Disposable cat litter box

A disposable cat litter box comprising a single sheet of stiff paperboard which is folded and perforated for assembly into an open top, generally rectangular cat litter box is disclosed. The box is prepackaged with cat litter and may be assembled to form a cat litter box. The box preferably includes a horizontally extending bottom attached to upwardly extending side and end walls. The side and end walls having foldable portions which may be folded over and sealed to define a substantially rectangular closed box. For use, the upper portions of the side and end walls are unfolded and positioned substantially perpendicular to the bottom portion. End flaps on the side and end walls may be folded inwardly forming a rigid perimeter defining an open, generally rectangular box. After use, the side and end walls may be collapsed and folded over to enclose the cat litter for disposal.

BACKGROUND OF THE INVENTION 
This invention relates to cat litter boxes, particularly, a disposable cat 
litter box which is prepackaged with cat litter. 
It is conventional and well known in the prior art for households having 
cats to provide a cat litter box for the cat, particularly when the cat is 
a house pet residing primarily indoors. Consequently, many devices have 
been designed to retain cat litter. Typically, cat litter boxes are formed 
of a hard plastic material open at the top and typically rectangular in 
shape. Cat litter is separately packaged in a bag requiring that the cat 
litter be poured into the litter box. After usage, it is necessary to 
discard the cat litter and clean the litter box. This is a particularly 
messy and unpleasant duty which must be repeated regularly. Therefore, 
many attempts have been made to develop a superior and less time consuming 
system for disposal of cat litter. 
U.S. Pat. No. 4,305,544 to Noonan exemplifies prior attempts to overcome 
the unpleasantness associated with clean up of cat litter boxes. Noonan 
describes a disposable cat litter box formed of paperboard. The box is 
substantially rectangular in shape open at the top and closed at the 
bottom. The box is provided with a horizontally oriented and inwardly 
extending border about the open end of the box to prevent the loss of 
litter during usage. The litter box of Noonan is disposable and 
specifically designed to receive cat litter but not to merchandise cat 
litter. Thus, use of the Noonan litter box still requires that cat litter 
be poured from a separate bag into the litter box. Cat litter is a 
granular material which is easily spilled if care is not taken when 
pouring it into the litter box. Also, sufficient cat litter must be poured 
into the litter box to provide adequate absorption during use; however, 
too much cat litter in the litter box may result in cat litter being 
kicked out of the box by the cat during use. It is, therefore, apparent 
that some care must be exercised when placing cat litter from the bag into 
the cat litter box insuring that an adequate amount, but not a surplus, of 
the cat litter is used. The present invention provides a disposable cat 
litter box prepackaged with cat litter for overcoming these prior art 
difficulties. 
The cat litter box of the present disclosure provides many advantages over 
the prior art device for the manufacturer, retail stores and the customer. 
Prepackaging cat litter in a thin package provides many advantages to the 
manufacturer by reducing handling costs. The thin rectangular box-like 
package of the present disclosure stacks better than bags for 
transportation and reduces the risk of damage associated with bags which 
may be easily torn. The ability of the box of the present disclosure to be 
stacked enables accurate counting of the boxes in a shipping load. Also, 
the cat litter boxes of the present disclosure may be banded together in 
convenient size lots for more efficient loading for shipment, thus further 
reducing shipping costs. 
The dual function of the cat litter box of the present disclosure provides 
similar advantages to retail stores. The folded or collapsed arrangement 
of the cat litter box is particularly suited for stacking, taking up less 
shelf space than bags of cat litter. Broken cat litter bags are 
eliminated. The dual function of the cat litter box of the present 
disclosure also eliminates the need to stock both bags of cat litter and 
cat litter boxes. The flat, thin rectangular package shape of the cat 
litter boxes of the invention permit stacking anywhere in the retail store 
which may be aesthetically displayed. 
The advantages to the consumer are numerous. The prepackaged design of the 
present disclosure eliminates purchase of both a bag of cat litter and a 
cat litter box. The cat litter box of the present disclosure is 
prepackaged with a predetermined amount of cat litter so that each box may 
be used for approximately one week. The design of the cat litter box 
enables the customer to easily carry two or three boxes. When not in use, 
the boxes may be conveniently stored on a shelf in the garage or the like. 
This eliminates purchasing a 20 or 25 pound bag of cat litter, a portion 
of which is to be periodically poured into a cat litter box. The 
prepackaged design of the disclosed cat litter box insures that the proper 
amount of cat litter is used, thus eliminating measuring or waste of cat 
litter. Often times, a small amount of cat litter is left in a bag which 
is not enough for use in the litter box and is, therefore, discarded. The 
disclosed litter box eliminates waste of cat litter. 
The litter box of the present disclosure is provided with a large open top 
area defined by the upstanding side walls forming the litter box. A 
relatively large opening is preferred by cats. The side panels or walls of 
the litter box extend above the level of cat litter in the box a 
sufficient distance to reduce the amount of cat litter which may be kicked 
over the sides of a cat. 
The litter box of the disclosure may be conveniently closed and locked for 
disposal. Closing the litter box reduces the odor associated with litter 
boxes by sealing the litter box upon closure. 
The litter box of the present disclosure is portable and reusable. This is 
very convenient for travel. The litter box may be opened and closed as 
required and moved from place to place until such time as the litter box 
is ready for disposal. 
SUMMARY OF THE INVENTION 
The present invention provides a disposable cat litter box formed of 
paperboard which is coated with a waterproof material. The cat litter box 
of the invention is prepackaged with a premeasured amount of cat litter 
and closed to form a sealed, substantially rectangular box which may be 
subsequently opened to form a cat litter box having upstanding side walls 
extending from a substantially horizontal bottom portion to form an open 
top cat litter box. 
The cat litter box of the present disclosure assembles into two forms, one 
being a folded and compact form and the other being a fully deployed cat 
litter box. In the folded arrangement, the cat litter box is folded into a 
relatively thin package containing cat litter. In the deployed 
arrangement, the cat litter box unfolds to define a large, rectangular 
bottom with surrounding, upright walls on four sides. The side walls are 
reinforced lengthwise and along the top edge of the side walls by foldable 
portions of the side walls which may be folded inwardly and downwardly 
against the side walls for strengthening the side walls and thereby 
defining a stiff surrounding wall extending about the bottom of the cat 
litter box. The surrounding wall extends a sufficient distance above the 
level of the cat litter in the litter box to prevent the loss of cat 
litter during usage. The litter box may be used for a period of time, 
typically a week. After use, the cat litter box of the present disclosure 
can be collapsed to enclose the cat litter and fecal matter for convenient 
disposal. The litter box is provided with locking tabs to hold the 
refolded ends in position to again form a relatively thin package for 
disposal.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
Attention is first directed to FIGS. 1-3 of the drawings wherein the 
disposable cat litter box of the present invention is generally identified 
by the reference numeral 10. The cat litter box 10 is prepackaged with a 
predetermined amount of cat litter 12. The cat litter box 10 is preferably 
usable for holding cat litter therein for use by cats or other domestic 
house pets, for example, rabbits or small dogs. The litter box 10 includes 
a bottom portion formed by bottom members 14, 15, 16 and 17, best shown in 
FIG. 4. Referring now specifically to FIG. 4, the blank 18 of material 
forming the litter box 10 is shown. The blank 18 is cut, perforated, 
scored and otherwise shaped into the litter box 10. The bottom members 
14-17 are substantially rectangular in shape and comprise the bottom of 
the litter box 10. The bottom members 14-17 fold along the score line 20 
which is a machine formed crease extending across the paperboard blank 18. 
The score line 20 defines the lower edge 22 of the cat litter box 10 as 
shown in FIGS. 1-3. A second score line 24 is spaced from the score line 
20 and parallel thereto extending the full length of the paper board blank 
18. The score line 24 permits folding of the side walls of the litter box 
10 to enclose the cat litter 12 and defines the circumferential edge 26 of 
the litter box 10 shown in FIGS. 2 and 3. The space between the score 
lines 20 and 24 defines the height of the litter box 10 in the closed or 
folded position. 
The sides of the litter box 10 are defined by walls which may be folded to 
form the closed container shown in FIG. 3 or erected to form the opened 
litter box shown in FIG. 1. The surrounding wall is formed by end wall 
members 28, 30 and side wall members 32, 34. Each wall member includes a 
flap which may be folded inwardly to reinforce and provide stiffness for 
the wall members in the erected position shown in FIG. 1. End wall members 
28 and 30 therefore include end flaps 29 and 31 extending therefrom, 
respectively. Likewise, side wall members 32 and 34 include end flaps 33 
and 35 extending therefrom, respectively. A pair of score lines 38 and 40 
extending the length of the blank 18 form a crease permitting the end 
flaps 29, 31, 33 and 35 to be double folded defining the uppermost 
peripheral edge 41 shown in FIG. 1. 
The cat litter box 10 is fabricated of paperboard material which is coated 
with a sealant to make it waterproof. Thus, moisture in the litter box 10 
will not leak through the paperboard material. When assembled, the bottom 
members 14-17 are overlapped to form the bottom of the litter box 10. The 
overlapping surfaces of the bottom members 14-17 are provided with glue or 
other type of adhesive material for joining the bottom members together to 
form a leak-proof bottom. Vertical score lines 42 formed in the blank 18 
permit the wall members to be folded towards each other to form the 
box-like structure of the litter box 10. The flap 44 projecting from the 
wall member 28 is adhesively joined along the vertical edge 46 of the wall 
member 34 and end flap 35 shown in FIG. 4; thus forming substantially the 
profile of the partially opened litter box 10 shown in FIG. 2. In the 
prepackaged form of the cat litter box 10 which may be found at a retail 
store, the side walls and end walls of the litter box 10 are folded over 
and glued, thereby sealing the litter box 10 completely enclosing the cat 
litter 12. Preferably, glue is applied on the surface of the slotted end 
flap 33 in the form of a bead 37 illustrated by a dark line in FIG. 4. A 
glue strip 39 is also applied to the folded end flaps 29 and 31 in the 
manner illustrated in FIG. 8. When the walls of the litter box 10 are 
folded over in the manner illustrated in FIG. 8, a lengthwise seal is 
formed joining the overlapping end flaps together. 
To open the litter box 10 for use, the folded end flaps 29 and 31 are 
pulled apart from the end flaps 33 and 35 along the glue strip 39. 
Thereafter, the end flaps 33 and 35 are separated along the glue bead 37 
permitting the side and end walls of the litter box 10 to be erected as 
shown in FIG. 2. When fully erected, the end flaps 29, 31, 33 and 35 are 
folded 180.degree. to provide added stiffness to the wall members 28, 30, 
32 and 34 as best shown in FIG. 1. The wall members 28, 30, 32 and 34 
extend to the bottom of the litter box 10 and consequently a specified 
height above the level of the cat litter 12. 
Attention is next directed to FIG. 5 which is an enlarged view showing the 
perforated connection joining the end flaps 29, 31, 33 and 35. In the 
prepackaged assembly, the flaps are joined along the perforations so that 
when the end flaps are folded over to close the cat litter box 10, the cat 
litter 12 does not leak out. However, upon deployment of the side walls to 
form the cat litter box 10 for use by a cat, the end flaps must be 
separated so that they may be folded inwardly against the side walls as 
shown in FIG. 1. the end flaps are separated along the small perforations 
50 and 52 shown in FIG. 5. The perforations 50 and 52 are offset from each 
other and separated by a straight cut 54. A pair of large perforations 56 
and 58 are spaced from and are parallel to the small perforations 50 and 
52, respectively. Each pair of large and small perforations defines a tab 
60 and 62 therebetween. Separation between the end flaps is along the 
small perforations 50 and 52. In FIG. 5, the connection between end flaps 
31 and 35 is shown in detail. Each of the end flap corner connections is 
the same. The following discussion is, therefore, equally applicable for 
each corner connection. The large perforations 56 and 58 permit the tabs 
60 and 62 to be folded inwardly and out of the way as the flaps 31 and 35 
are folded toward the end walls 30 and 34, respectively. Space is limited 
at the corner connection, thus folding the tabs 60 and 62 along the large 
perforations 56 and 58 permits the tabs 60 and 62 to be out of the way as 
the flaps 33 and 35 are folded into position, thus preventing binding at 
the corner junction. Right angle cuts 55 permit the flap 62 to be folded 
against the end flap 35 and also permit the end flaps 31 and 35 to be 
folded over along the double fold defined by the score lines 38 and 40. 
In FIG. 6, an alternate embodiment of the corner connection is disclosed. 
The embodiment of FIG. 6 is substantially identical to the embodiment of 
FIG. 5; however, in FIG. 6, the flap 60 has been eliminated. Thus, a gap 
64 is provided between the end flaps 31 and 35. The gap 64 terminates at 
the straight cut 54. 
Assembly of the cat litter box 10 occurs in the following manner. First of 
all, the flap 44 is folded along score line 42 so that it is substantially 
perpendicular to the wall member 28. Each of the wall members is folded 
along the score lines 42 so that the flap 44 is positioned to be 
adhesively joined to the wall member 34 along the edge 46, thus forming a 
substantially rectangular shaped enclosure. The bottom members 14-17 which 
have been coated with adhesive are folded along the score line 20 in an 
overlapping fashion to form the bottom of the litter box 10. The bottom 
members 14 and 16 are folded inwardly first and contact adhesive is 
applied on the back surface thereof. Likewise, contact adhesive is applied 
to the bottom members 15 and 17 on the facing surface shown in FIG. 4 for 
connection to the bottom surface of the bottom members 14 and 16. The 
adhesive may be applied across the surface of the bottom members or along 
the edges thereof as desired. The interior of the litter box 10 is coated 
with a waterproof sealant material. A premeasured amount of cat litter 12 
is poured into the cat litter box 10. A sufficient amount of cat litter 12 
is used so that the cat litter box may be used for approximately one week 
under normal usage conditions and then discarded. Once the cat litter 12 
has been poured into the litter box 10 to a sufficient level, the litter 
box 10 is ready to be closed for shipment. 
At this point, the end wall members 28 and 30 are simultaneously folded 
outwardly about the score line 24 and inwardly along the angular 
perforations 70. Simultaneously therewith, the side wall members 32 and 34 
are folded inwardly about the score line 24 to cover the cat litter 12. 
The end wall members 28 and 30 are then folded over 180.degree. onto the 
end wall members 32 and 34 and are glued thereto at 37 and 39, thereby 
closing the litter box 10 to form a relatively thin, substantially 
rectangular package for shipment. 
The cat litter box 10 is thus packaged in the foregoing manner for 
distribution to the consumer. To assemble the cat litter box 10 for use by 
a cat or other household pet, the folded end wall members 28 and 30 which 
are glued to the side wall members 32 and 34 are separated from the wall 
members 28 and 30 in the manner described above so that the wall members 
may be erected as shown in FIG. 2. The perforations 50 and 52 are then 
torn, thereby separating the end flaps 29, 31, 33 and 35. At this 
juncture, the end flaps 29 and 31 are folded inwardly 180.degree. at the 
double fold defined between the score lines 38 and 40. The side flaps 33 
and 35 are then folded inwardly 180.degree. to complete the assembly of 
the cat litter box 10 as shown in FIG. 1. As each end flap is folded 
against the end or side wall members, the tab 60 (FIG. 5) or tab 61 (FIG. 
6) locks or extends into the slot or gap formed at the corners of the 
litter box 10 where the slotted edges of the end flaps come together. The 
tabs 60 and 61 thus perform a locking function to hold the end flaps 
against its side wall members. 
For disposal purposes, the cat litter box is disassembled and closed in the 
following manner. The end flaps 33 and 35, followed by end flaps 29 and 
31, are initially unfolded and deployed upwardly to the position shown in 
FIG. 2. Then, the side wall members 32 and 34 are folded inward above the 
litter 12 while the end wall members are folded outward. The lock tabs 72 
on the flap 35 are popped up so that they extend through the slots 74 
incorporated in the flap 33 upon closure thereof over the cat litter 12 as 
shown in FIG. 3. The end flaps 29 and 31 are folded along the perforations 
70 and folded 90.degree. to the closed position shown in FIG. 3. The 
pointed ends 76 of the folded end flaps 29 and 31 extend through the 
locking tabs 72 to lock the end flaps in position as shown in FIG. 3 for 
convenient disposal of the cat litter box 10. 
Referring now to FIGS. 7 and 8, an alternate embodiment of the litter box 
10 is shown. The alternate embodiment of FIGS. 7 and 8 is substantially 
identical to the previously described embodiment and therefore like 
reference numerals have been used to identify the same or similar parts. 
The embodiment of FIGS. 7 and 8 differs in two important details. First, 
the longitudinal edge 79 of the end flaps 29 and 31 is not straight but 
instead tapers slightly toward the center of the flaps, terminating at the 
apex of the perforations 70. The taper is very slight, forming a very wide 
V in profile. The other difference of note is the elimination of offset 
perforations at the joinder of each end flap. As best shown in FIG. 7, the 
blank 80 of the alternate embodiment is provided with a single small 
perforation 81 adjacent to a parallel long perforation 82 spaced 
therefrom. The end flaps are notched to form a small gap 84 terminating at 
the straight cut 54 which separates the end flaps. The cat litter box of 
FIG. 7 is deployed to form a litter box in substantially the same manner 
as previously described. The end flaps are separated along the small 
perforations 81 to be folded inwardly to the position shown in FIG. 1. The 
tabs 88 fold at the large perforation 82 approximately 90.degree. allowing 
tab 89 to look into the slot 84. Closure of the cat litter box 10 is 
likewise substantially the same with the end flaps first being unfolded 
and the lock tabs 72 popped up for extension through the slots 74. The end 
flaps 29 and 30, however, when folded along perforations 70 include 
portions which overlap as shown in FIG. 8. The overlap is such that the 
edges 86 and the straight cut 54 defining the slot 84 come together to 
close the slot so that leakage of cat litter is not permitted past the 
point of overlap. The end flaps are then folded over and locked in the 
locking tabs 72 as previously described and the cat litter box 10 may be 
discarded. 
The dimensions of the cat litter box of the invention can be varied in a 
relative manner. For instance, the bottom of the cat litter box is 
typically in the range of 16-24 inches in length and has a width between 
12-16 inches. These dimensions, however, are only typical, certainly not 
limiting. The erected side walls should extend approximately six inches in 
height to provide an adequate barrier to prevent cat litter from being 
easily kicked out by a cat. Again, these dimensions are typical and can be 
varied over a wide range. Preferably, the cat litter box of the invention 
is made of corrugated paperboard stock. Needless to say, various weights 
and types of sheet material can be used. Single wall corrugated paperboard 
material is ordinarily the most desirable material. 
While the foregoing is directed to the preferred embodiment of the present 
invention, other and further embodiments of the invention may be devised 
without departing from the basic scope thereof, and the scope thereof is 
determined by the claims which follow.