Reduced Height Casket Shell Stamping and Display Base Nesting
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Solution Overview
Problem
The conventional method of manufacturing sheet metal casket shells is labor-intensive and requires significant raw materials, with numerous manual steps and energy consumption, leading to inefficiencies and quality control issues.
Innovation Solution
A reduced height casket shell design that can be stamped from a single piece of sheet metal, eliminating the need for extensive welding and grinding, and paired with a casket display base to maintain a conventional appearance while reducing material and labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional sheet metal casket shells are manufactured using multiple panels welded together, then the desired structural strength and appearance are achieved, but the manufacturing process becomes labor-intensive and produces unsightly weld lines
Solution Approach 1:
The patent merges multiple separate panels into a single monolithic sheet metal structure. The casket shell is formed from one continuous piece of sheet metal that is stamped and formed to create the side walls, end walls, and bottom panel as an integrated unit, eliminating the need for welding multiple panels together.
Solution Approach 2:
The patent segments the manufacturing process by forming the entire casket shell from a single blank piece of sheet metal through stamping operations, rather than assembling pre-fabricated panels. This single-stage forming approach eliminates welding while maintaining structural integrity.
2Shape
If multiple panels are welded together to form the casket shell, then the desired shape and structure are achieved, but extensive welding and grinding operations are required
Solution Approach 1:
The patent combines the formation of side walls, end walls, and bottom panel into a single stamping operation that forms the entire casket shell from one piece of sheet metal, eliminating the need for separate welding and grinding operations.
Solution Approach 2:
The patent changes the manufacturing approach from assembling multiple panels through welding to forming a single monolithic structure through stamping. This parameter change in the manufacturing process eliminates complex welding and grinding operations while achieving the desired casket shell shape.
3Shape
If conventional height casket shells are manufactured, then the traditional appearance is maintained, but significant raw material is required and manufacturing is labor-intensive
Solution Approach 1:
The patent changes the casket shell height parameter to a reduced height, which decreases the amount of raw sheet metal required while maintaining the traditional casket appearance when displayed on a base. This parameter change reduces material consumption and manufacturing complexity.
Solution Approach 2:
The patent introduces a display base as a separate component that, when combined with the reduced height casket shell, restores the traditional overall appearance. This dimensional solution allows material reduction in the casket shell while maintaining the desired aesthetic through the added base dimension.
Data Source
AI summary
A combination casket and casket display comprises a reduced height casket shell adapted to receive the remains of a deceased and having a pair of side walls, a pair of end walls, and a bottom wall, the side walls and end walls having lower edges, the bottom wall extending below the lower edges of the side walls and end walls, a casket lid closable on the reduced height casket shell, and a casket display base having a pair of side walls and a pair of end walls, the side walls and end walls having upper edges. The reduced height casket shell is supported by the casket display base such that the lower edges of the side walls and end walls of the reduced height casket shell are at about the same height as the upper edges of the side walls and end walls of the casket display base, and the bottom wall of the reduced height casket shell extends below the upper edges of the side walls and end walls of the casket display base so as to nest within the casket display base. A combined height of the reduced height casket shell and display base is about equal to a height of a conventional height casket shell.