Casket Lid Multi-Layer Support System
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Solution Overview
Problem
Casket lids often display faults in workmanship, leading to separation of boards, which compromises their structural integrity and aesthetic appeal.
Innovation Solution
A casket lid design featuring a multi-layered internal support system with alternating butt and picture joints, secured by glue, pegs, nails, or straps, ensuring stability and minimizing the likelihood of board separation, while the external face is constructed using various joining methods to maintain integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layer construction is used for the casket lid, then the manufacturing process is simple, but the structural integrity is compromised leading to board separation
Solution Approach 1:
The casket lid is divided into three separate layers (first layer with initial boards, second layer with subsequent boards, and third layer with final boards) instead of using a single-layer construction. Each layer is joined using alternating butt and picture joints, creating a segmented structure that prevents board separation while maintaining manufacturing feasibility through systematic assembly procedures
Solution Approach 2:
The invention uses composite construction by combining multiple wood layers with different board orientations and joint types. The alternating butt and picture joints create a composite structure where each layer complements the others, providing enhanced structural integrity and preventing the board separation issues that occur in single-layer constructions
2Ease of manufacture
If traditional joining methods are used without alternating joint types, then the construction process is straightforward, but board separation occurs compromising workmanship quality
Solution Approach 1:
The joining process is segmented into alternating butt joints and picture joints across the three layers. This segmentation of joint types prevents the repetitive stress patterns that cause board separation in traditional single-joint-type constructions, thereby improving workmanship quality while maintaining construction straightforwardness through systematic alternation
Solution Approach 2:
Instead of using the same joint type throughout (traditional approach), the invention inverts the approach by alternating between butt joints and picture joints. This inversion of the uniform joint pattern prevents board separation and enhances workmanship quality while keeping the construction process straightforward through regular alternation
3Strength
If multiple layers with alternating joints are used, then board separation is prevented improving structural integrity, but the device complexity increases
Solution Approach 1:
The lid is segmented into three layers with alternating joint types, which prevents board separation and enhances structural integrity. The segmentation is designed to be systematic rather than arbitrary, with each layer following a predictable pattern that reduces the perceived complexity while maintaining the structural benefits
Solution Approach 2:
The invention inverts the traditional single-layer uniform joint approach by using alternating joint types across multiple layers. This inversion creates a more complex structure that prevents board separation, but the complexity is managed through regular alternation patterns that make the construction systematic rather than chaotic
Data Source
AI summary
In one example, the present invention relates to a casket lid having two long sides and two short sides, including an internal support system and an external face, wherein (i) the internal support system comprises three layers that are each co-extensive with each of the long sides and short sides, (ii) the first layer and the third layer are each in contact with the second layer, and (iii) each of said layers is in contact with the external face on each of said long sides and said short sides.