Nesting Casket Lid Assembly for Shipping Cost Reduction
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Solution Overview
Problem
Caskets made from lower-cost materials like corrugated paperboard and manufactured wood products face high costs due to material and shipment expenses, making them inaccessible to many.
Innovation Solution
The design includes a detachable and invertible lid system, a lightweight body construction using multilayer corrugated paper, and a modular bridge assembly for the lid, allowing for cost-effective manufacturing and shipping by optimizing the casket's shape and configuration for both transport and use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If caskets are made from lower-cost materials like corrugated paperboard and manufactured wood products, then manufacturing cost is reduced, but material and shipment costs remain high
Solution Approach 1:
The lid is designed to nest within the casket body during shipment, with the lid configuration allowing it to be placed inside the container. This nesting arrangement reduces the shipping volume required for the casket components, thereby lowering material and shipment costs while maintaining the ability to manufacture from lower-cost materials.
Solution Approach 2:
The casket is divided into separable components including the lid and container, which can be manufactured independently from lower-cost materials and then assembled. This segmentation allows for more efficient manufacturing processes and reduced material costs while maintaining structural integrity.
2Quantity of substance
If the lid is made detachable and invertible for shipping, then shipment costs are reduced, but device complexity increases
Solution Approach 1:
The invertible lid nests within the casket body during shipment, reducing the space required for transportation. This nesting mechanism simplifies the shipping process while the lid can be easily removed and repositioned for funereal purposes, balancing complexity reduction with functional requirements.
Solution Approach 2:
The lid is designed with dynamic characteristics, allowing it to be detached and inverted between shipping and use configurations. This dynamic design enables the lid to adapt between two states (nested/inverted for shipping, positioned for use), reducing shipment costs while maintaining operational simplicity through clear transition states.
3Weight of moving object
If the casket uses lightweight multilayer corrugated paper construction, then weight is reduced, but structural strength may be compromised
Solution Approach 1:
The casket employs multilayer corrugated paper construction, which is a composite material structure. The corrugated layers provide both lightweight properties and structural strength through their layered, wave-like configuration. This composite approach allows the casket to maintain adequate strength while minimizing weight, addressing both requirements simultaneously.
Solution Approach 2:
The corrugated paper construction applies local quality enhancement by using the wave-like pattern of the corrugated layers to provide structural reinforcement at critical points. The multilayer design concentrates material strength where needed while maintaining overall lightweight characteristics, allowing the casket to be both light and structurally sound.
Data Source
AI summary
A casket lid assembly includes a plurality of layers of corrugated paper and a bridge assembly. The plurality of layers of corrugated paper are formed into a lid structure having a top surface, a bottom surface, a first end and a second end, Thea bridge assembly is attached to the second end of a casket lid. The bridge assembly includes two end pieces and at least one intermediate piece, and wherein the at least one intermediate piece is configured to be removably attached to the end pieces.