Cremation urn and methods of manufacture

Abstract

A cremation urn comprising an internal structure with an opening, an external opening with an opening that is correspondingly aligned with the opening on the internal structure, and sealing means in the form of a threaded lid or press fit lid. A threaded flange is attached to the opening on the internal structure and is molded into the urn during manufacturing. The materials used for the urn produce an urn with the appearance of marble. Once the urn is made, by use of a manufacturing method, the threaded lid is screwed into the threaded flange, thereby creating a one-piece, air-tight and water-tight cremation urn.

Claims

1. A method of manufacture of a cremation urn, wherein said method comprises the following steps: a) acquire a blow mold for an urn internal structure, wherein the blow mold has an opening in a lower section, b) attach a threaded flange with no drain holes to the blow mold, with the flange being locked into the opening to create a tight seal and fit, c) insert a toggle bolt into the blow mold with the threaded shaft of the bolt passing through a center section of a plastic support holder for the flange, d) continue inserting the bolt's threaded shaft through an opening on a weighted metal plate which has metal stud supports to stabilize and maintain the blow mold attached to the plate, e) secure the toggle bolt with a wing nut, f) acquire a mold for an urn external structure, g) prepare the mold by applying to the inner surface a coating of release agent, h) apply unsaturated polyester clear gel coat monomer to the mold, and allow to air dry, i) prepare a matrix for the external structure utilizing unsaturated polyester resin, j) add methyl ethyl ketone peroxide or benzoyl peroxide which functions as a catalyst to cure the matrix at room temperature, k) add calcium carbonate fillers or aluminum trihydrates to the resin, l) add organic or inorganic pigments or titanium dioxide to the matrix to create a desired color, m) insert the matrix into the mold and pull the matrix up on the sides of the mold, n) insert the internal structure blow mold with weighted metal plate attached into a cavity in the external structure mold, o) align guide pins with openings in the external structure mold, thereby centering the internal blow mold within the external mold, p) allow the matrix to flow on all sides and bottom of the external mold, q) vibrate the external mold to level the matrix and to fill any empty voids between the internal blow mold and the external structure, r) allow the matrix within the external mold to cure, s) loosen the toggle bolt which allows the weighted metal plate to be removed, t) remove the toggle bolt and wing nut from the internal blow mold, u) remove from the mold the complete urn which comprises the urn external structure and the urn internal structure within the external structure, v) sand the lower surface of the urn, w) fill any voids and air pockets on lower surface with a filing compound, then said lower surface, x) buff exterior surfaces of the urn, y) apply epoxy paint onto the urn's lower surface, z) spray rayon flocking material onto the urn's lower surface, aa) wipe edges of the urn's lower surface with acetone, bb) vacuum interior of the blow mold, cc) screw a removable sealing means in the form of a threaded lid onto the threaded flange in the opening which extends through both the internal structure and the external structure.

2. The cremation urn as specified in claim 1 wherein said completed urn is a one-piece, air-tight and water-tight structure.

3. The cremation urn as specified in claim 1 wherein the materials that are formulated and used in said manufacturing method produce the urn with a marble appearance.

4. A method of manufacture of a cremation urn, wherein said method comprises the following steps: a) acquire a mold for an urn lower surface having an opening and an attached threaded flange, b) prepare a resin matrix, c) insert the resin matrix into the lower surface mold and allow to cure, d) remove the urn lower surface from the mold, e) acquire a blow mold for an urn internal structure, wherein the blow mold has an opening on a lower surface, f) insert a toggle bolt having a nut into the blow mold with the threaded shaft of the bolt passing through the flange opening, g) continue inserting the bolt's threaded shaft through an opening on a weighted metal plate, h) secure the toggle bolt with a wing nut, i) acquire a mold for an urn external structure, j) prepare the mold by applying to the inner surface a coating of release agent, k) apply unsaturated polyester clear gel coat monomer to the mold, and allow to air dry, l) prepare a matrix for the external structure utilizing unsaturated polyester resin, m) add methyl ethyl ketone peroxide or benzoyl peroxide which functions as a catalyst to cure the matrix at room temperature, n) add calcium carbonate fillers or aluminum trihydrates to the resin, o) add organic or inorganic pigments or titanium dioxide to the matrix to create a desired color, p) insert the matrix into the mold and pull the matrix up on the sides of the mold, q) insert the internal structure blow mold with weighted metal plate attached into a cavity in the external structure mold, r) allow the matrix to flow on all sides of the external mold, s) vibrate the external mold to level the matrix and to fill any empty voids between the internal blow mold and the external structure, t) allow the matrix within the external mold to cure, u) loosen the toggle bolt nut which allows the weighted metal plate to be removed, v) remove the toggle bolt from the internal blow mold, w) remove from the mold the complete urn which comprises the urn external structure and the urn internal structure within the external structure, x) sand the lower surface of the urn, y) attach by an attachment means the pre-made lower surface to the bottom of the external structure, with the opening on the lower surface aligned with the opening on the internal structure, z) lightly sand the lower surface of the urn, aa) apply a pre-cut flocking material to the lower surface of the urn, and bb) screw a removable sealing means in the form of a threaded lid onto the threaded flange in the opening which extends through both the internal structure and the external structure.

5. A method of manufacture of a cremation urn, wherein said method comprises the following steps: a) acquire a mold for an urn lower surface having an opening and an attached threaded flange, b) prepare a resin matrix, c) insert the resin matrix into the lower surface mold and allow to cure, d) remove the urn lower surface from the mold, e) acquire a blow mold for an urn internal structure, wherein the blow mold has an opening on a lower surface, f) insert a toggle bolt having a nut into the blow mold with the threaded shaft of the bolt passing through the flange opening, g) continue inserting the bolt's threaded shaft through an opening on a weighted metal plate, h) secure the toggle bolt with a wing nut, i) acquire a mold for an urn external structure, j) prepare the mold by applying to the inner surface a coating of release agent, k) apply unsaturated polyester clear gel coat monomer to the mold, and allow to air dry, l) prepare a matrix for the external structure utilizing unsaturated polyester resin, m) add methyl ethyl ketone peroxide or benzoyl peroxide which functions as a catalyst to cure the matrix at room temperature, n) add calcium carbonate fillers or aluminum trihydrates to the resin, o) add organic or inorganic pigments or titanium dioxide to the matrix to create a desired color, p) insert the matrix into the mold and pull the matrix up on the sides of the mold, q) insert the internal structure blow mold with weighted metal plate attached into a cavity in the external structure mold, r) allow the matrix to flow on all sides of the external mold, s) vibrate the external mold to level the matrix and to fill any empty voids between the internal blow mold and the external structure, t) the matrix within the external allow mold to cure, u) loosen the toggle bolt nut which allows the weighted metal plate to be removed, v) remove the toggle bolt from the internal blow mold, w) remove from the mold the complete urn which comprises the urn external structure and the urn internal structure within the external structure, x) sand the lower surface of the urn, y) attach by an attachment means the pre-made lower surface to the bottom of the external structure, with the opening on the lower surface aligned with the opening on the internal structure, z) lightly sand the lower surface of the urn, aa) apply a pre-cut flocking material to the lower surface of the urn, and bb) screw a removable sealing means in the form of a threaded lid onto the threaded flange in the opening which extends through both the internal structure and the external structure, wherein said completed urn is a one-piece, air-tight and water-tight structure.

6. A method of manufacture of a cremation urn, wherein said method comprises the following steps: a) acquire a mold for an urn lower surface having an opening and an attached threaded flange, b) prepare a resin matrix, c) insert the resin matrix into the lower surface mold and allow to cure, d) remove the urn lower surface from the mold, e) acquire a blow mold for an urn internal structure, wherein the blow mold has an opening on a lower surface, f) insert a toggle bolt having a nut into the blow mold with the threaded shaft of the bolt passing through the flange opening, g) continue inserting the bolt's threaded shaft through an opening on a weighted metal plate, h) secure the toggle bolt with a wing nut, i) acquire a mold for an urn external structure, j) prepare the mold by applying to the inner surface a coating of release agent, k) apply unsaturated polyester clear gel coat monomer to the mold, and allow to air dry, l) prepare a matrix for the external structure utilizing unsaturated polyester resin, m) add methyl ethyl ketone peroxide or benzoyl peroxide which functions as a catalyst to cure the matrix at room temperature, n) add calcium carbonate fillers or aluminum trihydrates to the resin, o) add organic or inorganic pigments or titanium dioxide to the matrix to create a desired color, p) insert the matrix into the mold and pull the matrix up on the sides of the mold, q) insert the internal structure blow mold with weighted metal plate attached into a cavity in the external structure mold, r) allow the matrix to flow on all sides of the external mold, s) vibrate the external mold to level the matrix and to fill any empty voids between the internal blow mold and the external structure, t) the matrix within the external allow mold to cure, u) loosen the toggle bolt nut which allows the weighted metal plate to be removed, v) remove the toggle bolt from the internal blow mold, w) remove from the mold the complete urn which comprises the urn external structure and the urn internal structure within the external structure, x) sand the lower surface of the urn, y) attach by an attachment means the pre-made lower surface to the bottom of the external structure, with the opening on the lower surface aligned with the opening on the internal structure, z) lightly sand the lower surface of the urn, aa) apply a pre-cut flocking material to the lower surface of the urn, and bb) screw a removable sealing means in the form of a threaded lid onto the threaded flange in the opening which extends through both the internal structure and the external structure, wherein the attachment means for attaching the lower surface to the bottom of the external structure is comprised of an adhesive.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is an orthographic exploded view of the cremation urn showing the external structure, the internal structure and the elements of the sealing means.

(2) FIG. 2 is a front elevational view of a cremation urn.

(3) FIG. 3 is a side elevational view of the cremation urn.

(4) FIG. 4 is a top plan view of the cremation urn.

(5) FIG. 5 is a bottom plan view of the cremation urn.

(6) FIG. 6 is a cut-a-way view of the cremation urn showing a corner of an internal structure.

(7) FIG. 7 is an orthographic bottom view of the cremation urn showing an exploded view of sealing means comprising a threaded flange, threaded lid and gasket.

(8) FIG. 8 is a front elevational view of the cremation urn showing the external structure of the urn with the appearance including color and veining of marble.

(9) FIG. 9 is a front elevational view of the cremation urn showing the external structure of the urn having a vinyl wrap.

(10) FIG. 10 is a front elevational view of the cremation urn showing the external structure of the urn painted.

(11) FIG. 11 is a front elevational view of the cremation urn showing the external structure of the urn with spray stone applied.

BEST MODE FOR CARRYING OUT THE INVENTION

(12) The best mode for carrying out the invention is presented in terms that disclose a preferred structural embodiment of, and multiple manufacturing methods for, a cremation urn. In the modern world, especially in developed nations, there are two primary ways of dealing with a dead human body. The first way is to bury the body along with a coffin, or place the body and coffin in an above-ground mausoleum. Both burying in the ground and placing a body and coffin in a mausoleum require a significant financial cost. More importantly, both of these require an amount of space that is becoming less available.

(13) The second way of dealing with a dead human body is to burn or cremate the body. In regard to space requirements, cremation is preferred since all that remains after cremation are a relatively small amount of ashes, which are then placed in a suitable container, which typically consists of an urn.

(14) The problem is that many cremation urns are actually not suitable for human ashes. The instant cremation urn offers a solution to this by providing a cremation urn that has an internal structure for maintaining and protecting the ashes, and an external structure that encases and protects the internal structure. The instant cremation urn has an aesthetically pleasing appearance while providing a safe and secure location to maintain human ashes either for burial, placement in a mausoleum, or keeping in a home or other location.

(15) The cremation urn 10, as shown in FIGS. 1-11, is comprised of the following major elements: an internal structure 12, an external structure 38, and sealing means 68 in the form of a lid 70.

(16) The internal structure 12, as shown in FIGS. 1-6, is preferably made of plastic by a blow mold process. Other materials, including rubber, metal, concrete, wood, ceramic, glass, fiberglass, biodegradable material or other synthetics can also be utilized. The internal structure 12 is preferably substantially rectangular in shape, but can be made in any geometric or non-geometric shape. For the purpose of this disclosure, the substantially rectangular design will be described and shown.

(17) The internal structure 12 has an outer surface 14, an inner surface 16, a first side surface 18, a second side surface 20, a third side surface 22, a fourth side surface 24, an upper surface 26, and a lower surface 28. As shown in FIGS. 1, 2, 3 and 6, along each side of the internal structure's upper surface extends an upward and inward section 30 that terminates at the substantially flat upper surface 26. Located on the lower surface 28 is an opening 32, as shown in FIG. 7. Prior to molding the urn, a threaded flange 34 is attached to the opening 32.

(18) The external structure 38, as shown in FIGS. 1-7, is preferably made of a material known as cultured marble, which is a synthetic material that has the appearance and texture of real marble. The external structure 38 is made by a molding manufacturing method. Although cultured marble is the preferred material, the external structure 38 can be made of other materials including rubber, plastic, metal, concrete, wood, ceramic, glass, fiberglass, biodegradable material or other synthetics. The shape of the external structure 38 corresponds to the shape of the internal structure 12, with the external structure 38 dimensioned slightly larger to allow the internal structure to be placed within the external structure, as shown in FIGS. 1 and 6. As shown in FIGS. 1, 2 and 3, the external structure 38 has an outer surface 40, an inner surface 42, a first side surface 44, a second side surface 46, a third side surface 48, a fourth side surface 50, an upper surface 52 and a lower surface 54. As with the internal structure, along each side of the external structure's upper surface extends an upward and inward section 56 that terminates at the substantially flat upper surface 52. Also, at each corner where the respective sides interface is a rounded section 58, as shown in FIGS. 1, 2 and 3, which provides an aesthetic column. Located on the lower surface of the external structure 38 is an opening 60 that is dimensioned to and correspondingly aligned with the opening 32 on the internal structure 12. After the urn 10 is made, the two openings 32,60 allow human remains in the form of ashes to be placed into the internal structure 12.

(19) In order to maintain the ashes within the urn 10, the sealing means 68 is utilized. As shown in FIGS. 1, 5 and 7, the sealing means 68 is in the form of a lid 70 comprising an outer surface 72 with an indented area having at least one finger tab 74, an inner surface 76, an outer perimeter 78 with threads 80 that correspond to the threads on the flange 34, and a gasket 82 to provide a tight seal of the lid. A lid 70 having four finger tabs 74, is shown in FIGS. 5 and 7. To access the internal structure 12, or to seal the urn 10 once ashes have been placed within the urn, the lid 70 is screwed into or out of the threaded flange. Since the lid 70 sits flush with the outer surface of the external structure 38, the finger tabs 74 allow a person to acquire a grasp of the lid and to rotate the lid when screwing the lid on or off. Additionally, a lid 70 without finger tabs can also be effectively utilized.

(20) After an urn 10 has been made, a flocking material 86 is applied onto the lower surface of the external structure 38, as shown in FIGS. 5 and 7. The flocking material is either a sprayed substance or pre-cut to size flocked craft paper with pressure sensitive coating, which is also known as an adhesive.

(21) As previously disclosed the cremation urn is preferably made of cultured marble by a manufacturing method comprised of molding. The cultured marble material produces an urn with an attractive appearance of real marble, complete with marble color and veining 90, as shown in FIG. 8. Preferably the molds used to fabricate the external structure are made of fiberglass, but the molds can be made of other materials including metal, rubber or concrete.

(22) During manufacture a pigment is added to produce the color and marble appearance of the urn 10. If desired, the pigment can be omitted which results in an urn with a comparatively un-attractive creamy brown appearance. Omitting the pigment is utilized when other outward appearances of the urn are desired. Some examples of other appearances include: a vinyl wrap 52 that tightly adheres to the outer surface of the external structure 38. The wrap 52, as shown in FIG. 9, can be any color or have any image printed thereon. Another alternate appearance is a simple painted external structure, as shown in FIG. 10. The paint 98 can be applied by spray or brush and can be any conceivable color or any image desired. Similar to paint is a finish known as spray stone or spray granite which, as its name implies is sprayed onto the external structure's outer surface and gives the appearance of natural stone or rock, as shown in FIG. 11. When an urn is made of metal or plastic, the outer surface can be plated with a material such as chrome or gold (not shown). An aluminum urn can have an anodized surface. These are examples to indicate that the instant cremation urn 10 is not limited to any specific material or appearance/finish option. Additionally, to add to the appearance and/or functionality of the urn 10, text, either applied such as with paint or engraved, and/or images such as a photograph of the deceased person, can be placed on the external structure's outer surface. Other images that reflect the deceased person's interests or hobby can also be utilized.

(23) There are two main manufacturing methods. The first, preferred method is comprised of the following steps:

(24) A. Acquire a blow mold 120 for an urn internal structure, wherein the blow mold has an opening in a lower section.

(25) B. Attach a threaded flange with no drain holes to the blow mold, with the flange being locked into the opening to create a tight seal and fit.

(26) C. Insert a toggle bolt 104 into the blow mold with the threaded shaft of the bolt passing through a center section of a plastic support holder 110 for the flange.

(27) D. Continue inserting the bolt's threaded shaft through an opening on a weighted metal plate which has metal stud supports to stabilize and maintain the blow mold attached to the plate.

(28) E. Secure the toggle bolt with a wing nut 106.

(29) F. Acquire a mold 118 for an urn external structure.

(30) G. Prepare the mold by applying to an inner surface a coating of release agent.

(31) H. Apply unsaturated polyester clear gel coat monomer to the mold 118, and allow to air dry.

(32) I. Prepare a matrix for the external structure utilizing unsaturated polyester resin.

(33) J. Add methyl ethyl ketone peroxide or benzoyl peroxide which functions as a catalyst to cure the matrix at room temperature.

(34) K. Add calcium carbonate fillers or aluminum trihydrates to the resin.

(35) L. Add organic or inorganic pigments or titanium dioxide to the matrix to create a desired color.

(36) M. Insert the matrix into the mold 118 and pull the matrix up on the sides of the mold.

(37) N. Insert the internal structure blow mold 120 with weighted metal plate 108 attached into a cavity in the external structure mold.

(38) O. Align guide pins 112 with openings in the external structure mold 118, thereby centering the internal blow mold 120 within the external mold.

(39) P. Allow the matrix to flow on all sides and bottom of the external mold 118.

(40) Q. Vibrate the external mold 118 to level the matrix and to fill any empty voids between the internal blow mold 120 and the external structure.

(41) R. Allow the matrix within the external mold 118 to cure.

(42) S. Loosen the toggle bolt 104 which allows the weighted metal plate 108 to be removed.

(43) T. Remove the toggle bolt 120 and wing nut 106 from the internal blow mold.

(44) U. Remove from the mold 118 the complete urn which comprises the urn external structure and the urn internal structure within the external structure.

(45) V. Sand the lower surface of the urn.

(46) W. Fill any voids and air pockets on lower surface with a filling compound, then sand lower surface.

(47) X. Buff exterior surfaces of urn.

(48) Y. Apply epoxy paint onto the urn's lower surface.

(49) Z. Spray rayon flocking material onto urn's lower surface.

(50) AA. Wipe edges of urn's lower surface with acetone.

(51) BB. Vacuum interior of blow mold.

(52) CC. Screw a removable sealing means in the form of a threaded lid 70 onto the threaded flange in the opening which extends through both the internal structure and the external structure.

(53) The second alternate method is similar to the first method except a separate, pre-made lower surface is utilized instead of the one-piece design of the first method. The second method comprises the following steps:

(54) A. Acquire a mold 122 for an urn lower surface having an opening and an attached threaded flange 34.

(55) B. Prepare a resin matrix.

(56) C. Insert the resin matrix into the lower surface mold 122 and allow to cure.

(57) D. Remove the urn lower surface from the mold 122.

(58) E. Acquire a blow mold 120 for an urn internal structure, wherein the blow mold has an opening on a lower surface.

(59) F. Insert a toggle bolt 104 having a nut into the blow mold 120 with the threaded shaft of the bolt passing through the flange opening.

(60) G. Continue inserting the bolt's threaded shaft through an opening on a weighted metal plate 108.

(61) H. Secure the toggle bolt 104 with a wing nut 106.

(62) I. Acquire a mold 118 for an urn external structure.

(63) J. Prepare the mold 118 by applying to the inner surface a coating of release agent.

(64) K. Apply unsaturated polyester clear gel coat monomer to the mold 118, and allow to air dry.

(65) L. Prepare a matrix for the external structure utilizing unsaturated polyester resin.

(66) M. Add methyl ethyl ketone peroxide or benzoyl peroxide which functions as a catalyst to cure the matrix at room temperature.

(67) N. Add calcium carbonate fillers or aluminum trihydrates to the resin.

(68) O. Add organic or inorganic pigments or titanium dioxide to the matrix to create a desired color.

(69) P. Insert the matrix into the mold and pull the matrix up on the sides of the mold 118.

(70) Q. Insert the internal structure blow mold 120 with weighted metal plate 108 attached into a cavity in the external structure mold 118.

(71) R. Allow the matrix to flow on all sides of the external mold 118.

(72) S. Vibrate the external mold 118 to level the matrix and to fill any empty voids between the internal blow mold 120 and the external structure.

(73) T. Allow the matrix within the external mold 118 to cure.

(74) U. Loosen the toggle bolt nut 106 which allows the weighted metal plate 108 to be removed.

(75) V. Remove the toggle bolt 106 from the internal blow mold 118.

(76) W. Remove from the mold 118 the complete urn which comprises the urn external structure and the urn internal structure within the external structure.

(77) X. Sand the lower surface of the urn.

(78) Y. Remove the external structure with the internal structure from the mold 118.

(79) Z. Attach by an attachment means the pre-made lower surface to the bottom of the external structure, with the opening on the lower surface aligned with the opening on the internal structure.

(80) AA. Lightly sand the lower surface of the urn.

(81) BB. Apply a pre-cut flocking material to the lower surface of the urn, and

(82) CC. Screw a removable sealing means in the form of a threaded lid 70 onto the threaded flange 34 in the opening which extends through both the internal structure and the external structure.

(83) Although the above two methods are the most widely used, the instant cremation urn 10 should not be limited to those only. Other methods can also be employed. For example, a manufacturing method that utilizes component parts of an urn. Each of the component parts, such as the side surfaces, the upper surface, etc. can be manually alternated together by an attachment means. No mold is utilized and the attachment means can be comprised of an adhesive, a plurality of screws, or nuts and bolts. Obviously, an urn manufactured by this method would not be as high quality or possess the air-tight and water-tight attributes as the previously disclosed preferred first method, but a cremation urn having an internal structure and an external structure could still be realized.

(84) While the invention has been described in detail and pictorially shown in the accompanying drawings it is not to be limited to such details, since many changes and modification may be made to the invention without departing from the spirit and the scope thereof. Hence, it is described to cover any and all modifications and forms which may come within the language and scope of the claims.