Collapsible casket with reduced shipping and/or storage footprint

Abstract

A folded blank includes a bottom panel, side panels, and end panels. The bottom panel has opposite side edges and opposite end edges defining a length and width sized to support a deceased human body in the supine position. The side panels are connected to the opposite side edges of the bottom panel, and extend outward from and substantially parallel to the bottom panel. The end panels are foldably connected to the opposite end edges of the bottom panel, and are folded to extend inward from the corresponding opposite end edges. The folded blank also includes at least one gusset foldably connected to a side panel along a first fold line and connected to an end panel along a second fold line. The gusset has a diagonal fold, and has a first surface disposed adjacent to and coupled to the side panel in an additional location away from the first fold line.

Claims

1. A folded blank, comprising: a bottom panel having opposite side edges and opposite end edges defining a length and width sized to support a deceased human body in the supine position; first and second side panels connected to the opposite side edges of the bottom panel, the first and second side panels extending outward from and substantially parallel to the bottom panel; first and second end panels foldably connected to the opposite end edges of the bottom panel, the first and second end panels folded to extend inward from the corresponding opposite end edges; at least a first gusset foldably connected to the first side panel along a first fold line and connected to the first end panel along a second fold line, the first gusset having a diagonal fold, the first gusset having a first surface disposed adjacent to and coupled to the first side panel by a connector disposed at a location away from the first fold line.

2. The folded blank of claim 1, further comprising a second gusset foldably connected to and between the second side panel and the first end panel, the second gusset having a first surface disposed adjacent the second side panel.

3. The folded blank of claim 2, wherein the second gusset is connected to the second side panel only at foldably connected edges of the second gusset and the second side panel.

4. The folded blank of claim 1, wherein the folded blank defines a rectangular folded blank with at least one chamfered corner.

5. The folded blank of claim 4, wherein the at least one chamfered corner defines a chamfer in each of the first gusset and the first side panel.

6. The folded blank of claim 4, wherein the rectangular folded blank has at least two diametrically opposed chamfered corners.

7. The folded blank of claim 4, wherein the rectangular folded blank has four chamfered corners.

8. A method comprising: a) providing a blank having a bottom panel having opposite side edges and opposite end edges defining a length and width sized to support a deceased human body in the supine position, first and second side panels foldably connected to the opposite side edges of the bottom panel, the first and second side panels extending outward from and substantially parallel to the bottom panel, first and second end panels foldably connected to the opposite end edges of the bottom panel, the first and second end panels extending outward from and substantially parallel to the bottom panel, at least a first gusset foldably connected to the first side panel along a first fold line and connected to the first end panel along a second fold line, the first gusset having a diagonal fold; b) folding the first end panel and the first gusset such that a first surface of the end panel abuts the bottom panel, and a first surface of the first gusset abuts a first surface of the first side panel; c) after step b), disposing the blank on a shipping support while the first and second side panels extend outward from and substantially parallel to the bottom panel; and d) loading the shipping support with the blank onto a bed of a vehicle or trailer.

9. The method of claim 8, wherein step a) further comprises providing the blank wherein the blank has a second gusset foldably connected to the first side panel along the first fold line and connected to the second end panel along a third fold line, a third gusset foldably connected to the second side panel along a fourth fold line and connected to the second end panel along the third fold line, and a fourth gusset foldably connected to the second side panel along the fourth fold line and connected to the first end panel along the second fold line.

10. The method of claim 9, wherein step b) further comprises securing a portion of the first surface of the first gusset to the first surface of the first side panel, and securing a portion of a first surface of the second gusset to the first surface of the first side panel.

11. The method of claim 9, wherein step b) further comprises folding the first end panel and the fourth gusset such that a first surface of the fourth gusset abuts a first surface of the second side panel.

12. The method of claim 11, wherein step b) further comprises folding the second end panel, the second gusset and the third gusset such that a first surface of the second end panel abuts the bottom panel, a first surface of the second gusset abuts the first surface of the first side panel, and a first surface of the third gusset abuts the first surface of the second side panel.

13. The method of claim 12, wherein step b) further comprises securing a portion of the first surface of the first gusset to the first surface of the first side panel, and securing a portion of a first surface of the second gusset to the first surface of the first side panel.

14. The method of claim 9 wherein step b) further comprises folding the second end panel such that the blank defines a rectangular folded blank with at least one chamfered corner.

15. The method of claim 9 wherein step b) further comprises folding the second end panel such that the blank defines a rectangular folded blank with a plurality of chamfered corners.

16. A folded blank, comprising: a bottom panel having opposite side edges and opposite end edges defining a length and width sized to support a deceased human body in the supine position; first and second side panels connected to the opposite side edges of the bottom panel, the first and second side panels extending outward from and substantially parallel to the bottom panel; first and second end panels foldably connected to the opposite end edges of the bottom panel, the first and second end panels folded to extend inward from the corresponding opposite end edges; at least a first gusset foldably connected to the first side panel along a first fold line and connected to the first end panel along a second fold line, the first gusset having a diagonal fold, the first gusset having a first surface disposed adjacent to the first side panel in a location away from the first fold line and wherein the folded blank defines a rectangular folded blank with at least one chamfered corner.

17. The folded blank of claim 16 wherein the first and second end panels are folded to extend inward from and substantially parallel to the bottom panel.

18. The folded blank of claim 16, wherein the at least one chamfered corner defines a chamfer in each of the first gusset and the first side panel.

19. The folded blank of claim 16, wherein the rectangular folded blank has at least two diametrically opposed chamfered corners.

20. The folded blank of claim 16, wherein the rectangular folded blank has four chamfered corners.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a top plan view of an exemplary embodiment of an unfolded blank for a casket container according to at least some aspects of the invention;

(2) FIG. 2 shows a top plan view of a folded blank formed from the blank of FIG. 1, configured for shipment;

(3) FIG. 3 show a side representative view of the folded blank of FIG. 2 loaded for shipment in context with a transport vehicle;

(4) FIG. 4 shows a perspective view of the folded blank of FIG. 2 partially assembled into a casket container and in a condition for inserting a deceased onto the bottom panel; and

(5) FIG. 5 shows a casket container assembled from the folded blank of FIG. 2.

DETAILED DESCRIPTION

(6) FIG. 1 shows a top plan view an exemplary embodiment of a blank 100 that may be assembled into a casket container. The blank 100 may suitably be made of corrugated paper. FIG. 2 shows a top plan view of a folded blank 102 formed from the blank 100 of FIG. 1. The folded blank 102 is configured in a mode for shipment and storage, and has a reduced hypotenuse compared to the blank 100. As will be discussed below, FIG. 5 shows a fully assembled casket container 104 made from the blank 100.

(7) Referring to FIG. 1, the blank 100 is preferably made of a single piece of corrugated paper or corrugate cardboard. The blank 100 includes a bottom panel 106, which is foldably connected to end panels 108a, 108b along fold lines 152a, 152b, and is further foldably connected to side panels 110a, 110b via fold lines 154a, 154b. The blank 100 further included unfolded gussets 112a-112d, which form the corner connections between the side panels 110a, 110b and the respective end panels 108a, 108b.

(8) The bottom panel 106 is generally rectangular in this embodiment, and defines the length and width of the interior of the container 100. The bottom panel has an upper surface 106a visible in FIG. 1, and an opposite bottom surface, not shown. In this embodiment, the bottom panel 106 has a length l of 77.625″ (between fold lines 154a and 154b), and a width w of 22.75″ (between fold lines 152a and 152b), which is larger than the standard Kraft cremation box.

(9) The end panel 108a extends the width w of bottom panel 106 on the fold line 154a, and extends away from the bottom panel by a distance h of 10.187″. The distance h will define the height of the interior of the container 100 when constructed for use (e.g. casket container 104 of FIG. 5). The end panel 108a includes a first surface 170a that is parallel to the upper surface 106a of the bottom panel 106 in the blank 100. The end panel 108b similarly extends the width w of bottom panel 106 on the fold line 154a, and extends away from the bottom panel by the distance h of 10.187″. The side panel 110b also includes a first surface 172b parallel to the upper surface 106a in the unfolded blank 100. It will be appreciated that the values of h, 1, and/or w can vary and still provide a casket container that incorporates elements of the embodiment described herein.

(10) The side panel 110a extends the length l of bottom panel 106 on the fold line 152a, and extends away from the bottom panel 106 by the distance h to an outer edge 111a. The side panel 110b similarly extends the length l of bottom panel 106 on the fold line 152b, and extends away from the bottom panel 106 by a distance h to an outer edge 111b. The side panel 110a includes a first surface 172a that is parallel to the upper surface 106a of the bottom panel 106 in the blank 100. The side panel 110a has a chamfered corner 128a that extends at an angle from the fold line 154a to the outer edge 111a, and a chamfered corner 128b that extends at an angle from the fold line 154b to the outer edge 111a. Similarly, the side panel 110b has a chamfered corner 128c that extends at an angle from the fold line 154b to the outer edge 111b, and a chamfered corner 128d that extends from the fold line 154a to the outer edge 111b. The chamfers 128a-128d may suitable extend between 2 and 5 inches.

(11) The side panel 110a further includes two cable through-holes 123a, 123b, two angled handle through-holes 132a, 132b, and two main handle through-holes 124a, 124b. The cable through-hole 123a is adjacent to the chamfered corner 128a, and is sized to fit a cable tie or similar element, not shown in FIG. 1. The angled handle through-hole 132a is disposed proximate the cable through-hole 123a and approximately midway between the fold line 152a and the outer edge 111a and is sized to receive at least three fingers of a typical adult human hand. The cable through-hole 123b is adjacent to the chamfered corner 128b, and is sized to fit a cable tie or similar element, not shown in FIG. 1. The angled handle through-hole 132b is disposed proximate the cable through-hole 123b and approximately midway between the fold line 152a and the outer edge 111a and is sized to receive at least three fingers of a typical adult human hand. The main handle through-holes 124a-124b are similarly sized or slightly larger than the handle through-holes 132a, 132b. The main hand through-holes 124a, 124b are spaced apart and are intermediate of the angled handle through-holes 132a, 132b.

(12) The side panel 110b further includes two cable through-holes 123c, 123d, two angled handle through-holes 132c, 132d, and two main handle through-holes 124c, 124d, that are correspondingly disposed as their respective counterparts of the side panel 110a.

(13) The gusset 112a is disposed at the corner between the end panel 108b and the side panel 110a. The gusset 112a is foldably connected to the end panel 108b along the fold line 152a, and is foldably connected to the side panel 110a along fold line 154a. The gusset 112a includes a first surface 174a that is parallel to the upper surface 106a of the bottom panel 106 in the blank 100. In this embodiment, the gusset 112a extends from the fold line 152a to a side edge 153a by the same distance that the side panel 110a extends from the fold line 152a. The gusset 112a extends from the fold line 154a by the same distance by which the end panel 108b extends from the fold line 154a.

(14) The intersection of the fold lines 152a and 154a forms an interior corner 156a of the gusset 112a. A gusset fold line 118a extends from this corner 156a to the diametrically opposite corner 158a of the gusset 112a. The fold line 118a divides the gusset 112a into a side panel portion 160a adjacent the side panel 110a and an end panel portion 162a adjacent the end panel 108b. The side panel portion 160a includes a chamfered corner 130a extending parallel to the fold line 118a for 2-5 inches from the fold line 154a to the side edge 153a. The chamfered corner 130a is disposed adjacent to and is preferably a mirror image of the chamfered corner 128a, such that the chamfers 128a, 130a collectively form a symmetrical V-shaped cutout between the edges 153a, 111a. The gusset 112a further includes plurality of holes 122 disposed symmetrically about the gusset fold line 118a.

(15) The gusset 112b is disposed at the corner between the end panel 108a and the side panel 110a. The gusset 112b is foldably connected to the end panel 108a along the fold line 152a, and is foldably connected to the side panel 110a along fold line 154b. The gusset 112b includes a first surface 174b that is parallel to the upper surface 106a of the bottom panel 106 in the blank 100. Similar to the gusset 112a, the gusset 112b extends from the fold line 152a to a side edge 153b by the same distance that the side panel 110a extends from the fold line 152a. The gusset 112b extends from the fold line 154b by the same distance by which the end panel 108a extends from the fold line 154b.

(16) A gusset fold line 118b extends from the intersection of the fold lines 152a and 154b to the diametrically opposite corner of the gusset 112b. The fold line 118b divides the gusset 112b into a side panel portion 160b adjacent the side panel 110a and an end panel portion 162b adjacent the end panel 108a. The side panel portion 160b includes a chamfered corner 130b extending parallel to the fold line 118b for 2-5 inches from the fold line 154b to the side edge 153b. The chamfered corner 130b is disposed adjacent to and is preferably a mirror image of the chamfered corner 128b, such that the chamfers 128b, 130b collectively form a symmetrical V-shaped cutout between the edges 153b, 111a. The gusset 112b further includes plurality of holes 122 disposed symmetrically about the gusset fold line 118b.

(17) The gusset 112c is disposed at the corner between the end panel 108a and the side panel 110b. The gusset 112c is foldably connected to the end panel 108a along the fold line 152b, and is foldably connected to the side panel 110b along fold line 154b. The gusset 112c includes a first surface 174c that is parallel to the upper surface 106a of the bottom panel 106 in the blank 100. The gusset 112c extends from the fold line 152b to a side edge 153c by the same distance that the side panel 110b extends from the fold line 152a. The gusset 112b extends from the fold line 154b by the same distance by which the end panel 108a extends from the fold line 154b. A gusset fold line 118c extends from the intersection of the fold lines 152b and 154b to the diametrically opposite corner of the gusset 112c. The fold line 118c divides the gusset 112c into a side panel portion 160c adjacent the side panel 110b and an end panel portion 162c adjacent the end panel 108a. The side panel portion 160c includes a chamfered corner 130c having a length of 2-5 inches, extending parallel to the fold line 118c from the fold line 154b to the side edge 153c. The chamfered corner 130c is disposed adjacent to and is preferably a mirror image of the chamfered corner 128c, such that the chamfers 128c, 130c collectively form a symmetrical V between the edges 153c, 111b. The gusset 112c further includes plurality of holes 122 disposed symmetrically about the gusset fold line 118c.

(18) The gusset 112d is disposed at the corner between the end panel 108b and the side panel 110b. The gusset 112d is foldably connected to the end panel 108b along the fold line 152b, and is foldably connected to the side panel 110b along fold line 154a. The gusset 112d includes a first surface 174d that is parallel to the upper surface 106a of the bottom panel 106 in the blank 100. Similar to the gusset 112c, the gusset 112d extends from the fold line 152b to a side edge 153c by the same distance that the side panel 110b extends from the fold line 152b. The gusset 112d extends from the fold line 154a by the same distance by which the end panel 108b extends from the fold line 154a. A gusset fold line 118d extends from the intersection of the fold lines 152b and 154a to the diametrically opposite corner of the gusset 112d. The fold line 118d divides the gusset 112d into a side panel portion 160d adjacent the side panel 110b and an end panel portion 162d adjacent the end panel 108b. The side panel portion 160d includes a chamfered corner 130d extending 2-5 inches parallel to the fold line 118d from the fold line 154a to the side edge 153d. The chamfered corner 130d is disposed adjacent to and is preferably a mirror image of the chamfered corner 128d, such that the chamfers 128d, 130d collectively form a symmetrical V-shaped cutout between the edges 153d, 111b. The gusset 112d further includes plurality of holes 122 disposed symmetrically about the gusset fold line 118d.

(19) In this embodiment, the blank 100 includes a connector 126a (in this case, double-sided tape) on the gusset part 160a, and another connector 126b on the gusset part 160b.

(20) As shown in FIG. 1, the largest dimensions of the blank are a length of 98″ and a width of 43.125″. In this embodiment, the blank 100 is folded into a casket that will have dimensions that are larger than standard prior art Kraft containers to conform to evolving body sizes. As discussed above, the assembled casket in this embodiment will have a length l of 77.625″ (as opposed to 73″) and a width w of 22.75″ (as opposed to 22″). However, the same design may be used with a blank configured for the standard casket dimensions.

(21) To ship the blank 100 to an end user, the blank 100 is first converted to a shipment configuration or shipment configuration. FIG. 2 shows a top plan view the blank 100 in shipment configuration, which is referred to herein as the folded blank 102.

(22) To convert the blank 100 in the shipment blank 102, one folds the first end panel 108a and the gussets 112b and 112c as a group along the fold line 154b. The end panel 108a and gussets 112b and 112c are folded such that a first surface 170a of the end panel 108a abuts the top surface 106a of the bottom panel 106, and the corresponding surfaces 174b and 174c of the gussets 112b, 112c abut, respectively, the surfaces 172a, 172b of the side panels 110a, 110b. The end panel 108b and gussets 112a and 112d are similarly folded over along fold line 154a. Thus, as shown in FIG. 2, the folded blank 102 is essentially the blank 100 with both end panels 108a, 108b and their corresponding gussets 112a-112d folded 180° inward along fold lines 154a, 154b of FIG. 1.

(23) The connector 126a, which as discussed above may be double-sided tape, is used to secure the gusset part 160a of the gusset 112a to the side panel 110a and the other connector 126b is used is used to secure the gusset part 160b of the gusset 112b to the side panel 110a. It will be appreciated that connectors other than two sided tape may be used, including ties, staples, adhesives etc. To allow proper subsequent folding of the gussets 112a, 112b, the respective portions 162a, 162b are not secured to the side panels 110a. In addition, for reasons that will be discussed below, the gussets 112c, 112d need not be secured to the side panel 110b. However, in other embodiments, the gussets 112c, 112d may be secured to the side panel 110b in the same way that the gussets 112a, 112b are secured to the side panel 110a

(24) As shown in FIG. 2, in the folded blank 102, the cutouts 130a-130d align vertically with the respective cutouts 128a-128d such that they form chamfered corners of the folded blank 102.

(25) These corners reduce the hypotenuse of the folded blank 102 to increase the rotatability of the blanks 102 in small spaces, such as within a delivery truck. More significantly, because the end panels 108a, 108b have been folded over, the length of the folded blank 102 has been reduced from the length of the original blank 100 to approximately the length of the bottom panel 106 (i.e. the length of the constructed casket). Such reduction also greatly improves maneuverability (rotation) of the blank 102. The reduction in the hypotenuse from the chamfered corners 128a-128d and 130a-130d combined with the reduced length allows a folded blank for the standard size (or even larger) casket body to be shipped and rotated within standard commercial shipping vehicles.

(26) As shown in FIG. 3, the folded blank 102 may then be loaded onto a pallet 202, or other shipping support for conveyance in a vehicle 204, and in this case, a vehicle trailer 206. Several folded blanks having the design and configuration of the folded blank 102 may be stacked (with chamfered corners aligned) and shipped on the same support 202. The support or pallet 202 may be loaded into the trailer 206 of the vehicle 204 in any horizontal orientation. Once the vehicle 204 arrives at the destination the pallet 202 may be moved out of the trailer 206 by a pallet jack, not shown. It may be necessary, depending on the geometry of the loading dock at the destination, which varies from destination to destination, to rotate the pallet 202 (e.g. 90 degrees) within the vehicle 204 to facilitate unloading. The reduced dimensions of the folded blanks 102 allow such rotation.

(27) At the destination, the end user can store the folded blank 102 until use. For use, the folded blank 102 must be assembled into a casket body 104. Assembly of the folded blank 102 into a casket body is now discussed in connection with FIGS. 4 and 5. FIG. 4 shows a perspective view of the folded blank 102 partially assembled into a casket container and in a condition for inserting a deceased onto the bottom panel 106. FIG. 5 shows an assembled casket container 104.

(28) Referring to FIG. 4, once the folded blank 102 is ready for use, the side panel 110a and the end panels 108a, 108b are folded upward 90 degrees. Because the gusset part 160a of the gusset 112a is secured to the side panel 110a and the gusset part 160b of the gusset 112b is secured to the side panel 110a, the other respective gusset parts 162a, 162b of the gussets 112a, 112b fold over along respective fold lines 118a, 118b to abut the respective parts 160a, 160b as the end panels 108a, 108b and side panel 110a are folded upward. In this folded position, it is noted that the symmetrically disposed through holes 122 (on parts 160a, 162a) of the gusset 112a are aligned.

(29) In addition, the through-holes 122 of the gusset 112a align with the through-hole 123a of the side panel 110a and a portion of the angled handle through-hole 132a. A cable tie 125 or similar flexible means can be inserted through the aligned through-holes 122 and 123a, and around through the other through-hole 122 and the handle through-hole 132a to secure the gusset 112a in place on the side panel 110a. In the secured position, the portion of the surface 174a of the gusset part 160b abuts the surface 172a of the side panel 110a, and the part of the surface 174a of the gusset part 162a faces away from the side panel 110a. The gusset 112b is secured in a similar manner.

(30) Because the surfaces 174c, 174d of respective gussets 112c, 112d were not coupled to the side panel 110b, the gussets 112c, 112d stand vertically parallel to the end panels 108a, 108b and are not yet folded along lines 118c, 118d (except perhaps to small degree from pre-folding). In this configuration shown in FIG. 4, the casket body 104 has an open side in which a deceased may be inserted into the casket interior 105. Once the deceased is fully inserted onto the bottom panel 106, the side panel 110b can be folded upright, causing gussets 112c, 112d to fold along lines 118c, 118d. The gussets 112c, 112d can then be secured to the side panel 110b in the same manner used to secure the gussets 112a, 112b to the side panel 110a, discussed above. After the gussets 112a, 112b are secured to the side panel 110a and the gussets 112c, 112d are secured to the side panel 110b as discussed above, the casket body 104 is fully formed, as shown in FIG. 5.

(31) As discussed above, cable ties 125 are used to secure the gussets 112a, 112b, 112c and 112d in the folded position shown in FIG. 5. Referring to FIG. 1, it is noted that in this embodiment, the small diagonal handles 132a-132d on the ends of the side panels 110a, 110b are used both as a through-hole for a cable tie, and to facilitate manipulation of the blanks 100, 102.

(32) Referring to FIG. 5, an appropriate lid, not shown, may be used, including one formed of foldable corrugated paper.

(33) It will be appreciated that the above-described embodiments are merely exemplary, and that those of ordinary skill in the art may readily devise their own implementations that incorporate the principles of the invention and fall within the spirit and scope thereof