Pet carrier

A carrier includes a main unit and an insert unit. The main unit defines a carrying space having a closed bottom and four sides, one of which has an opening therethrough large enough to permit an animal to enter the space through the opening. The insert unit has a closed top, four sides, and an open bottom. After the animal has entered the main unit, the insert unit is lowered down into the main unit to close off the side opening. Then a foldable top closure for the main unit is folded to secure the carrier and form a handle structure for carrying the carrier. Both units are foldable and are structured to provide an enhanced strength carrier. Strength enhancing features include the foldable bottom of the main unit, double and triple thickness portions of the top closure, and the presence of the insert unit in the main unit.

TECHNICAL FIELD 
This invention relates to foldable paperboard carriers for cats and other 
small animals, and particularly to a carrier having a telescoping insert 
box which functions as a trap door, allowing the animal to enter or exit 
the carrier without prodding or assistance. The structure of the main body 
of the carrier and the insert box provide the carrier with enhanced 
strength. 
BACKGROUND INFORMATION 
The animal carriers that are currently on the market provide only a top 
opening for placing an animal in the carrier. The animal is placed in the 
carrier by lowering it into the carrier. Many animals are frightened and 
reluctant to be placed into a carrier and struggle against the person 
attempting to place them into the carrier. This makes the use of the 
carrier unpleasant and difficult for both the animal and the person. In 
addition, conventional animal carriers that are constructed of corrugated 
paperboard are relatively weak and have relatively short useful lives. The 
present invention provides an improved design for corrugated paperboard 
carriers. 
SUMMARY OF THE INVENTION 
A subject of the present invention is a carrier for a small animal 
comprising a main unit and an insert unit. The main unit includes four 
sides and a bottom defining a carrying space having a top opening. One of 
the sides has a side opening therethrough large enough to permit the 
animal to enter the carrying space through the side opening. The insert 
unit includes four sides, a closed top, and an open bottom. The insert 
unit is dimensioned to slide down through the top opening of the main unit 
into a use position in the carrying space and to closely fit inside the 
main unit in the use position. When the insert unit is in its use 
position, it at least substantially blocks the side opening. 
The insert unit may completely block the side opening. However, preferably 
one of the sides of the insert unit has an air hole extending therethrough 
and positioned to align with the side opening when the insert unit is in 
its use position. The air hole is sufficiently small to prevent the animal 
from exiting the carrier therethrough. 
A preferred feature of the carrier is a main unit that includes an openable 
closure for the top opening having a plurality of air holes extending 
therethrough. The top of the insert unit has a plurality of air holes 
positioned to be aligned with the air holes in the closure when the insert 
unit is in its use position. Preferably, the air holes in the top of the 
insert unit are sized to serve as finger holes for pulling the insert unit 
out of the main unit. 
Another subject of the invention is a foldable carrier for a small animal 
comprising a body having four sides and a bottom defining a carrying 
space, and an openable top closure for the carrying space. The bottom 
includes a first panel substantially coextensive with the bottom and 
foldable along a first bottom edge of a first of the sides into the 
carrying space. A second panel is foldable toward the first panel along a 
second bottom edge of a second of the sides opposite the first side. The 
second panel has a pair of spaced apart wing opposite the second bottom 
edge. Opposite side panels are foldable toward the second panel along 
bottom edges of the sides substantially perpendicular to the first and 
second bottom edges. Each side panel has a main portion that folds over a 
bottom surface of a respective one of the wings, and a flap portion that 
folds around the respective wing into a position adjacent to a top surface 
of the respective wing to secure the second panel in a use position. 
Preferably, the body has a slot extending therethrough along the second 
bottom edge. The first panel has a projecting tab positioned to engage the 
slot to hold the first panel in a use position substantially abutting the 
second panel and the flap portions of the side panels. 
Another preferred feature is a second panel that is formed from a blank 
substantially coextensive with the first panel and having spaced apart 
slits defining inner edges of the wings. An intermediate portion between 
the slits is folded back against the upper surface of the second panel to 
permit the flap portions to be folded around the wings. Preferably, when 
the flap portions are folded around the wings, the flap portions extend 
toward each other beyond the wings along an upwardly facing surface of the 
second panel. 
The preferred embodiment of the carrier of the invention includes both the 
insert unit and the foldable bottom structure described above. This 
combination of features enhances the strength of the carrier. The 
combination of the insert unit and the side opening provides a means for 
allowing the animal to enter or exit the carrier without assistance or 
prodding. This procedure avoids frightening the animal and the necessity 
of struggling with the animal to place it in the carrier.

BEST MODE FOR CARRYING OUT THE INVENTION 
The drawings show a carrier for a small animal that is constructed 
according to the invention and that constitutes the best mode for carrying 
out the invention currently known to the applicant. As shown in the 
drawings, the carrier includes a main unit, shown in FIGS. 1, 2, 5-11, and 
15-22, and an insert unit shown in FIGS. 3, 4, and 12-14. Both of the 
units are preferably made from corrugated paperboard. 
The main unit, in its use configuration shown in FIGS. 15-22 forms a 
rectangular box. Referring to FIG. 1, the rectangular box is made by 
folding a die cut corrugated paperboard blank. The fold lines are 
indicated by broken lines in FIG. 1. The main unit has four sides, 
including two large sides 2, 4 and two smaller sides or ends 1, 3. An end 
tab 7 is formed on the outer edge of one of the smaller sides 1. In the 
manufacture of the carrier, the end tab 7 is glued to the inner surface of 
the panel 4 adjacent the free edge of the panel 4 to form the continuous 
perimeter of the main unit, as shown in FIG. 2. Two spaced-apart slots 8 
extend through the side 2 along the lower edge of the side 2. 
Corresponding tabs 9, 9A are formed on the free ends of a first bottom 
panel 12 and a second bottom panel 13 and are positioned to be engaged in 
the slots 8 when the main unit is folded for use. A large side opening 10 
is formed in the side 3 and is dimensioned to be large enough to permit an 
animal to enter the carrier and the carrying space defined thereby through 
the side opening 10. A plurality of air holes 6 are provided in each of 
the larger sides 2, 4. An air hole 11 is provided in smaller side 1. 
The bottom of the main unit has a strong structure that is an important 
feature of the invention. The bottom includes the first panel 12, which 
extends from the bottom edge of the side 4 and is substantially 
coextensive with the bottom. In the use configuration of the carrier, the 
four sides 1, 2, 3, and 4 and the bottom define the carrying space for the 
animal. The panel 12 serves as the floor of the carrying space and 
supports the animal. The second panel 13 extends from the bottom edge of 
the side 2 and has a pair of spaced apart wings 16 opposite this bottom 
edge. In the blank shown in FIG. 1, the second panel 13 is substantially 
coextensive with the first panel 12. The second panel 13 has a pair of 
spaced apart slits 26 defining the inner edges of the wings 16 and 
separating the wings 16 from an intermediate portion 27. In addition to 
the first panel 12 and the second panel 13, the bottom includes two side 
or end panels 14, 15. Each of the end panels includes a main portion 14 
that extends from the bottom edge of one of the smaller sides 1, 3 and a 
flap portion 15 extending from the main portion 14. 
The carrying space of the main unit has a top opening. The main unit also 
includes an openable closure for this top opening. The closure includes 
two main panels 17, 21, 21A and 17, 22. These panels extend, respectively, 
from the top edges of the sides 2, 4. The closure also includes securing 
panels 18 extending from the top edges of the smaller sides 1, 3. Each 
securing panel 18 has a pair of slots 19 positioned to align with each 
other when the securing panel 18 is folded along its narrow waist to 
provide the securing panel 18 with a double thickness. An extension 20 
extends from the outer edge of the securing panel 18. 
The first main closure panel 17, 21, 21A includes a cover portion 17 and 
two handle portions 21, 21A. The second main closure panel 17, 22 includes 
a cover portion 17 and a single handle portion 22. Each of the handle 
portions 21, 21A, 22 is provided with a grip opening 23. In the handle 
portions 21, 22, the blank is cut all the way around the grip openings 23 
and the paperboard material is removed therefrom. In the handle portion 
21A, the blank is cut only partially around the grip opening 23 to leave a 
lock tab 24. In addition to the grip openings 23, each of the handle 
portions is provided with a pair of opposite notches 25. The cover 
portions 17 are provided with a plurality of air holes 5. 
In its use configuration shown in FIGS. 14-16, the insert unit forms a 
five-sided box with an open bottom. The box includes two larger sides 28, 
30 having air holes 39 and two smaller sides or ends 29, 31 each having a 
single air hole 32. 
Referring to FIG. 3, the free end of side 28 has an end tab 35 which is 
glued to the inner surface of the side 31 to form a continuous perimeter 
of the insert unit, as indicated in FIG. 4. The top of the insert unit is 
formed from opposite top end panels 36, a first top side panel 37, and a 
second top side panel 38. Air holes 40 are formed in the first and second 
top side panels 37, 38. 
Both the main unit and the insert unit are storable, an are preferably 
sold, in the flattened configurations shown in FIGS. 2 and 4. In these 
configurations, the fold lines are shown in solid lines since they have 
been prefolded by the manufacturer to facilitate the assembly of the 
carrier by the user. FIGS. 5-22 illustrate the folding of the units into 
their use configurations. 
FIGS. 5-11 show the main unit upside down and illustrate the folding of the 
main unit. FIG. 5 shows the main unit after the four sides have been moved 
from their flattened positions shown in FIG. 2 into the use position in 
which they form the perimeter of a rectangular box. In this configuration, 
the larger sides 2, 4 and their bottom edges are opposite each other and 
the smaller sides 1, 3 are at least substantially perpendicular to the 
sides 2, 4. Once the unit has been opened up, the bottom elements are 
folded as shown in FIGS. 6-11. FIGS. 5 and 6 illustrate the folding of the 
first bottom panel 12 in the direction indicated by the arrows 41, 42 in 
FIGS. 5 and 6, respectively. Panel 12 is folded along its connection with 
side 4, which is the bottom edge of side 4, and down into the carrying 
space toward the inner surface of the side 4. Then, the intermediate 
portion 27 of the second panel 13 is folded back against the main portion 
of the panel 13, and the panel 13 is folded along the bottom edge of the 
side 2 toward the first panel 12, as shown in FIGS. 7 and 8. The panel 13 
is folded into a horizontal position in which the tabs 9A are received in 
the slots 8. 
Referring to FIG. 9, once the second panel 13 has been folded down into a 
horizontal position, the two opposite side bottom panels 14, 15 are folded 
down over the bottom surfaces of the wings 16. The flap portion 15 of each 
side bottom panel 14, 15 is folded around the respective wing 16 and into 
a position in which it is adjacent to a top surface of the wing 16 to 
secure the second panel 13 in its use position, shown in FIG. 11. The flap 
portions 15 are preferably sized so that, when they are folded around the 
wings 16, they extend toward each other beyond the wings 16 along an 
upwardly facing surface of the second panel 13. In the case of the 
illustrated embodiment, this upwardly facing surface is the adjacent 
surface of the intermediate portion 27. 
When the side bottom panels 14, 15 have been folded into position, the user 
reaches into the carrying space through the still open top closure and 
pushes the first panel 12 in the direction shown by the arrow 43 in FIG. 
10. The panel 12 is pushed into a position in which the tabs 9 are 
received in the slots 8 to secure the panel 12 in its use position. In 
this position, the first panel 12 substantially abuts the second panel 13 
and the folded flap portions 15 of the side bottom panels 14, 15. The 
result is an extremely sturdy bottom structure that will easily support 
even a relatively heavy animal placed in the carrier. 
The engagement of the tabs 9A in the slots 8 contributes to the strength of 
the bottom structure by helping to hold the second panel 13 and its 
intermediate portion 27 in position. However, the tabs 9A may be omitted 
without substantially affecting the strength. The first panel 12 and the 
end panels 14, 15 folded around the second panel 13 also serve to hold the 
second panel 13 and portion 27 in position. 
FIGS. 12 and 13 illustrate the folding of the insert, unit into its use 
configuration. As with the main unit, the insert unit is first pulled out 
of its flattened storage configuration into the rectangular configuration 
shown in FIG. 12. Then, the top panels are folded into position. The first 
top side panel 37 is folded first, as indicated by the arrow 44 in FIG. 
12. Then the top end panels 36 are folded down over the first panel 37. 
Finally, the second top side panel 38 is folded down and the tab on its 
projecting end is pushed under the free end of the first panel 37, as 
indicated by the arrow 45 in FIG. 13. This completes the assembly of the 
insert unit. 
FIGS. 15-18 illustrate the lowering of the insert unit down through the 
open top closure of the main unit into the carrying space defined by the 
main unit. Before the insert unit is lowered, each securing panel 18 is 
folded along its narrow waist and the free end of the panel 18 is folded 
down so that the extension 20 extends down into the carrying space, as 
shown in FIGS. 17-19. The units are sized so that the insert unit slides 
down into the main unit without difficulty but fits closely inside the 
main unit to maximize the available carrying space and the strengthening 
effect of the insert unit. The close fit also causes the insert unit to 
engage the extensions 20 to maintain the folded position of the securing 
panels 18, as shown in FIG. 19. 
When the insert unit is in the partially lowered position shown in FIG. 16, 
the animal may be invited to enter the carrier. Many small animals, and 
especially cats, will enter the carrier without coaxing. If there is some 
reluctance on the part of the animal, the animal can be enticed by placing 
a treat inside the carrying space. While the animal is deciding whether to 
enter and is entering the carrier, there is no need for anyone to hold the 
insert unit in place since the snug engagement of the insert unit by the 
extensions 20 holds the insert unit in the partially lowered position. 
After the animal has entered the carrying space, the insert unit is simply 
pushed all the way down into the carrying space to block the side opening 
10 in the main unit and prevent the animal from exiting. The air holes 6, 
39 in the larger sides of the units align with each other. The air holes 
32 in the smaller sides of the insert unit align with the air hole 11 and 
the side opening 10 in the main unit. Either of the air holes 32 may be 
aligned with the side opening 10. 
Once the insert unit is in position, the top closure of the main unit is 
secured to secure the insert unit in place and assemble the carrying 
handle portions of the carrier. 
Referring to FIGS. 20-22, the first and second main closure panels 17, 21, 
21A and 17, 22 are folded down over the top of the insert unit. At the 
same time, the handle portions 21, 21A, 22 are folded upwardly. The result 
is that the cover portions 17 are substantially coextensive with and cover 
the top of the insert unit, and the handle portions extend upwardly from 
the adjacent edges of the cover portions 17. Air holes 5 align with air 
holes 40. Handle portion 22 abuts handle portion 21. The extra handle 
portion 21A is folded down over the opposite surface of the handle portion 
22 so that handle portion 22 is sandwiched between handle portions 21L, 
21A. Then, the lock tab 24 is pushed through the grip openings 23 in the 
three handle portions to secure the handle portions together. Finally, the 
two opposite securing panels 18 are folded down over the handle 21, 21A, 
22 with the edges of the handle being received into the slots 19. The 
notches 25 engage the ends of the slots 19 to lock the top closure in its 
secured use position shown in FIG. 22. Lifting the carrier by the handle 
further secures the engagement of the slot ends in the notches 25. The 
double and triple thicknesses of the panels 18 and the handle 21, 21A, 22 
provide a strong and durable handle and reliable locking of the top 
closure. 
After the carrier has been taken to its destination, the animal may be 
removed from the carrier by opening the top closure and lifting the insert 
unit into the position shown in FIG. 16 to allow the animal to exit under 
its own power. The opening of the top closure is accomplished by reversing 
the procedure for closing the top closure. If the animal would rather 
remain in the carrier, the insert unit can be completely removed from the 
main unit and the animal lifted out. Preferably, the air holes 40 in the 
top of the insert unit are sized to serve as finger holes to facilitate 
the lifting of the insert upwardly relative to the main unit. 
The carrier may be stored in the assembled configuration shown in FIG. 22. 
However, in most cases, it is preferable to return the carrier units to 
the flattened configurations shown in FIGS. 2 and 4 to conserve storage 
space. The insert unit may be flattened by pulling the second top panel 
38, then the top end panels 36, and then the first top panel 37 upwardly 
into positions parallel to the sides 30, 29, 31, 28, and pushing the sides 
together. Pulling the second panel 38 can be facilitated by engaging the 
finger holes 40. Disassembling the bottom of the main unit is accomplished 
by pushing inwardly on the first bottom panel 12 to disengage the tabs 9 
from the slots 8 and pivot the panel 12 into the carrying space. Then, the 
bottom end panels 14, 15 are unfolded away from the second bottom panel 
13, the second bottom panel 13 is unfolded, and the unit is flattened. A 
finger hole (not shown) may be provided in the main portion of the second 
panel 13 to facilitate disengagement of the tabs 9, 9A from the slots 8. 
Although the preferred embodiment of the invention has been illustrated and 
described herein, it is intended to be understood by those skilled in the 
art that various modifications and omissions in form and detail may be 
made without departing from the spirit and scope of the invention as 
defined by the following claims.