Abstract:
The present invention relates to apparatus and methods for providing nestable pet beds which combine a flexible base and sidewall in a design which is readily stackable for compact transport, storage and display. The base and sidewall are cut from foam or other flexible material utilizing straight cuts which can be mass produced. The sidewall is cut along an arc as a unitary piece or as multiple pieces which collectively define an arcuate configuration. Providing an arcuate wall and attaching it in a flat wall to edge relationship with the base achieves a pet bed design with flared walls that can be nested. The relationship between the sidewall and the base causes radial forces to be exerted on the base, creating a concavity and convexity in the base when viewed from its lower and upper surface, respectively. The concavo-convex configuration imparts an aesthetically appealing, fluffy and comfortable appearance to the pet bed.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to apparatus and methods for providing pet beds, and more particularly, to a partially enclosed pet bed which combines a flexible base and sidewall in a design which is readily stackable for compact transport, storage and display. 
     BACKGROUND OF THE INVENTION 
     Pet owners desire a secure, safe and comfortable environment for their cherished pets. Oftentimes, owners will purchase pet beds in an attempt to provide a cozy and snug shelter in which their pets can rest and relax. While various structures are available, pet beds which provide soft and flexible enclosures are desirable. Preferably, a comfortable base surrounded around its perimeter by a sidewall creates a cradle-like structure between the sidewall and the base. This enclosure provides a secure and snug feeling to the pet which can lean against the sidewall while resting on the base. These types of pet beds are constructed from various materials, including suitable flexible material such as soft or cushioned foam. While a thicker foam material may result in a softer, more comfortable bed, typically it will create a bulkier configuration. 
     Nestability of bulky pet beds is a desirable feature to manufacturers and retailers in the industry. Retail shelving space is a premium and the ability to display multiple pet beds which are fully assembled is desirable. Typically, a lack of shelving space dictates that a sole “floor model ” be displayed, while the pet beds which are actually for sale are stored in the back of the retail store away from the view of the customer. However, nested beds can be stacked neatly and compactly on retail shelving in their fully assembled configuration without distracting from the overall appearance of the bed. Further, nestable beds are less cumbersome to transport. The nestability feature creates a densely packed shipping container without the need to deform, fold or compress the beds. This is particularly desirable as the flexible material or foam may tend to retain an inflicted deformity rather than returning to its original shape. 
     A variety of pet beds are available. For example, U.S. Pat. No. 5,515,811 to McAlister discloses a cushion comprised of a pad made of a number of layers of fibers. While this structure seeks to provide a soft and comfortable resting place for a pet, it does not provide upwardly extending sidewalls which create a cradle-like structure for pets to snuggle against while resting on the cushion. 
     Other beds are available that feature a cradle-like structure. U.S. Pat. No. 5,136,981 to Barreto, III et al. discloses a pet bed having an upwardly extending sidewall which encloses a base around its perimeter. A removable cover which is washable separately encases the sidewall and the base. While the disclosed structure provides a preferred cradle-like enclosure for a pet, its substantially vertical sidewall prevents nesting of fully assembled beds. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, there is provided a novel apparatus and method for providing a pet bed design which is easy to manufacture, provides a comfortable and secure enclosure for a pet and, in addition, can be compactly transported, stored and displayed in a fully assembled configuration. 
     The pet bed generally comprises a base and an arcuate sidewall which are constructed of foam matting or other suitable flexible material. The base serves as a bed or cushion on which a pet rests or naps. The arcuate sidewall is affixed at a lower edge around the perimeter of the base to form a cradle-like structure. The pet can snuggle or lean against the sidewall while resting on the base. The arcuate configuration of the sidewall causes the sidewall to flare outward when affixed to the base. 
     The base is comprised generally of upper and lower surfaces and a side surface which generally defines the perimeter of the base. The configuration for the base can be substantially oval, circular, rectangular, square or any other desirable geometric configuration. 
     The arcuate sidewall can be cut as a unitary piece or, alternatively, can be constructed of multiple pieces which collectively define an arc. The sidewall is comprised generally of a lower edge having a minor peripheral dimension, an upper edge having a major peripheral dimension, an interior wall, and an exterior wall. The curvature of the arcuate sidewall generally defines the relationship between the major and minor peripheral dimensions. A larger curvature defines a major peripheral dimension which is relatively greater than minor peripheral dimension, while a smaller curvature defines a major peripheral dimension which is closer in length to the minor peripheral dimension. The minor peripheral dimension of the lower edge of the sidewall can be substantially the same as the perimeter of the base. Preferably, the minor peripheral dimension of the sidewall is less than the base perimeter so that the sidewall is stretched to wrap around the base. 
     The arcuate sidewall is wrapped around the base by affixing the lower edge of the sidewall interior wall around the side surface of the base. The resulting relationship between the interior sidewall and base side surface creates a pet bed having a sidewall which flares outwardly and upwardly from the upper surface of the base. The outward flare is dependent on the curvature of the arcuate sidewall. A sidewall having a larger curvature achieves a greater flare than a sidewall having a smaller curvature. Further, the lower edge of the sidewall at its exterior surface and the lower surface of the base define the bottom of the pet bed having a perimeter dimension. 
     The curvature of the sidewall and the tension created by stretching the sidewall around the side surface of the base causes radial forces to be exerted on the base. The radial forces create a concavity and a convexity in the base when viewed from its lower and upper surfaces, respectively. This concavo-convex configuration gives the upper surface of the base an aesthetically appealing, fluffy and comfortable appearance. 
     The concavo convex configuration of the base can be modified by varying the radial forces exerted on the base. As previously indicated, the radial forces are a function of the curvature of the sidewall and the relationship of the minor peripheral dimension of the sidewall to the base perimeter. Additionally, variable radial forces on the base can be accomplished during the cutting process of the base and sidewall from suitable flexible material. Preferably, the material is cut vertically to form a base having a side surface which is oriented in a substantially ninety degree relationship with the upper and lower surfaces of the base. This angled relationship of the base surfaces contributes to the radial forces exerted on the base when the sidewall is affixed around the base, and enhances the concavo-convex configuration of the base. 
     Similarly, vertical cuts could be used to form a sidewall having a substantially ninety degree relationship between the upper and lower edges and the interior and exterior walls. The substantially ninety degree orientation between the sidewall edges and walls and the base surfaces is an inexpensive and economical design, as the verticle cuts can be mass produced. 
     Alternatively, the radial forces on the base could be increased, and the concavo-convex configuration enhanced, by cutting the base side surface at an angle greater than ninety degrees from the lower surface of the base. Conversely, a decrease in the angle between the base side and lower surfaces could result in a reduction of radial forces exerted on the base and concavo-convex appearance. 
     The flared sidewall affixed to the base achieves a pet bed design that is readily stackable for compact transport, storage and display. Nestability is accomplished when the major peripheral dimension of the upper edge of the sidewall is larger than the perimeter of the bottom of the pet bed so that a first pet bed can fit neatly inside a second bed. This nestability can be repeated to stack multiple beds. Preferably, the bottom of the first pet bed would rest upon the upper surface of the base of the second bed in which is it nested. Accordingly, the greater the outward flare of the sidewall, the more efficient the nesting arrangement is, measured in terms of minimizing the overall height of a stack of beds. 
     The outward flare of the pet bad sidewall has a further advantage in that a smaller size base can be used to accommodate a larger pet. As a result, material costs are kept to a minimum while providing a comfortable and snug resting place for a pet. 
     A portion of the sidewall may be lower in height as measured from the base thereby defining an egress and ingress into the pet bed. Further, a notch can be formed along the upper edge of the sidewall to relieve any stress attributed by the curvature of the sidewall. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will be better understood and its numerous advantages will become apparent to those skilled in the art by reference to the following drawings in which: 
     FIG. 1 is a perspective view of a pet bed constructed in accordance with the teachings of the present invention. 
     FIG. 2 is a perspective view of the elements of an embodiment of a pet bed of the present invention. 
     FIG. 3 is an exploded perspective view of a pet bed of the present invention. 
     FIG. 4 is a top plan view of a pet bed of the present invention. 
     FIG. 5 is a cross-sectional view taken along lines  5 — 5  of FIG. 4 of a pet bed of the present invention. 
     FIG. 6 is a front plan view of pet beds of the present invention shown in a nesting arrangement. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to FIG. 1, a pet bed  10  constructed in accordance with the teachings of the present invention will now be described in greater detail. The pet bed  10  is generally comprised of a base  20  and a sidewall  30  constructed of foam or other suitable flexible material. Base  20  serves as a bed or cushion on which a pet rests or naps. Sidewall  30  is affixed to base  20  around its perimeter to form a sidewall enclosure against which the pet can lean, and which provides a comfortable, secure and snug space for the pet. 
     Base  20  and sidewall  30  can be made of a soft, flexible foam-core material such as foam rubber or the like which is commonly used in the manufacture of mattress and cushions. Additionally, materials which are suitable for the present invention include those of the type disclosed, for example, in U.S. Pat. No. 5,136,981 to Barreto, III et al. As discussed in Barreto, III et al, a soft, flexible foam-core material, such as an open-cell or closed cell foam rubber, or similar material can be used in the construction of base  20  and sidewall  30 . Alternatively, base  20  and sidewall  30  may be made with a hollow structure made of polyethylene, polypropylene, or similar material. Such a hollow structure could be formed by several different processes, including blow molding, rotational molding, vacuum molding, or injection molding. Since such a structure is hollow, base  20  and sidewall  30  are flexible. Further, this structure provides insulating, weight-supporting, and shock absorbent characteristics. 
     The thickness of base  20  and sidewall  30  is dependent on the desired softness and flexibility of the pet bed  10 , as well as the size and weight of the pet. Base  20  and sidewall  30  may have substantially the same thickness by cutting them from the same or similar pieces of flexible material. Alternatively, the thicknesses may vary. It may be desirable to provide base  20  having a thickness greater than that of sidewall  30  to provide a comfortable cushion, while minimizing the bulkiness of sidewall  30 . While a range of thicknesses is suitable, preferably the thickness for base  20  and sidewall  30  is approximately one and one half inches. 
     Referring now to FIGS. 2 and 3, base  20  is comprised of an upper surface  22 , a lower surface  24  and a side surface  26  which generally defines the perimeter of base  20 . While the shape of base  20  is illustrated in the figures as oval, the present invention is not limited to this configuration. Other suitable shapes include circles, rectangles, squares, or other desirable geometric configurations. 
     Sidewall  30  is a generally arcuate configuration which can be a unitary piece or can be constructed of multiple pieces, for example two or more sidewall portions  30 A,  30 B which collectively define an arc. While the following discussion is directed to a two piece construction of sidewall  30 , it is to be understand that the same general concept applies to a one piece or other multiple piece configurations of sidewall  30  suitable for manufacturing pet bed  10  of the present invention. Each of sidewall portions  30 A,  30 B is comprised generally of a lower edge  32 A,  32 B, an upper edge  34 A,  34 B, an interior wall  36 A,  36 B and an exterior wall  38 A,  38 B. Further, each of sidewall portions  30 A,  30 B comprises back side  50 A,  50 B and front side  54 A,  54 B. Back sides  50 A and  50 B of sidewall portions  30 A,  30 B are joined to form unitary sidewall  30  having a unitary lower edge  32 , a unitary upper edge  34 , a unitary interior wall  36  and a unitary exterior wall  38 . Lower edge  32  of sidewall  30  defines a minor peripheral dimension  42  and upper edge  34  defines a major peripheral dimension  44 . 
     The curvature of arcuate sidewall  30  generally defines the relationship of minor and major peripheral dimensions  42 ,  44  of lower and upper edges  32 ,  34 , respectively. A larger curvature defines major peripheral dimension  44  which is relatively greater than minor peripheral dimension  42  of sidewall  30 . Conversely, a smaller curvature defines a major peripheral dimension  44  which is closer in length to minor peripheral dimension  42 . Further, sidewall  30  having substantially no curvature defines major and minor peripheral dimensions  44 ,  42  which are relatively the same. 
     To wrap sidewall  30  around base  20 , minor peripheral dimension  42  of sidewall  30  can be substantially the same as the perimeter of base  20  defined by its side surface  26 . Alternatively, minor peripheral dimension  42  of sidewall  30  is less than the perimeter of base  20 , so that sidewall  30  is stretched to wrap around base  20 . It is to be understood that the other relationships between minor peripheral dimension  42  of sidewall  30  and the perimeter of base  20  are suitable, so long as sidewall  30  can be wrapped around base  20 . 
     Referring now to FIG. 3, pet bed  10  is constructed by wrapping sidewall  30  around base  20 . Interior walls  36 A,  36 B of sidewall portions  30 A,  30 B are affixed proximate their lower edges  32 A,  32 B to side surface  26  of base  20 . Suitable materials for affixing sidewall portions  30 A,  30 B to base  20  include, but are not limited to, glue, epoxy, paste, gum, cement, sealant, or other bonding agents. Back sides  50 A,  50 B of sidewall portions  30 A,  30 B are joined. Similarly, front sides  54 A,  54 B are joined. It is to be understood that the foregoing order of steps is not important. For example, back sides  50 A,  50 B can be joined before or after sidewall portions  30 A,  30 B are affixed to base  20 . Similarly, front sides  54 A,  54 B can be joined before or after sidewall portions  30 A,  30 B are affixed to base  20 , or before or after back sides  50 A,  50 B are joined. Further, lower edge  32  of sidewall  30  at its exterior wall  38  and lower surface  24  of base  20  generally define bottom  12  of pet bed  10  (See FIG. 5) having a perimeter dimension  14 . 
     Referring now to FIGS. 4 and 5, lower edge  32  of sidewall interior wall  36  which is affixed to side surface  26  of base  20  creates a pet bed  10  having sidewall  30  which flares outwardly and upwardly from upper surface  22  of base  20 . The curvature of sidewall  30  generally defines its outward flare when affixed to base  20 . Sidewall  30  having a larger curvature achieves a greater flare than sidewall  30  having a smaller curvature. 
     Stretching sidewall  30  around base  20  exerts radial forces on base  20 . The radial forces are amplified by the arcuate configuration of sidewall  30  which urges upper edge  34  outwardly when sidewall  30  is affixed to base  20 . The radial forces on base  20  create a concavity in base  20  when viewed from its lower surface  24 , and a convexity when viewed from the base upper surface  22 . The concavo-convex configuration gives upper surface  22  of base  20  an aesthetically appealing, fluffy and comfortable appearance. 
     Returning to FIGS. 2 and 5, the concavo-convex configuration of base  20  is dependent on additional novel features of the present invention. Radial forces on base  20  can also be created by the cutting technique of base  20  and sidewall  30  from flexible material, as well as the thickness of the material, its density and flexibility. Preferably, the flexible material is cut vertically to form base  20  having side surface  26  oriented in a substantially ninety degree relationship with upper and lower base surfaces  22 ,  24 . This angled relationship of base surfaces  22 ,  24 ,  26  contributes to the exertion of radial forces on base  20  when sidewall  30  is affixed around base  20 , and advances the novel feature of the concavo-convex appearance. 
     Similarly, verticle cuts can be used to form sidewall  30 , wherein lower edge  32  and upper edge  34  are oriented in a substantially ninety degree angle with interior and exterior walls  36 ,  38 . The ninety degree orientation between sidewall edges  32 , 34  and walls  36 , 38 , and between base surfaces  22 , 24 , 26  is a relatively inexpensive and economical design, as the verticle cuts from a suitable material can be mass produced. However, it is to be understood that other angles between the surfaces of base  20  and the edges and walls of sidewall  30  may be suitable. 
     For example, it may be desirable to enhance the concavo-convex appearance of base  20 . Base side surface  26  can be cut at an angle greater than ninety degrees from lower surface  24  of base  20 , thereby increasing the radial forces exerted on base  20  when sidewall  30  is affixed thereto. Conversely, a smaller angle between base side surface  26  and lower surface  24  would result in smaller radial forces on base  20  and likewise, a less enhanced concavo-convex appearance. 
     Referring to FIG. 6, the nestability feature of pet bed  10  will now be described in greater detail. Nestability is achieved when sidewall upper edge  34  has a larger major peripheral dimension  44  than the perimeter  14  of bottom  12  of the pet bed so that the bottom  12  of a first pet bed  60  fits inside a second pet bed  70 . A nesting arrangement which keeps the overall height of a stack of pet beds to a minimum is desirable. The greater the outward flare of sidewall  30 , the further a first pet bed  60  can fit inside a second pet bed  70 , thereby minimizing the stack height. Preferably, bottom  12  of a first pet bed  60  rests upon upper surface  22  of base  10  of a second pet bed  70 . Nestability is also generally dependent on the thickness of sidewall  30 . A pet bed having a thicker sidewall would not nest as compactly as one with a thinner sidewall. 
     The nestability feature of the present invention allows pet beds  60 , 70  to be stacked neatly and compactly on retail shelving in their fully assembled configuration without distracting from the overall appearance of the bed. The nestability feature also allows pet beds  60 , 70  to be densely packed in shipping containers without the need to deform, fold or compress the beds. This is particularly desirable as the flexible material or foam may tend to retain an inflicted deformity rather than returning to its original shape. 
     Returning to the figures and specifically to FIGS. 1 and 2, a notch  52  can be formed in sidewall  30  proximate its backside  50  to relieve any stress in sidewall  30  caused by stretching lower edge  32  around base  20 . Notch  52  also relieves sidewall  30  of any excess material at upper edge  34 . In a multiple piece configuration for sidewall  30 , notch  52  preferably is proximate backsides  50 A,  50 B of sidewall portions  30 A,  30 B, respectively. It is to be understood that any location proximate the upper edge of sidewall  30  is suitable. 
     An entry  56  can be formed in sidewall  30  by lowering the height of upper edge  34  proximate front side  54  of sidewall  30 . Entry  56  defines an egress and ingress into pet bed  10 . Preferably, entry  56  is opposite notch  52  of sidewall  30 , although other configurations may be suitable. In a multiple piece configuration for sidewall  30 , entry  56  is proximate front sides  54 A,  54 B of sidewall portions  30 A,  30 B, respectively. 
     Using the aforementioned concepts, a wide variety of differently configured pet beds can be manufactured. For example, the base and sidewalls may be configured to create a circular pet bed, a rectangular pet bed, or any other desirable configuration.