GB2462321A

GB2462321A - Flat-pack coffin with L-shaped bracket for securing side panels to base panel

Info

Publication number: GB2462321A
Application number: GB0814296A
Authority: GB
Inventors: Robert John Morphet
Original assignee: Joseph A Hey & Son Ltd
Current assignee: Joseph A Hey & Son Ltd
Priority date: 2008-08-05
Filing date: 2008-08-05
Publication date: 2010-02-10
Also published as: GB0814296D0

Abstract

A flat-pack coffin [1, Fig. 1] comprises a lid [3, Fig. 1], and at least one side panel 2, secured to a base panel 4 using an L-shaped support bracket 18 in combination with a plurality of dowels 14 provided around the periphery of the base panel 4. The dowels project outwards from the base panel 4 in a direction substantially parallel to the plane of the base panel 4 and are received in a series of bores 15 formed in the side panels 2. The L-shaped support strip 18 has one flange 19 which is secured to the lower edge of the outer side of the side panel 2 while its other flange 20 extends around the edge of the side panel 2 to project outwards from panel 2 and under base panel 4. Pilot holes [21, Fig. 4] are formed respectively in flange 20 of the support strip 18 and in the base panel 4 to enable a screw fastener 17 to be used to secure the support strip 18 to the base 4. Preferably, the coffin (1) is made substantially of inexpensive, recycled and/ or biodegradable material such as paper-pulp based materials such as cardboard and fibreboard. Panels of the coffin may be of honeycomb construction with a wood veneer. The coffin can be stored in flat-pack form and can be assembled quickly using a screwdriver.

Description

IMPROVEMENTS TO COFFINS

The present invention relates to a coffin or casket and in particular to a flat pack coffin or casket that can be made of inexpensive, recycled and/or biodegradable material.

Hereinafter and in the claims, the term coffin' is used for all receptacles, regardless of shape or size, suitable for repose of a body or body ashes including animal bodies and ashes. Likewise, the term cardboard' will be used to refer to any heavy paper-pulp based board such as card stock or, where specified, to corrugated fiberboard. The latter is a paper-based material comprising fluted corrugated sheet.

Traditional wooden coffins are expensive items and take up a great deal of storage space at funeral homes. Funeral directors often wish to stock a variety of different types of coffin and it is also necessary that they store a range of different sizes but the storage space available usually limits what can be done.

The object of the present invention is to overcome or substantially mitigate the aforementioned problem by the provision of a flat pack coffin that which can be stored in a knocked-down state and erected only when required. This enables considerably more coffins to be stored than would otherwise be the case and also reduces shipping costs.

If a body is to be cremated, conventionally the coffin is incinerated along with the body. Many people, however, see this as wasteful both from a financial and from an environmental point of view. As a result coffins made from less expensive, environmentally friendly materials such as cardboard and wicker are now commonly used.

It is, therefore, a secondary object of the present invention to provide a flat pack coffin capable of being made substantially of paper-pulp based materials such as cardboard but which can have the external appearance of a conventional wooden coffin, in particular one that is traditionally shaped.

According to the present invention there is provided a flat pack coffin comprising: a base panel around the periphery of which is fitted a plurality of dowels that project outwards from the base panel in a direction substantially parallel to the plane of the base panel; at least one side panel defining an outer side and an inner side along the lower edge of which is a series of bores adapted to accommodate some or all of the dowels that project outwards from the base panel; an L-shaped support strip, one flange of which is secured along the lower edge of the outer side of the side panel and the other flange of which extends around the edge of the side panel to project outwards from the inner side of the panel; a series of pairs of pilot holes formed respectively in the other flange of the support strip and in the base panel such that the holes of each pair align when the coffin is assembled and the dowels in the base are inserted into the bores in the side panel to enable a screw fastener to be used to secure the bracket to the base; and a lid adapted for securernent to said at least one side panel.

It will be appreciated that a coffin must be strong enough to carry a body and the coffin according to the invention must, therefore, be strong enough, when erected, for this purpose. However, it is also important that the coffin is simple and quick to erect. Advantageously, a coffin according to the invention can be readily assembled requiring only the use of a screwdriver as a tool. The dowels are pre-fitted to the base and do not need gluing into the bores in the side panel or panels as it is the screw fasteners that hold the coffin together when in use. The dowels are provided simply to locate the side panel or panels in the correct position relative to the base.

Preferably, the L-shaped support strip is secured by adhesive to the lower edge of the outer side of the side panel.

Preferably also, the base has a traditional coffin shape to define a head portion at one end that adjoins a tapering body portion at a shoulder portion, and wherein two side panels are provided that can be secured via said dowels and a plurality of said screw fasteners to the opposing longer sides of the base, the side panels being adapted to bend around the shoulder portions of the base when they are fitted thereto.

In one embodiment of the inventions four side panels are preferably provided that include a head panel and a foot panel which can be secured via the dowels and a plurality of said screw fasteners to opposing shorter sides of the base.

Other preferred but non-essential features of the various aspects of the present invention are described in the dependent claims appended hereto.

An embodiment of the present invention will now be described by way of example with reference to the accompanying drawings, in which:-Fig. 1 is an exploded schematic view of an embodiment of flat pack coffin in accordance with the present invention; Fig. 2 is a perspective view of part of a side panel and lid of the coffin shown in Fig. 1, when erected and to an enlarged scale, with some outer covering layers removed therefrom; Fig. 3 is a perspective view from below and one side of the coffin shown in Fig. 1 when assembled; Fig. 4 is a detail showing schematically the way the side panels of the coffin are fitted to the base; Fig. 5 is a vertical section along the line V-V in Fig. 3 showing the joint between the side panel and the base when assembled; and Fig. 6 is a perspective view of an interior corner of the coffin when erected.

The embodiment of coffin 1 shown in the drawings comprises a series of panels comprising side panels 2, a lid 3 and a base panel 4. The side panels 2 must therefore be secured to the base panel 4 when it is desired to erect the coffin. Whilst it would be possible to supply a single side panel that could be folded around the base 4, as described below, to define the side walls of the erected coffin, preferably the side panels comprise two separate longer side panels 2a, a head panel 2b and a foot panel 2c as in the illustrated embodiment. Until erection the side panels 2a will lie flat along with the other panels 2b, 2c, the base 4 and the lid 3.

Although the coffin 1 could be made wholly of wood, chipboard, fibreboard or similar, preferably the side panels 2, the lid 3 and the base panel 4 are primarily made from cardboard. Other components, which are provided to connect the panels 2 and 4 together may also be made of wood, chipboard or fibreboard and in some cases may also be made of cardboard.

Rigidity and strength are imparted to cardboard panels 2, 3, 4 by an inner honeycomb layer 5, as shown in Fig. 2, that is secured to linerboards 6, 7 on its inner and outer sides respectively. Typically, the honeycomb layer 5 is be made of heavy paper-pulp based board which is approximately 1 mm thick. The honeycomb can be formed in a conventional manner, for example from appropriately folded cardboard. Hence, the individual cells of the honeycomb 5 each has its longitudinal axis perpendicular to the plane of the panel 2, 3, 4 and the linerboards 6, 7. The depth of the honeycomb layer 5, that is the length of each cell along its longitudinal axis, is of the order of 13 mm (0.5 inches). Each cell of the honeycomb preferably comprises a regular hexagon with a width that is also of the order of 13 mm (0.5 inches).

The linerboard 6 which is intended to be located towards the interior of the coffin 1 has its exterior surface, that is its exposed side inside the coffin, painted or covered with a thin sheet of appropriately coloured or decorated paper. Preferably, the outer linerboards 7 of the side panels 2 and the lid 3, which will be visible in use, also have an outer covering layer 8 in the form of a veneer, which can be of any suitable material such as wood, printed wood-effect plastics or paper sheet decorated as desired.

In order to enable fasteners, such as dowels, screws (as described below) and coffin furniture such as lid fixture fittings, nameplates, handles 9 and the like to be attached to various portions of the panels 2, 3, 4, these portions must be reinforced if the panels 2, 3,4 are made fiom cardboard as described above. One way of accomplishing this is to inset blocks of material that can hold fasteners, such as dowels, screws and the like, into the structure of the panels 2, 3, 4. Such blocks 10 are therefore preferably comprised of wood, particleboard (chipboard) or medium density fibreboard (MDF).

The base panel 4 is preferably made in a traditional coffin shape with a head portion 11 at one end that adjoins a tapering body portion 12 at a shoulder portion 13. However it will be appreciated that the base panel 4 could be rectangular if a casket-type coffin is required. A plurality of spaced dowels 14 project outwards from the base panel 4 in a direction substantially parallel to the plane of the panel 4. These are used to secure the panel 4 to the side panels 2a, 2b and 2c. Each of the dowels 14 is secured, preferably by gluing, in a blind bore formed in the edge of the base panel 4 and arranged to project for approximately half its length from the panel 4 so that they can be fitted to similar blind bores 15 in the intended adjacent side panel 2. The dowels 14 are pre-fitted to the base panel 4 so that they do not need to be secured thereto when it is desired to erect the coffin.

Also attached to the interior side of the base panel 4 is an L-shaped edging strip 16 that is secured by adhesive or similar around the periphery of the panel 4. The edging strip 16 includes an upstanding flange that provides additional support for the erected coffin structure.

Each of the side panels 2a, 2b, 2c is secured to the base panel 4 via the dowels 14 and a plurality of screw fasteners 17. The two side panels 2a are adapted to bend around the shoulder portions 13 of the base panel 4 when they are fitted thereto. If the panels 2a are made of a solid material, then they are usually sawn part way through at the shoulder with a series of parallel, transverse cuts, as is conventional. If they are made of a cardboard material, as described above, then that part of the inner linerboard 6 which will lie adjacent the shoulder is omitted or removed and the honeycomb layer 5 in this region is provided with a plurality of parallel, transverse cuts or gaps so that it is flexible. The outer linerboard 7 will then readily fold around the shoulder portion 13 of the base panel 4. In both cases, these panels 2a can be laid flat for transportation and storage and only need to be shaped to fit around the base panel4 on erection of the coffin 1.

To enable the panels 2a, 2b and 2c to be rigidly secured to the base panel 4 in addition to the fitment of the dowels 14 into the bores 15, an L-shaped support strip 18 is attached to the lower edge of the outer side of each side panel 2a, 2b, 2c. The strip has one flange 19 which is secured, for example by an adhesive, to the side panel 2a, 2b, 2c and has its other flange extending around the edge of the panel 2a, 2b, 2c to project outwards from the inner side of the panel. When the panel 2a, 2b, 2c is connected to the base panel 4 via the dowels 14, the extending flange 20 locates beneath the base panel 4. A series of pairs of pilot holes 21 are formed respectively in the flange 20 and in the base panel 4 in order that the holes 21 of each pair align when the coffin is erected. The holes 21 in the flange 20 can be provided with appropriate countersinking and the screw fasteners 17 can then be screwed into the holes 21 through the flange 20 to secure the support strip 18 and thereby the side panels 2a, 2b, 2c to the base panel 4. When the panels 2a, 2b, 2c have been connected to the base panel 4, the upstanding flange of the edging strip 16 attached to the base panel 4 abuts the inner surface of the panels 2a, 2b, 2c and covers the joint between the base panel 4 and these side panels 2a, 2b, 2c.

In order to make the support strip 18 appear less utilitarian, it preferably has secured to it an ornamental beading 22. This can comprise a conventional wooden beading or one made of moulded strips of paper-pulp based material.

One the panels 2a, 2b, 2c have been attached to the base panel 4a, they then attached to each other by at least four wedge-shaped connectors 23 located at each of the interior corners of the coffin 1 between adjacent side panels. The wedge-shaped connectors 23 are provided with two spaced series of holes 24 that align with series of pilot holes located along margins of the inner sides of two adjacent side panels 2a, 2b, 2c to enable a plurality of screw fasteners (not shown) to be inserted and screwed in to secure the adjacent side panels 2a, 2b, 2c to one another.

The lid 4 is also provided a series of holes 25 around its periphery that align with a series of blind holes 26 formed in the upper edges of the side panels 2a, 2b, 2c. Tapped inserts with exterior flanges 27 (see Fig., 2) are located within these blind holes 26 to enable the lid 3 to be screwed down by a series of threaded bolts (not shown) in conventional fashion once a body has been placed inside the coffin 1.

It will be appreciated that a coffin 1 according to the invention can be made entirely from bio-degradable materials and is preferably made from recycled material. This means that the coffin is environmentally friendly and inexpensive whilst it can still give the appearance, if desired, of a traditional coffin. The coffin 1 can be stored in a knocked-down state, mainly as a series of flat panels 2, 3, 4 and erected only when required. This takes up considerably less space than a traditional coffin. When required for use, the coffin 1 can be readily erected speedily, as described above, using only a screwdriver. In most cases, it is expected that a coffin 1 can be erected and ready for use in around 5 minutes.

Claims

CLAIMS1. A flat pack coffin comprising a base panel around the periphery of which is fitted a plurality of dowels that project outwards from the base panel in a direction substantially parallel to the plane of the base panel; at least one side panel defining an outer side and an inner side along the lower edge of which is a series of bores adapted to accommodate some or all of the dowels that project outwards from the base panel; an L-shaped support strip, one flange of which is secured to the lower edge of the outer side of the side panel and the other flange of which extends around the edge of the side panel to project outwards from the inner side of the panel; and a series of pairs of pilot holes formed respectively in the other flange of the support strip and in the base panel such that the holes of each pair align when the coffin is assembled and the dowels in the base are inserted into the bores in the side panel to enable a screw fastener to be used to secure the bracket to the base; and a lid adapted for securement to said at least one side panel.
2. A coffin as claimed in Claim 1, wherein the L-shaped support strip is secured by adhesive to the lower edge of the outer side of the side panel.
3. A coffin as claimed in Claim 1 or Claim 2, wherein the base has a traditional coffin shape to define a head portion at one end that adjoins a tapering body portion at a shoulder portion, and wherein two side panels are provided that can be secured via said dowels and a plurality of said screw fasteners to the opposing longer sides of the base, the side panels being adapted to bend around the shoulder portions of the base when they are fitted thereto.

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4. A coffin as claimed in any of Claims ito 3, wherein four side panels are provided that include a head panel and a foot panel which can be secured via the dowels and a plurality of said screw fasteners to opposing shorter sides of the base.
A coffin as claimed in any of Claims ito 4, wherein the base panel is provided with an edging strip with an upstanding flange around its periphery on its interior side.
6. A coffin as claimed in any of Claims i to 5, wherein at least four wedge-shaped connectors are provided that are adapted to be located in the inner corners formed between adjacent side panels when the coffin is assembled, the wedge-shaped connectors being provided with a series of holes that align with series of holes located along margins of the inner sides of two adjacent side panels to enable a plurality of screw fasteners to be used to secure the adjacent side panels to one another.
7. A coffin as claimed in any of Claims i to 6, comprising a lid with a series of holes formed around its periphery that align with a series of blind holes formed in the side panels when the coffin has been assembled, tapped inserts being located within the blind holes to enable the lid to be screwed down by a series of threaded bolts.
8. A coffin as claimed in any of Claims ito 7, wherein the side panel or panels are made substantially of cardboard and are provided with inset blocks of material that are provided with the pilot holes and blind bores at the positions whereat these fasteners are to be connected to the side panel or panels.
9. A coffin as claimed in Claim 8, wherein the side panels comprise a sandwich honeycomb layer arranged such that the cells of the honeycomb have longitudinal axes perpendicular to the plane of the -11 -panel and to linerboards secured to the honeycomb on both sides thereof, the blocks of material being located between the linerboards within the honeycomb layer.
10. A coffin as claimed in Claim 9, wherein the sandwich honeycomb layer is comprised wholly of heavy paper-pulp based board.
11. A coffin as claimed in Claim 9 or Claim 10 when dependent on Claim 3, wherein the side panels are adapted to bend around the shoulder portions of the base when they are fitted thereto by omission or removal of part of the linerboard on the interior side of the coffin and the provision of a plurality of parallel, transverse gaps or cuts in the honeycomb.
12. A coffin as claimed in any of Claims 8 to 11, wherein the blocks of material are made from wood, particleboard or medium density fibreboard.
13. A coffin as claimed in any of Claims 1 to 12, wherein the L-shaped support strip comprises an ornamental beading.
14. A coffin as claimed in Claim 13, wherein the beading comprises moulded strips of paper-pulp based material.
15. A coffin as claimed in any of Claims ito 14, wherein at least the side panel or panels comprises an outer layer in the form of a veneer.
16. A flat pack coffin substantially as described herein with reference to the accompanying drawings.