
Optionally, lateral or U-shaped reinforcing member 26 may be coupled to one or more of the left and right side panels 16, 18 and base panel 20 using mechanical fasteners, adhesives, welding, or the like, to provide enhanced structural support and resistance to torsional bending or flexion of the casket 10. It will be appreciated that multiple U-shaped reinforcing members may be positioned in spaced arrangement along the interior of casket 10 to increase the stiffness or rigidity of the casket to a desired degree. In the illustrated embodiment, U-shaped reinforcing member 26 is a metal U-section bar arranged with the open side of the U-section facing generally upwardly, the U-section bar being bent to form horizontal portion 36 and upstanding leg portions 38, with intermediate angled portions 37 disposed between horizontal portion 36 and leg portions 38, thus forming the U-shape of lateral reinforcing member 26 (
Accordingly, longitudinal reinforcing members 24 and U-shaped reinforcing member 26 are positioned along the interior surfaces of casket 10 so as to be unobtrusive and readily concealed by other interior components of the casket (e.g., a raisable/lowerable support cot 30 and finishing upholstery), so that the appearance of the finished casket is substantially unaffected by the installation of the structural supports or reinforcing members. Longitudinal reinforcing members 24 resist bending loads and thus resist flexing of the casket 10 about a lateral axis (i.e., an axis substantially parallel to the horizontal portion 36 of U-shaped reinforcing member 26), and also resist torsional flexing of the casket whereby foot end panel 12 and head end panel 14 would rotate relative to one another about a longitudinal axis (i.e., an axis that is substantially parallel to longitudinal reinforcing members 24).
Lateral reinforcing member 26 resists inward bending of left and right side panels 16, 18, resists flexing of the entire casket 10 about its longitudinal axis, and also resists torsional flexing. The rigidizing or stiffening effect of the lateral reinforcing member may be increased by using two or more lateral reinforcing members spaced longitudinally along the interior of the casket. For example, a “heavy duty” structurally reinforced casket may be constructed with two or three or more U-shaped reinforcing members 26 or other cross-members in spaced arrangement between the foot and head end panels 12, 14.
Optionally, and with reference to
Once the panels of casket 110 are assembled together, a two-layer structural sealant includes a lightweight panel liner 144 that is sprayed or spread (or applied in a similar manner) along all of the interior surfaces of foot end panel 112, head end panel 114, left side panel 116, right side panel 118, and base panel 120 that define cavity 123. For example, panel liner 144 may be a thermoset urethane foam that is applied in a liquid or semi-liquid state (such as a liquid resin) with sufficient thickness to substantially fill the spaces or voids between all of the stiffening ribs along the interior surfaces of the panels, and which may have a cured density of approximately two pounds per cubic foot (2-lb/ft3). However, the density of panel liner 144 may be increased to as much as approximately six pounds per cubic foot (6-lb/ft3) when used in conjunction with inner liner 146, to as much as approximately twelve pounds per cubic foot (12-lb/ft3), for example, if the panel liner is to be used as a stand-alone structural sealant layer.
Panel liner 144 leaves a generally smooth inner surface 144a once it has cured, and although panel liner 144 is shown for clarity in
Once lightweight panel liner 144 is at least partially cured, a second layer of the structural sealant in the form of an inner liner 146 is applied to inner surface 144a of panel liner 144. Inner liner 146 is significantly stronger and stiffer than panel liner 144, and forms a tub-like inner seal and structural shell of the casket 110 once it has been cured, such as in an exothermic reaction. Although inner liner 146 is shown for clarity in
Inner liner 146 may be an acrylic or urethane thermoset material that is sprayed or spread (or applied in a similar manner) in a liquid or semi-liquid state (such as liquid resin) along inner surface 144a of panel liner 144, and allowed to cure to a hardened state having a density of approximately eighty pounds per cubic foot (80-lb/ft3), for example. Suitable materials for inner liner 146 include ACRYLOBOND® brand TP-1155-4 two-component polyurethane, which is available from Isotec International, Inc. of Canton, Ga., and which can be sprayed using a two-component high-pressure spray machine. Optionally, the material inner liner 146 may incorporate glass or other fibers for added strength and rigidity. Inner liner 146 thus forms a substantially fluid-impervious and vapor-impervious layer over panel liner 144.
Optionally, and without departing from the spirit and scope of the present invention, panel liner 144 and inner liner 146 may be applied to a modular casket with one or more longitudinal or lateral reinforcing members already in place, such as described above with reference to casket 10, so that the reinforcing members are encased in at least the panel liner material. It is envisioned that this arrangement would further rigidize the finished casket, albeit with potentially increased weight and cost.
It will be appreciated that the structural sealant of the present invention is not limited to a two-layer sealant as shown, and that a single-layer or three or more layer structural sealant may be used to rigidize and seal the casket, depending on the particular casket's desired strength, weight, and stiffness requirements, for example. In the case of a single-layer structural sealant, for example, it may be desirable to select a cured foam material having a density greater than that of the panel liner 144 described above, and less than that of the inner liner 146, such as a density of about six to twelve pounds per cubic foot (6-lb/ft3 to 12-lb/ft3). Thus, it will be appreciated that the thickness and density of panel liner 144 and inner liner 146 (when included) may be varied significantly to achieve the desired strength-to-weight ratio for the finished casket, with the thickness and/or density of the panel liner generally increasing when a thinner or weaker inner liner is used, and vice versa, to achieve desired properties of the finished casket. Panel liner 144 and inner liner 146 may also be made thinner and/or of comparatively weaker materials if used in combination with longitudinal or lateral reinforcing members, described above.
Once panel liner 144 and inner liner 146 have both at least partially cured, a cot, upholstery, and other finishing hardware and materials may be installed or applied to the casket 110 so that the interior surfaces of the casket panels, and the panel liner 144 and inner liner 146, are completely covered and obscured by the casket upholstery. Upholstery may be attached to inner surfaces of inner liner 146 and any exposed inwardly-facing surfaces of foot end panel 112, head end panel 114, left side panel 116, and right side panel 118 that are not covered by inner liner 146, using mechanical fasteners such as hook-and-loop fasteners, threaded screws, magnets, or the like.
The resultant casket 110 is substantially rigidized and sealed by the application of the low-density panel liner 144 and the higher-strength inner liner 146 to the interior surfaces of foot end panel 112, head end panel 114, left side panel 116, right side panel 118, and base panel 120. The panels are substantially permanently joined together by the cured liner layers, and the casket 110 is strong, stiff, and still relatively lightweight with its hardened inner and outer shells (i.e. inner liner 146 and combined end panels 112, 114, side panels 116, 118, and base panel 120) with lightweight inner foam core (i.e., panel liner 144).
Thus, the present invention provides a modular casket that may be made of lightweight materials, such as plastics including thermoplastics [such as acrylonitrile butadiene styrene (ABS)] or other polymeric material or the like, and which is structurally reinforced to substantially limit or prevent undesirable flexing or bending of the casket, particularly when the casket is lifted from a support surface. The structural reinforcement of a modular casket also facilitates sealing it against leakage by limiting the extent to which the prefabricated panels will move relative to one another during handling, and/or by filling gaps with a sealing material. This reduces or fills gaps and increases the effectiveness of gaskets or seals that may optionally be used between the panels to seal the casket. The structural reinforcing members or materials are unobtrusive and readily obscured or covered by other components of the casket, such as upholstery. Thus, a modular casket is provided that is structurally reinforced without substantial penalties in aesthetics, cost, or weight.
Changes and modifications in the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law including the doctrine of equivalents.
The present application claims the priority benefit of U.S. provisional application Ser. No. 61/345,735, filed May 18, 2010, and of U.S. provisional application Ser. No. 61/324,075, filed Apr. 14, 2010, which are hereby incorporated herein by reference in their entireties.
| Number | Date | Country | |
|---|---|---|---|
| 61345735 | May 2010 | US | |
| 61324075 | Apr 2010 | US |
