Abstract:
A pet crate is provided having a blow molded polymeric base along with side, front and top panels made with strong, lightweight polymeric frame members and grates. The grates are used in the front, back and side panels to provide strength as well as a large open mesh area for better visibility and pet comfort. The mesh preferably is provided as hinged access panels at least on the sides. The front and top of the crate are also openable for access to the pet crate. The pet crate is collapsible to a folded, flat condition by unlatching the front panel and stowing it along the inside of the top panel and releasing latches between the top and back panels and the side panels. The side panels, back panel and top panel can then be collapsed inwardly onto one another to form a generally flat, stowed configuration for the pet crate.

Description:
BACKGROUND 
       [0001]    The invention relates to a foldable pet crate, and more particularly to a light weight, foldable pet crate which can be erected to form a rigid structure having multiple access doors. 
         [0002]    Pet crates allow pet owners to place pets in a confined area in order to prevent pets from roaming about when the owner is not home, and are also used for transporting pets safely so that a pet does not escape during travel and potentially become lost or injured. Additionally, certain animals such as dogs find comfort in cave-like areas provided by a pet crate. Thus, pet crates have a variety of uses for both home and travel. 
         [0003]    Known pet crates have several drawbacks. One is the fact that most crates are made from steel which provides the required security for larger animals, but has sharp edges and/or corners that can cut into material upon which the crate is placed as well as scrape both the owner and the pet during movement. Additionally, the all steel crates generally weigh more, and are often difficult to erect and collapse, requiring flexing of the metal pieces in order to have the panel end hooks engage with corresponding structure affixed to the side, top or end panels. Additionally, there is no easy way to move such crates while folded or if an animal is within the crate. Finally, most pet crates have only a single door which provides challenges to the pet owner if the pet is uncooperative or something is blocking one of the doors based on a position of the crate either within a vehicle or other confined space during travel. 
       SUMMARY 
       [0004]    Briefly stated, the present invention provides a pet crate having a base along with side, front and top panels that form a strong, lightweight frame, preferably formed of a rigid polymeric material, and grates located within the frame. The grates are preferably provided in the front, back and side panels to provide an open mesh area for better visibility and pet comfort. The grates are preferably provided as hinged access panels at least on the sides. The front and top of the crate are preferably also openable for access in to the pet crate. 
         [0005]    The pet crate is collapsible to a folded, flat condition by unlatching the front panel and stowing it along the inside of the top panel and releasing latches to allow the side panels, back panel and top panel to be collapsed inwardly onto one another to form a generally flat, stowed configuration for the pet crate. 
         [0006]    In the preferred embodiment, the use of a molded polymeric bottom provides rigidity as well as an easily cleanable structure for the pet crate. Preferably, the bottom of the pet crate includes wheels to allow for easy movement of the pet crate in both the erected and stowed configurations, with or without a pet located therein. A pull handle is provided on top of the pet crate, on an opposite side from the wheels, for ease of movement. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The following detailed description of the preferred embodiments of the invention will be better understood when read with reference to the appended drawings. For the purposes of illustrating the invention, there is shown in the drawing an embodiment which is presently preferred. It is understood, however, that the invention is not limited to the precise arrangements and instrumentality shown in the drawings. 
           [0008]      FIG. 1  is a top, right, front perspective view of a pet crate according to a preferred embodiment of the present invention. 
           [0009]      FIG. 2  is a perspective view similar to  FIG. 1 . 
           [0010]      FIG. 3  is a bottom, left, rear perspective view of the pet crate according to the invention. 
           [0011]      FIG. 4  is a right side elevational view of the pet crate of  FIG. 1 . 
           [0012]      FIG. 5  is a front elevational view of the pet crate of  FIG. 1 . 
           [0013]      FIG. 6  is a left side elevational view of the pet crate of  FIG. 1 . 
           [0014]      FIG. 7  is a top view of the pet crate of  FIG. 1 . 
           [0015]      FIG. 8  is a back view of the pet crate of  FIG. 1 . 
           [0016]      FIG. 9  is a bottom view of the pet crate of  FIG. 1 . 
           [0017]      FIG. 10  is an exploded perspective view of the pet crate of  FIG. 1 . 
           [0018]      FIG. 11  is a detail view of the front door frame of the pet crate of  FIG. 1 . 
           [0019]      FIG. 12  is a view taken along line  12 - 12  in  FIG. 11 . 
           [0020]      FIG. 13  is a view taken along line  13 - 13  in  FIG. 12 . 
           [0021]      FIG. 14  is a detailed perspective view looking into the base of the pet crate of  FIG. 1 . 
           [0022]      FIG. 15  is a bottom perspective view of the base of the pet crate of  FIG. 14 . 
           [0023]      FIG. 16  is a detailed perspective view of the right side frame. 
           [0024]      FIG. 17  is a perspective view of the right side frame looking from inside outwardly. 
           [0025]      FIG. 18  is a detailed view of the top of the pet crate. 
           [0026]      FIG. 19  is a bottom view of the pet crate top of  FIG. 18 . 
           [0027]      FIG. 20  is a detailed perspective view of the top door for the pet crate. 
           [0028]      FIG. 21  is a view looking at the bottom of the top door shown in  FIG. 20 . 
           [0029]      FIG. 22  is a perspective view showing the pet crate divider. 
           [0030]      FIG. 23  is an opposite perspective view showing the pet crate divider. 
           [0031]      FIG. 24   a  is an enlarged detail view of a preferred catch with a smooth surface and C-shaped end portion used for holding the split rear walls of the pet crate in the unfolded position. 
           [0032]      FIG. 24   b  is an enlarged detail view of an alternate catch with a ribbed surface used for holding the split rear walls of the pet crate in the unfolded position. 
           [0033]      FIG. 25  is a detail perspective view of the latch. 
           [0034]      FIG. 26  is a view of the pet crate of  FIG. 1  with the front door opened and being slid under the top panel. 
           [0035]      FIG. 27  is a perspective view of the pet crate with the front door slid into a fully stowed position under the top panel. 
           [0036]      FIG. 28  is a perspective view of the pet crate with the top latches having been released and the top panel with stowed front door being folded upwardly for collapsing the crate to a folded configuration. 
           [0037]      FIG. 29  is a perspective view of the pet crate with the back panel having the catches released and pivoted backward with the top panel, and the right side being folded inwardly into the base. 
           [0038]      FIG. 30  is a perspective view of the pet crate with the right side fully folded into the base and the left side being folded into the base. 
           [0039]      FIG. 31  is a perspective view of the pet crate with the back panel being folded inwardly along the center split over the left and right sides which are fully folded onto the base. 
           [0040]      FIG. 32  is a perspective view of the pet crate with the top panel lowered so that the back edge is against the top, back wall of the base, and being folded over the split back panel and left and right side panels which are in the fully folded position. 
           [0041]      FIG. 33  is a perspective view of the fully folded configuration of the pet crate of  FIG. 1 . 
           [0042]      FIG. 34   a  is an enlarged profile view of a latch on the side edge of the top panel in an open position. 
           [0043]      FIG. 34   b  is the enlarged profile view of the latch of  FIG. 34   a  in a closed position. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0044]    Certain terminology is used in the following description for convenience only and is not limiting. The words “right”, “left”, “top”, “bottom”, “front”, and “back” designate directions in the drawings to which reference is made. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the pet crate and designated parts thereof. The words “a” and “one”, as used in the claims and in the corresponding portion of the specification, are defined as including one or more of the referenced item unless specifically stated otherwise. This terminology includes the words specifically noted above, derivatives thereof and words of similar import. 
         [0045]    Referring now to  FIGS. 1-25 , wherein like numerals indicate like elements throughout, a preferred embodiment of a foldable pet crate  10  is shown. The pet crate  10  includes a base  12 , left side  20 , right side  22 , front door  40 , split rear wall  60  and top panel  80 . The base has left, right, front and back base walls, and a bottom panel. These components and their assembly to form the foldable pet crate  10  are described in detail below along with the method for transitioning the pet crate from an assembled to a folded position. 
         [0046]    Referring to  FIGS. 1-3 ,  9 ,  10 ,  14  and  15 , the base  12  is shown in detail. The base  12  preferably includes a bottom panel  13  side walls  14 ,  15 , a front wall  16  with two latch mounting recesses  17 , and a back wall  18 . The corners of the base  12  are rounded to prevent damage to items the crate may be rested on, such as flooring or a car seat. Wheel recesses  19  are provided in which wheels  11 , shown in  FIG. 6 , are detachably mounted. The base  12  is preferably formed as a blow molded polymeric component in a single piece having an inner skin and an outer skin with reinforcements being provided by projections and recesses on the bottom thereof, as shown in detail in  FIG. 15 . As shown in  FIG. 14 , preferably the inner surface of the base  12  is smooth to allow for easy clean-ups. The side walls  14 ,  15 , front wall  16  and back wall  18  help to contain spills or pet accidents. While the preferred material is polypropylene, those skilled in the art will recognize that other suitable polymeric materials and possibly other materials may be used to form the base  12 . 
         [0047]    Referring to  FIGS. 1-4 ,  6 ,  10 ,  16  and  17 , the left and right sides  20 ,  22  are shown. The left and right sides  20 ,  22  each include a polymeric frame member  23 ,  24  respectively, in which a respective air-permeable grate  25 ,  26  is pivotably mounted. The grates  25 ,  26  are preferably a metal grates, but also may be a metal mesh, a fabric screen, or a flat panel with holes formed therein. Latches  27  are provided at the rear edge of the left side  20  and at the front edge of the right side  22  to hold the pivoting grates  25 ,  26  in a closed-position. The grates  25 ,  26  form doors for ingress and egress from the crate  10 . The front edge of the left side grate  25  is preferably, pivotably mounted to the front of the frame  23  using clips  28 , see  FIG. 6  for the left side, and a rear edge of the grate  26  for the right side  22  is pivotably mounted to the rear edge of the frame  24  also using clips  28 , as shown in  FIG. 4 . As will be more clearly recognized from  FIGS. 1-3 , this provides two separate side doors for ingress and egress which is particularly useful when the center divider  95  is slid into channels formed in the top panel and the base, to split the main confine area in crate  10  into two separate confined areas. 
         [0048]    As shown in detail in  FIGS. 16 and 17 , hinge lugs  30  are provided at the bottom of the frames  23 ,  24 . The hinge lugs  30  are connected via brackets to the base  12  in order to allow the left side and right side panels to pivot down into the base  12  during a folding operation for placing the crate  10  into a folded position. Additionally, as shown most clearly in  FIGS. 10 and 16 , engagement protrusions  31  are provided along the front edges of the frames  23 ,  24  for holding the front door  40  to prevent racking when the front door  40  is in the closed position, as described in more detail below. 
         [0049]    As shown in  FIGS. 10 and 16 , projections  32  are also provided along the top edges of the frames  23 ,  24  for engagement with the top panel  80 . Preferably, the left side and right side frames  23 ,  24  are made of blow molded single-piece polymeric material, such as polypropylene. Those skilled in the art will recognize that other suitable polymeric materials may also be utilized. While the right side  24  has been shown in detail in  FIGS. 16 and 17 , those skilled in the art will note that the left side  23  is generally a mirror image thereof, with the exception of the placement of the latch receiving recesses being switched from front to back and the hinge location for the grate  25  being moved to the front of the left side  23 . 
         [0050]    The pivotably attached grates  25 ,  26  are preferably formed of welded steel and may be painted or coated with a polymeric or chromed material depending upon the particular application. Alternatively, they may be made from stainless steel or any other suitable material. The latches  27 , shown in detail in  FIG. 25 , are preferably made of a polymeric material and are attached to the frames using mechanical fasteners, adhesive or any other suitable means. Although the exploded view in  FIG. 10  shows the grates  25 ,  26  located inside the respective frames  23 ,  24  for illustrative purposes, they are in fact located on the outside of the frames  23 ,  24  and pivot outwardly to open. The latches  27  hold the grates  25 ,  26  in the closed position by trapping the free ends of the grates  25 ,  26  opposite the pivotal attachment between the recessed portion of the frames  23 ,  24  and the extended latch tongue  28 . 
         [0051]    It is noted that the width of the frames  23 ,  24  is less than a distance between the front wall  16  and rear wall  18  of the base  12  so that both the left side  20  and the right side  22  can be pivoted downwardly about the hinges  30  into a folded position on top of the bottom panel  13  of the base  12 . 
         [0052]    A catch  66  shown in  FIG. 17  for the right side  22 , and shown in detail in  FIG. 24   a,  is used to hold the split rear wall  60  in the open position. The catch  66  is pivotably connected to the back of both the left and right sides  20 ,  22 . For the left side  20 , the catch  66  would be similarly mounted in the opposing position to the right side  22 . The catch  66  can be a simple hook or a flexible catch and can have either a smooth or ribbed surface, and holds the split back panel  60  in the opened configuration against the back edges of the left and right sides  20 ,  22 . As shown in  FIG. 24   a,  the preferred catch  66  is preferably a C-shaped hook with a smooth inner surface. An alternate catch is shown in  FIG. 24   b.    
         [0053]    Referring to  FIGS. 1-3 ,  5 ,  10  and  11 - 13 , the front door  40  of the crate  10  is comprised of the front frame  42  and a front grate  44  affixed thereto. The frame  42  preferably includes pivot pins  45 ,  46  and slide rails  47 ,  48  located on opposite sides thereof as shown in detail in  FIGS. 11-13 . The pivot pins  45 ,  46  are pivotably held in tracks  50 ,  51  mounted on the inner side of the top panel  80  along the left and right side edges thereof as described in detail below. 
         [0054]    The slides  47 ,  48  are sized to fit between the protrusions  31  on the front edges of the left side frame  23  and right side frame  24  when the front door  40  is closed, as shown in  FIGS. 1 and 2 . Recesses  49  are provided at the bottom front edge of the front frame  42  which are engaged by latches  27  mounted on the front wall  16  of the base  12  in order to hold the front door  40  in a closed position. Releasing the latches  27  allows the front door  40  to pivot open about the pivot pins  45 ,  46  and then be slid inwardly via the slide rails  47 ,  48  moving along the door tracks  50 ,  51  into a stowed position under the top panel  80 , as shown in  FIGS. 26 and 27 . 
         [0055]    In the preferred embodiment, the front door frame  42  is preferably made of blow molded polymeric material, such as polypropylene. Those skilled in the art will recognize that other suitable polymeric materials may be utilized. As shown in detail in  FIG. 13 , preferably a recess  52  is provided for mounting the grate  44  into the frame  42 . As the grate  44  is fixed mounted preferably using mechanical fasteners or clips or the like, it is mounted from the inside of the front door frame  42  and thus the front door  40  presents an outward smooth flush appearance, which facilitates its sliding into the open, stowed position under the top panel  80 . 
         [0056]    The front door grate  44  is preferably made of a metallic material, and can be painted, polymeric coated, or chrome coated steel, or may be made of stainless steel or any other suitable material. 
         [0057]    Referring now to  FIGS. 3 ,  8  and  10 , the foldable split rear wall  60  will be described in detail. The foldable split rear wall  60  includes a lower grate  62  and an upper grate  64  which are pivotably connected together along a medial portion by tubular clips  65  along the adjoining edges thereof. The bottom edge of the lower grate  62  is pivotably connected to the upper portion of the rear wall  18  of the base  12  using clips or brackets to allow pivoting movement of the lower grate  62  relative to the base  12 . The upper edge of the upper grate  64  is pivotably connected to the back edge of the top panel  80 , preferably using clips or brackets to allow pivoting movement of the upper grate  64  relative to the top panel  80 . Preferably, the catches  66  or  66 ′ shown in  FIG. 17  and in greatly enlarged detail in  FIGS. 24   a  and  24   b,  are pivotably mounted to the back edges of the left side frame  23  and right side frame  24 . These catches can be pivoted so that the center region of the rear wall  60  is hooked and held in position against the back edges of the left and right side frames  23 ,  24  respectively. With the preferred catches  66 , the slot in the catch  66 , shown in  FIG. 24   a  is large enough to engage the bottom wire of the upper grate  62  and the top wire of the bottom grate  64 . These catches  66  can also be pivoted upwardly in order to release their engagement with the horizontal bars used to form the upper and lower grates  62 ,  64  in order to allow the rear wall  60  of the pet crate  10  to be folded in half to facilitate folding of the pet crate  10 , as discussed in further detail below. Alternatively, the catches  66 ′ of  FIG. 24   b  could be used. 
         [0058]    The upper and lower grates  62 ,  64  are preferably formed of a metallic material and may be painted, polymeric coated or chrome coated steel, stainless steel or any other suitable material. The catches  66  are preferably formed of a polymeric material and preferably include teeth  67  to help engage and hold their position on the bars forming the grates  62 ,  64 . 
         [0059]    Referring now to  FIGS. 1 ,  2 ,  7 ,  10  and  18 - 21 , the top panel  80  is shown in detail. The top panel  80  includes a frame  82  having a door recess  83  in which a top hatch door  90  is located. 
         [0060]    As shown in  FIG. 19 , recesses  87  are provided along the bottom facing left and right sides of the top frame  82  which are complementary to the engagement projections  32  provided along the top edges of the left and right side frames  23 ,  24 . The front door tracks  50 ,  51  are preferably connected to the underside of the top frame  82  along the left and right sides and may be connected using mechanical fasteners, adhesives or any other suitable means. The handle  85  is preferably located along the right side edge of the top panel  80  opposite from the wheels  11  located on the base  12 . Latches  86  are provided at each of the left and right sides of the top  80 . As shown in  FIGS. 34   a  and  34   b,  the latches  86  may be moved between open and closed positions. The latches  86  are preferably over-center pivotable latches as shown in  FIGS. 34   a  and  34   b,  or can be of any other suitable type, such as the latch assemblies  27  or other types of latches or catches for engaging or releasably holding two pieces together. The latches  86  engage protrusions at the top edges of the left and right sides  20 ,  22 , respectively, as shown in  FIG. 34   a,  and then are pivoted upwardly about a connecting link which also pivots to an over-center position to retain the top panel  80  in the assembled position. 
         [0061]    The top frame  82  is preferably a blow molded polymeric part and includes stiffening recesses located on the underside thereof as shown in  FIG. 19 . These provide a structure that is both lightweight and having high rigidity based on the formation of the frame  82  as a blow molded part. 
         [0062]    Preferably, the top door  90  has hinge pins  91  and is pivotably mounted in the door recess  83  of the top frame  82 . A latch  27  is also mounted in a latch recess  88  in the top frame, shown in  FIG. 18 , opposite from the hinge side of the top door  90  to hold the top door  90  closed. Preferably finger recesses are molded into the top frame  82  along the edge of the door recess  83  to allow for easier opening of the door  90  when the latch  27  is released. The door  90  is preferably a blow-molded polymeric part, and is shown in detail in  FIGS. 20 and 21 . The hinge pins  91  are preferably integrally molded to the door  90 . Stiffening recesses are preferably provided in the underside of the top door  90  and are clearly shown in  FIG. 21 . 
         [0063]    Referring to  FIG. 25 , the latch assembly  27  is shown in detail, and includes a slide member  34  located in a tubular body  36 . A flexible catch  35  on the slide member  34  is normally biased outwardly, and extends through openings  37  or  38  in the body  36 . In the illustrated position, in which the latch assembly  27  would be closed, the flexible catch is in the first opening  37 . In order to open the latch assembly, the flexible catch  35  is pressed inwardly, and the slide member is moved back so that the flexible catch  35  passes under the frame piece between the openings  37 ,  38 , and then springs elastically out to its normal position and catches in the second opening  38 . Based on the arrangement of the flexible catch  35  with the fixed end being located to the right in  FIG. 25 , and the free end that acts as a catch being toward the left, the latch can be closed by just pushing the slide member  34  to the right, with the flexible catch  35  being automatically deflected by the frame piece as the slide member moves toward the right in  FIG. 25 , toward the illustrated closing position. 
         [0064]    Referring now to  FIGS. 26-33 , a series of views are shown of the crate  10  being broken down from the fully assembled position to the folded position. Referring to  FIG. 26 , the pet crate  10  is shown with the front door  40  having been folded upwardly about the pivot pins  45 ,  46  and being shown in the process of sliding inwardly along the left and right door tracks  50 ,  51 . This is accomplished via releasing the latches  27  located along the front wall  16  of the base  12  which allows the front door  40  to initially pivot open. 
         [0065]      FIG. 27  shows the front door  40  in the totally stowed position under the top panel  80 . After releasing the catches  66  and the top latches  86 , the top panel can now be pivoted upwardly about its back edge, and  FIG. 28  shows the top panel  80  pivoted up to a vertical position. 
         [0066]      FIG. 29  shows the tope panel  80  and split rear wall  60  pivoted further back away from the left and right sides, and the right side  22  is being folded inwardly on top of the base  12  about the hinges  30 .  FIG. 30  shows the left side  20  being folded down on top of the base  12  while the user holds the top panel  80  off to the rear, while it is still connected to the base  12  via the split rear wall  60 .  FIG. 31  shows the split rear wall  60  having been now folded inwardly, so that the bottom edge of the top grate  64  and the top edge of the bottom grate  62  extend inwardly and the top grate  64  folds on top of the bottom grate  62  allowing the rear edge of the top panel  80  to be lowered against the top of the rear wall  18  of the base  12 . 
         [0067]      FIG. 32  shows the top panel  80  now being folded downwardly on top of the base  12  in which the left and right sides  20 ,  22  and the split rear wall  60  having already been folded into the recess created by the front and rear walls  16 ,  18  of the base  12 .  FIG. 33  shows the crate  10  in the fully folded configuration. Clamps, latches or straps may be provided to secure the crate  10  in this folded configuration, which may be separate from or incorporated into the base  12  or the top panel  80 . In this configuration, a user can grasp the handle  85  and roll the folded crate  10  via the wheels  11  located on the base  12  on the opposite side from the handle  85 . 
         [0068]    While the preferred embodiment of the present invention has been described in detail, it will be recognized by those skilled in the art from the present disclosure that changes may be made to the above described embodiment of the invention without departing from the broad inventive concept thereof. It is understood, therefore, that this invention covers all modifications are within the scope and spirit of the invention as defined by the appended claims and/or shown in the attached drawings.