Rotomolded Double-Walled Animal Crate Design
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Solution Overview
Problem
Conventional portable animal crates suffer from lack of structural integrity, inadequate insulation, limited door mobility, interior soiling issues, and insecure attachment during transport, which can lead to animal safety concerns and practical usability problems.
Innovation Solution
A double-walled, rotational molded animal crate design with improved structural rigidity, thermal insulation, a pivotable door exceeding 180 degrees, a moat and drain system for liquid management, and integral attachment bars for secure placement, along with non-skid feet to prevent sliding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-layer material wall is used in conventional portable animal crates, then the crate remains lightweight and portable, but the structural integrity and toughness are insufficient, causing the wall to deflect or buckle under load
Solution Approach 1:
The patent implements a double-walled construction where an inner wall and an outer wall are nested within each other, creating a layered structure that enhances structural integrity while maintaining portability. The inner wall provides the enclosure boundary while the outer wall reinforces it, and the two walls work together to resist deformation under load without requiring excessive weight.
Solution Approach 2:
The patent employs a composite structure combining two distinct wall layers (inner wall and outer wall) made from rotomolded plastic material. This composite construction provides superior strength and toughness compared to single-layer designs, as the multiple layers distribute stress more effectively and resist buckling while maintaining reasonable weight.
2Temperature
If conventional single-layer animal crates are used, then the crate is portable and easy to move, but the insulation to animals in cold weather is inadequate
Solution Approach 1:
The nested double-walled construction creates an insulating air gap between the inner and outer walls, which provides thermal insulation for animals in cold weather. This structural arrangement inherently adds insulation capability without requiring separate insulating components, thus managing the trade-off between thermal performance and structural complexity.
3Ease of operation
If a conventional door with 90-180 degree range of motion is used, then the door provides basic access functionality, but it requires additional space around the kennel and may break or cause damage when forced further open
Solution Approach 1:
The patent implements a dynamic door system that can rotate beyond the conventional 180-degree limit, allowing the door to swing open up to 270 degrees or more. This dynamic range adjustment enables the door to adapt to different operational needs: when fully opened, it lies flat against the ground to minimize space requirements, while still providing complete access when needed.
Solution Approach 2:
The door rotation mechanism extends into a third dimension by allowing the door to swing around the side of the crate and lie flat on the ground, rather than simply opening in a plane perpendicular to the crate. This dimensional change enables the door to occupy minimal space when fully open while maintaining full accessibility.
4Reliability
If conventional single-layer crates are used, then the crate structure is simple, but the crates may be crushed or severely deformed during vehicle accidents or impacts, injuring or killing the animal
Solution Approach 1:
The double-walled composite construction provides enhanced impact resistance and structural reliability during vehicle accidents or drops. The inner and outer walls work together to absorb and distribute impact forces, preventing the severe deformation that would occur in single-layer crates and protecting the animal inside.
Solution Approach 2:
The air gap and structural design of the double-walled construction provide inherent cushioning against impact forces before they reach the animal. The outer wall acts as a protective barrier that absorbs initial impact energy, reducing the force transmitted to the inner enclosure and the animal within.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances animal safety by providing structural integrity, thermal comfort, improved door functionality, effective liquid drainage, and secure attachment, addressing the limitations of conventional crates.
Implementation Method 1
The kennel body may be rotomolded in one or more pieces
Implementation Method 2
The gap between the inner and outer walls provides structural rigidity and strength to the kennel body and also provides insulation to the enclosed space within the interior of the kennel
Data Source
AI summary
An animal enclosure includes an inner wall defining an enclosure space for an animal and an outer wall at least partially surrounding the inner wall. A gap is defined between the inner and outer walls. The gap is filled with a gas such as air in some embodiments. In other embodiments, the gap is filled with a filler material such as foam or polymer material. The animal enclosure includes an upper housing member and a lower housing member in some embodiments. The upper and lower housing members may be secured together using one or more fasteners to form the animal enclosure. Each of the upper and lower housing members is rotational molded in some embodiments. Each of the upper and lower housing members includes an outer wall and an inner wall, each separated by a gap, in some embodiments.