Note: Descriptions are shown in the official language in which they were submitted.
2155723
TITLE: FIBREBOARD CASKET BASE AND LID AND METHOD OF
MANUFACTURE SAME
FIELD OF THE lNV~N-LlON
The invention relates to a casket base and lid
employing corrugated fibreboard as the base material.
More specifically, the invention relates to an improved
form of base and lid particularly adapted for use in the
fabrication of coffins or caskets formed of corrugated
fibreboard. The caskets made in accordance with the
present invention have an inherent strength and do not
require additional framing elements or metal braces.
R~CK~ROUND OF THE lNV~NLlON
The use of wood in fabricating caskets is well-known.
Indeed, in recent periods, caskets or coffins made from
corrugated fibreboard have supplanted in some situations
the wooden type models since they provide numerous
advantages, notably in regards to manufacturing costs.
Thus, there have been efforts to provide such
fibreboard caskets. For example, U.S. patent number
3,490,114 issued to R.E Connelly describes more
particularly a coffin top having a dome shape. The top is
described as comprising a least one brace which can be
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made of wood or other similar material. U.S. patent
4,730,370 issued to Bruce E. Elder also describes a
fibreboard casket and a method for the manufacture of
same. Both the lid and the casket base comprise braces to
reinforce the strength of the structure. Therefore, the
casket is not entirely made of cardboard and/or additional
strengthening techniques must be provided for.
Each of the above-identified materials and products
seem to suffer from some type of disadvantage. The most
notable is that same require the addition of transverse
structural elements such as metal braces or framing
elements to increase the strength of the structure since
the casket does not have the necessary inherent
strength. In addition, it has been proved difficult to
provide a model which can readily be erected to give the
appearance of a conventional wooden coffin.
Accordingly, there is a need for a casket made
entirely of fibreboard not requiring any additional metal
braces or other non-fibreboard framing elements.
Moreover, a need exists for cosmetically pleasing
fibreboard casket that can be used not only in the
cremation itself, but also in the funeral services, thus,
eliminating the need for the traditional coffins. As it
will be readily appreciated, the present invention
provides a casket and lid structure which is lighter and
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cheaper than the older and more expensive wooden casket.
It will also be appreciated that due to the sturdy but
nevertheless yieldable characteristics of corrugated
fiberboard, a very dependable casket is provided.
The casket and lid made in accordance with the
present invention are preferably cut from a blank of
corrugated cardboard and faced with Kraft paper. A fabric
or cloth may similarly be applied to the interior of the
casket base and lid. A coating of wood-effect may be
advantageously applied to the outside of the blanks used
for the erection of the casket and lid. The wood-effect
pre-printed exterior paper will be preferably treated to
be moisture resistant to counter the effect that weather
may have on the casket during manual transport to exterior
locations. The blank of corrugated material may be cut on
conventional cutting machines.
OBJECTIVES AND STATEMENT OF THE lNV~NllON
An object of the present invention is to provide a
novel technique for the fabrication of a casket and lid
made from corrugated fibreboard, which casket and lid are
of substantial strength and rigidity.
Another object of the present invention is to provide
a novel casket base and lid employing novel manufacturing
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techniques and which can be manufactured with conventional
fibreboard cutting machines.
Still another object of the present invention is to
provide a technique to manufacture such a casket base and
lid made from single blanks cut from a planar sheet in
which the strength is attained by a novel folding
technique.
Yet another object of the present invention is to
provide a comestically pleasing fibreboard casket and lid
which are economical to manufacture, require a minimum
of man-hours for the erection, are durable and attractive
in appearance. Thus, a casket and lid made in accordance
with the present invention can be erected in a short
period of time.
Still another object of the present invention is to
provide a light, sturdy and dependable casket and lid,
made of corrugated fiberboard or the like.
By virtue of these techniques and material used, the
invention provides a highly, satisfactory and practical
configuration and method which may be carried out by the
use of fibreboard.
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The expression "cardboard" or "fibreboard" appearing
in the specification and claims is intended to mean any
type of material suitable for the fabrication of casket
and lid such as cardboard, fibreboard, straw-type building
board, hardboard, or any other materials having similar
characteristics.
As embodied and broadly described herein, the
invention provides a casket base having a planar side,
bottom and end walls which are integrally formed from at
least one planar sheet selected from the group comprising
cardboard, fibreboard, straw-type building board or
hardboard, said casket base comprising:
a) a rectangular main body portion having an
extending longitudinal axis, said main body comprises a
first and a second element, each of which includes outer
side and end walls, said walls being configured and
dimensioned to form the outer perimeter of the casket
base;
b) the height of said first and second elements
being defined by a pair of spaced apart generally parallel
linear score lines extending along the axis of said main
body, the end and side walls of each of said elements
being joined together along at least one relatively short
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linear score line extending in a direction transverse to
the longitudinal axis of the main body;
c) a first set of rectangularly-shaped portions
extends from said first and second elements, said
rectangularly-shaped portions being configured and
dimensioned so that same may be folded along one of said
longitudinally extending score line to form the outer
bottom walls of the casket base;
0
d) a second set of rectangularly-shaped portions
extends from said first and said second elements in an
opposite direction from said first set, said
rectangularly-shaped portions being configured and
dimensioned so that same may be folded along one of said
longitudinally extending score lines to form the inner
side walls of the casket base;
e) each of said rectangularly-shaped portions of
the second set further comprises a second rectangularly-
shaped portion configured and dimensioned so that same may
be folded along a longitudinally extending score line,
said second rectangularly-shaped portions thus forming the
inner bottom walls of the casket base; and
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f) securing means for securing the outer and inner
bottom walls of the casket base so that said walls are
held in said folded relationship.
The advantages of this casket structure are
immediately apparent. External or internal structural
members are no longer necessary to reinforce the base of
the casket and the latter is completely made of cardboard.
A casket constructed in accordance with the teaching
herein furnishes a durable and attractive lightweight
structure, possessed of the various advantages enumerated
at the beginning of the specification. The folding
technique disclosed provides a multiple layer wall
structure which is desirable to establish strength.
As embodied and broadly described herein, the invention
also provides a casket base further comprising another
sheet of material for forming a lid for the base, the
sheet comprising:
a) a generally rectangular main body portion having
a length greater than its width and a lengthwise extending
longitudinal axis, the width of said portion being defined
by a pair of spaced apart generally parallel linear score
lines;
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b) a generally rectangularly-shaped portion extends
on each side of said main body portion in a direction
transverse to said longitudinal axis so that each of said
portions may be folded along one of said score lines, said
portions being configured and dimensioned so that the
total width of the portions is slightly less than the
width of the main body portion;
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be shown by way of
illustrative embodiments only in the accompanying drawings
wherein:
- Figure 1 is a perspective view of a casket base and
lid as constructed in accordance with the present
invention;
- Figure la is a perspective view of a casket base
and lid showing a lid as constructed in accordance with a
second embodiment of the present invention;
- Figure 2 is a plan view of a blank cut from a
planar sheet of corrugated fibreboard in accordance with
the present invention;
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- Figure 2a is a plan view of a blank made of two
sections cut from a planar sheet of corrugated fibreboard
in accordance with a variant of the present invention;
5- Figure 3 is a cross-sectional view taken along line
3-3 of Figure 2;
- Figure 4 is a perspective view of the casket base
having the bottom walls partially folded;
- Figure 5 is a perspective view showing the casket
base with walls partially folded;
15- Figure 6 is a perspective view showing the casket
base with walls partially folded;
- Figure 7 is a perspective view showing the casket
base with walls partially folded;
- Figure 8 is a perspective view of the casket base
showing the addition of the rectangular portion to the
bottom of the casket base;
25- Figure 9 is a cross-sectional view taken along line
9-9 of Figure 8;
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- Figure 10 is a plan view of a blank cut from a
planar sheet of corrugated fibreboard to form a two
section lid;
- Figure lOa is a plan view of a blank cut from a
planar sheet of corrugated fibreboard to form one section
lid;
- Figure 11 is a perspective view showing the lid
folding technique;
- Figure 12 is a perspective view showing the lid
folding technique;
- Figure 13 is a perspective view showing the lid
folding technique;
- Figure 14 is a perspective view of the lid once
completely erected;
- Figure 15 is a cross-sectional view of the lid
taken along line 15-15 of Figure 14;
- Figure 16 is a plan view of a blank cut from a
planar sheet of corrugated fibreboard to form the lid
framing elements in accordance with the present invention;
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- Figure 17 is a perspective view of the framing
element folding technique;
- Figure 18 is a perspective view of a framing
element once erected and seamed;
- Figure 19 is a cross sectional taken along line 19-
19 of Figure 10;
- Figure 20 is a cross-sectional view taken along
line 20-20 of Figure 1;
- Figures 21 to 22 show the technique used for the
tests conducted on the casket base;
Identical or similar components throughout the
figures are designated by the same reference numerals.
DESCRIPTION OF PREFERRED EMBODIMENTS
Numeral 10 denotes generally an embodiment of the
present invention shown in Figure 1 comprising a casket
base 15 and lid 20 structure each of which is formed from
a blank of material selected from the group comprising
cardboard, corrugated cardboard, fibreboard or other
materials having similar characteristics.
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With reference to Figure 1, base 15 is generally
rectangular in shape and comprises outer side 22 and end
24 walls. In Figure 1, only one side and one end wall is
shown. The base 15 also comprises decorative elements 40,
42, 44 and 46. These decorative elements extend along the
lower 40 and upper edge 46 of the base 15 along the
periphery of same as illustrated. In a preferred
embodiment, the lower decorative elements 40 have a
triangular cross-section as shown more particularly in
Figure 20, said elements being also made of corrugated
material. These decorative elements may be adhesively
mounted or otherwise secured to the corrugated fibreboard
base 15 but preferably only when the erection of the
casket is completed. The decorative elements can also
include corner elements 48, 50 and 52 made of corrugated
material. Similarly, these decorative elements can also
include brass inserts (not shown). The casket may
comprise hardware such as an extended handrail 50 mounted
along the side of the casket 15 as shown in figure 1.
Appropriate means can be provided between lid 20 and
casket base 15 to accommodate said lid. Such means can
advantageously include hinge means such as the ones
illustrated in Figure 1 referred to as 23. Figure la
shows a casket 15 provided with a single piece lid 20.
Blank 25 used to form the casket base 15 is shown in
Figure 2 whereas the blank 30 used for the lid 20 is
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illustrated in Figures 10 and lOa. Each of the blanks 25
and 30 is advantageously cut from a planar sheet of multi-
layered corrugated fiberboard. In a preferred embodiment,
blank 30 is a single wall corrugated cardboard sheet such
as 200B flute single wall and has a thickness of 48". In
particular, blank 25 for base 15 is made of double wall
corrugated board which gives it suitable strength 500 AC
flute or double wall 500 BC flute. To facilitate folding
of blanks 25 and 30, score lines are provided as generally
indicated by referral number 35 in Figures 2, 10 and lOa.
Figure 3 shows the corrugated board in a cross-
section view obtained by laminating two corrugated sheets
72 and 74 to each other. By the use of multi-layered
corrugated material, the casket thus obtained will provide
a very high degree of strength and rigidity.
Blanks 25 and 30 may be cut using a cylindrical
cutting machine, a set of knives for each size of casket
and lid. However, since this type of machine is not part
of the present invention, same will not be described in
further details.
With reference to Figure 1, the lid structure 20
which will be described in further details hereinafter,
comprises in a preferred embodiment, two sections 54 and
56, each section being cone-shaped with framing elements
2155723
- 14 -
58 and 60 extending on the internal periphery of each of
sections 54 and 56. Section 54 is shown in a raised
position while section 56 is shown in a closed position.
As shown in Figure 16, each of said framing elements 58
5 and 60 comprises a generally rectangular main body further
including five generally rectangular-shaped sections 62,
64, 66, 68 and 69, each of which being configured and
dimensioned to be folded along one of the longitudinally
extending score lines 70.
The framing elements 58 and 60 are also preferably
made of corrugated fibreboard and are provided with
securing means for securing same so that they are held in
the folded relationship. The securing means can include
15 staples 71 shown in Figure 18. The framing elements are
secured to lid 20 by appropriate means such as gluing or
stapling.
As indicated previously from Figure la, it will be
20 seen a second embodiment of lid 20 comprising only one
section referred to generally as 54 ' . Section 54 ' also
comprises framing elements 58 ' and 60' similar in
construction to framing elements 58 and 60 described
above. Therefore, the present invention provides
25 alternatively for a single piece (Figure la) or split-lid
construction (Figure 1).
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- 15 -
Casket base 15 is formed by folding blank 25 in the
following manner. It will be further observed from Figure
2 that blank 25 comprises a rectangular main body portion
having an extending longitudinal axis, said main body
comprises a first 76 and a second 78 element, each of
which includes outer side 80 and end 82 walls, said walls
being configured and dimensioned to form the outer walls
of the casket base 15. One of said side walls 80 forms
the front wall of the casket whereas the other of said
side walls 80 forms the rear wall of the casket. The
height of said walls 80 and 82 being defined by a pair 84
of spaced apart generally parallel linear score lines
extending along the longitudinal axis of the main body.
The first element 76 extends from the second element 78
along at least one relatively short linear score line 86
in a direction transverse to the longitudinal axis of the
main body. As it will be appreciated from Figure 2a, in
a second embodiment, blank 25 can be formed from two
sections joined together along the lateral extension or
tab 25' by known means such a gluing, stapling or any
other appropriate means. Once the two sections are
secured together, the erection of casket base 15 is
similar to the one-section blank casket base shown in
Figure 1.
With reference to Figure 2, the outer side wall 80 of
blank 25 is provided with a lateral extension 106 which is
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- 16 -
used to join the outer side wall 80 of the first element
76 to the end wall 82 of the second element 78 by
appropriate means such as by gluing or stapling so as to
form a closed three dimensional body as shown in Figure 4.
The lateral extension 106 extends from side wall 80 along
the score lines 108.
A first set 88 of rectangularly-shaped portions
extends from said first 76 and second 78 element. The
portions comprise bottom walls 90 extending from the side
walls 80 and bottom walls 92 extending from end walls 82.
Bottom walls 90 and 92 being configured and dimensioned so
that same may be folded along one of said longitudinally
extending upper and lower score lines 84 to form the outer
bottom walls of casket base 15.
A second set 94 of rectangularly-shaped portions
extends from said first 76 and said second 78 element in
an opposite direction from said first set 88. The
20 rectangularly-shaped portions 94 comprise inner side walls
96 and end walls 98 walls which are configured and
dimensioned so that same may be folded along one of the
longitudinally extending upper score lines 84 to thus form
the inner side walls of the casket base.
Each of said inner side walls 96 and end walls 98
walls of the second set 94 further comprises a second
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rectangularly-shaped portion 100 configured and
dimensioned so that same may be folded along a
longitudinally extending score line 102, said second
rectangularly-shaped portions 100, thus folded, form the
5 inner bottom walls of casket base 15. Securing means 104,
such as staples, (see Figure 20) is provided for securing
the outer and inner bottom walls of the casket base so
that said walls are held in said folded relationship.
With reference to Figure 2, one set 101 of the
rectangularly extending portions forming the bottom walls
100 of the second element 78 are preferably slightly
longer (as shown by reference number 110) than the
extending portions 100 of the first element 76 so as to
15 accommodate the latter when they are folded in position to
take into account the thickness of the double side walls
80-96 as it will be appreciated hereinafter.
The folding of blank 25 erecting the base 15 is
20 illustrated in Figures 4 to 7 as comprising the following
steps: bottom walls 92 on both ends are first inwardly
folded along lower score lines 84, then, bottom walls 90
are folded meeting at the center of the casket as
illustrated in Figure 5 (see more particularly Figure 9).
25 Then, side walls 96 are inwardly folded along upper score
line 84 so as to form the inner side walls of the casket
and wall 101 now forms the bottom wall as illustrated in
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Figure 6. Then, the opposite side walls 96 are folded to
form the opposite inner walls and wall 100 now forms the
bottom walls as shown in Figure 7. Wall 100, as indicated
previously, is shorter than wall 101 to accommodate the
opposite double side walls 80-96. A rectangular shaped
bottom wall 102 is inserted as illustrated in Figures 8
and 9. As it was explained earlier, the second set of
walls 96 and 100 are cut in such manner that the thickness
of the first set of walls 96 and 100 is taken into
account. The final arrangement of the casket base 15 is
seen in Figure 9.
The method of fabricating lid 20 in accordance with
the present invention includes the steps described below.
As shown in Figure 10, blank 30 comprises a generally
rectangular main body portion 111 having a length greater
than its width W and a lengthwise extending longitudinal
axis, the width W of said portion being defined by a pair
of spaced apart generally parallel linear score lines 35.
A generally rectangularly-shaped portion 112 extends on
each side of said main body portion 111 in a direction
transverse to said longitudinal axis of the main body
portion 111 so that each of said portions 112 may be
folded along one of said score lines 35, said portions
being configured and dimensioned so that the total width
w of the portions 112 is slightly less than the width W of
the main body portion 111 so that a dome shape is formed
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as illustrated in Figures 13 and 14 when sections 112 are
forced one towards the other as shown in Figure 12.
Each of said portions 112 further includes sections
114 extending outwardly from the linear score lines 116 so
that they may be folded around that linear score lines to
form the generally vertical walls shown in Figure 15.
Each of said portions 114 further includes a generally
rectangular portions 118 extending from section 114 along
the score lines 120 so that they may be folded around the
linear score line to form the generally horizontal walls
shown in Figure 15. Blank 30 also comprises in a
preferred embodiment one end section 122, in the case of
the split lid configuration as shown in Figure 1. In the
case of the full length lid, blank 30 has two end section
122, each of which are generally a triangular in shape as
shown in Figure 10. Each of said sections 122 is defined
by a plurality of linear score lines 124 extending in a
direction perpendicular to the longitudinal axis of the
main body 111 and a plurality of linear score lines 126
extending in a direction inclined to the longitudinal axis
of the main body 111. A plurality of tabs 128 extend from
score lines 124 and 126 so that they may be folded around
these linear score lines to form securing means of
sections 122 as shown in more details in Figures 11 and
12. These tabs 128 are used to secure end sections 122 to
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the main body 111 thus forming the inclined wall 129 shown
in Figures 13 and 14.
Base 15 and lid 20 can be covered with a pre-printed
paper shown partially by reference number 48. In
addition, base 15 can preferably include hardware such as
an extended handrail 50 secured to the side walls 22 of
the casket base 10 as shown in Figure 1. Any other
appropriate handles can also be provided to base 15 in any
desired manner, such handle can be secured to the casket
by bolts and nuts not shown extending through side walls
22.
The technique of securing the different elements
together was described as comprising gluing and/or
stapling. However, it will be appreciated that such
connections may be made by butt joints, dovetails or other
interlocking means.
Tests conducted on a casket
The following tests were conducted on a casket
embodying the principles of this invention demonstrates
the inherent strength of its structure.
TEST NO. 1
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A casket base made in accordance with the present
invention was erected as the one shown in Figure 1. The
total length of the casket is 77 . 625 " by a width of
23 . 25 " and a height of 13 " .
Generally, the test shown in Figure 22 procedure
consisted of placing the casket on four supports 200, only
two are shown in Figure 22, one being located at each of
the corners of the casket. Each of said support 2 0 0
comprising a cylinder of 4 . 5 " of diameter with a height of
4 . 75" . Then, sand bags 205 were disposed as illustrated
in Figure 21.
Testing was done by loading extreme amounts of weight
into casket base 15 to confirm the outstanding strength of
base design.
1. Casket base 15 was placed on 4 cones 200 measuring 4
~" in diameter by 4 3~1' high. Cones 200 were situated
2 0 at each corner of casket leaving center of casket
totally suspended. (See Figure 22 )
2. Casket was then loaded with 11 sand bags 205 weighing
15 kg each (363 lbs). See Figure 22 for weight
2 5 distribution.
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3. Four hours later, a 140 lb man was seated in the
center of casket on top of sand bags 205, for 15
minutes.
5 4. A 200 lbs man then seated in center of casket
bringing the total weight load to 703 lbs. Both men
were seated in casket center on top of sand bags 205
for an additional 15 minutes (See figure 22). The
casket base 15 flexed by 1/8" at center proving the
enormous weight capacity of this design.
5. Test was then pursued with the 363 lbs in casket base
without any other weight for a 5 day period without
any base flex whatsoever.
6. After the five day period, another 10 minute test was
performed with the 363 lbs already in casket. Man #1
weighing 140 lbs, man #2 weighing 200 lbs and then
man #3 weighing 243 lbs were added for a grand total
of 946 lbs. This test result gave no change to
casket performance and no further flex at casket
base.
j TEST NO. 2
Using the same casket base 15, conventional casket
handles were secured to base sides. Screws and T nuts
(not shown) were used to secure handles 50 to casket 15.
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1. Six bearers were used to lift casket, with a 198 lb
load (6 lb sand bags) to waist height. There were no
reaction by casket base or handles.
2. Subsequently a 180 lb man was laid on top of sand
bags already weighing 198 lbs, giving a total weight
of 378 lbs. Casket was lifted to waist height with
no reaction by the casket base or handles.
3. Casket was then carried by six bearers over a
distance of 500 ft. No reaction by handles or casket
base.
4. Next, a 160 lb man was added. The two men now in
casket were seated face to face on top of sand bags.
The total weight was now 538 lbs. Casket was then
carried 500 ft, twice, with no reaction by the casket
base 15 or handles 50.
TEST NO. 3
This test was performed to determine side and bottom
strength under sever weight conditions. Furthermore, this
test would demonstrate performance of fastened steel
handles.
As shown in Figure 21, casket base 15 was suspended
by handles attaching nylon strapping 215 from ceiling
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beams 220 to casket handles 50. Casket was suspended 24 "
above floor.
1. Sand bags 205 totalling 330 lbs were placed in center
of the casket 15.
2. 15 minutes later, additional sand bags totalling 110
lbs were added.
3. 15 minutes later, additional sand bags totalling 66
lbs were added at each end of casket for a total of
506 lbs.
4. After 1 hour - no casket or handled reaction.
5. After 2 hours - steel handle had bent slightly. A
flex was measured at casket base.
6. 24 hours no further reaction.
7. 3 days later no further reaction.
8. Last step testing was done by shaking casket still
suspended in every possible direction, for 15 minutes
with the 506 lbs load. Casket handles demonstrated
a slight bend, but casket 15 bottom had no further
reaction.
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TEST SUMMARY
Tests No. 1, 2 and 3 were conclusive in demonstrating
the enormous capacity and strength of this casket design.
The funeral industry required a maximum of 360 lbs. We
5attained loads from 363 lbs to 946 lbs with outstanding
results.
In fact, the steel handles 50 conventionally used on
wood caskets demonstrated more flex than the casket base
15.
While an illustrative and presently preferred
embodiment of the invention has been described in detail
herein, it is to be understood that the scope of the
15present invention is not limited by the description,
examples and suggestive uses herein, as modifications can
be made without departing from the spirit of the
invention. Accordingly, reference should be made to the
following appended claims in determining the full scope of
20the invention. By way of example, in the above
description and in the following claims, directional and
oriental references, such as top, bottom, upward,
downward, front, rear, etc. are employed for convenience
of description only and should not be construed as
25limiting the present the invention. In addition, although
specific sizing has been established as shown in preceding
pages, different dimensions can be produced depending on
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order quantities. This design can accommodate several
sizes if proper quantities are met. Finally, in order to
permit the casket to provide a leak proof interior, a poly
bag may be placed inside the same to keep potential body
fluids from escaping or seeping through bottom.
