Animal toy and method of manufacture

Abstract

An animal toy is provided constructed from a latex or natural rubber material and formed into a ball. The ball is formed of an aggregate of particulate material that are bound together to form a substantially non-hollow construction. Pieces of latex are joined together to form balls, and the balls may be pressed together and constructed by hand or, alternatively, pressed into molds. By constructing the balls by hand, no two balls, even balls of similar size, are identical. Each ball has irregular outer surface that forms a variety of resilient protuberances that provide beneficial oral hygiene effects when chewed or rubbed against the teeth.

Claims

1. A method for manufacturing an animal toy comprising the steps: a. forming a solution of a calcium nitrate salt and water in a ratio of about 1:30 by weight; b. placing a liquid latex and/or natural rubber into said solution such as to coalesce the latex/rubber into a plurality of individual pieces; c. while in the solution, forming said plurality of individual pieces to join together to form and an animal toy shape; d. leaching said solution from said animal toy shape with water at a temperature of between about 85 degrees and about 100 degrees Celsius for about two hours; e. cooling and drying said animal toy shape to room temperature and a lower humidity; and f. curing the cooled and dried said animal toy shape in an oven or dryer until an internal temperature of the animal toy shape reaches about 180 degrees Fahrenheit.

2. The method of claim 1, wherein said animal toy shape is a ball.

3. The method of claim 1, further comprising filtering or softening said water prior to forming the solution.

4. The method of claim 1, wherein said forming said plurality of individual pieces to join together is accomplished at least in part as a manual hand operation.

5. The method of claim 2, wherein said forming said plurality of individual pieces to join together is accomplished at least in part as a manual hand operation.

6. The method of claim 3, wherein said forming said plurality of individual pieces to join together is accomplished at least in part as a manual hand operation.

7. The method of claim 1, wherein said forming said plurality of individual pieces to join together is accomplished at least in part by said piece being pressed into at least one mold.

8. The method of claim 2, wherein said forming said plurality of individual pieces to join together is accomplished at least in part by said piece being pressed into at least one mold.

9. The method of claim 3, wherein said forming said plurality of individual pieces to join together is accomplished at least in part by said piece being pressed into at least one mold.

10. The method of claim 1, wherein said cooling and drying occurs over a period of approximately at least 48 hours.

11. The method of claim 1, wherein said curing said animal toy shape in an oven or dryer occurs at a temperature of at least 200 degrees Fahrenheit for about 2 hours.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:

(2) FIG. 1 is a front elevational view of an animal toy according to a preferred embodiment of the present invention;

(3) FIG. 2 is a left side elevational thereof;

(4) FIG. 3 is a rear elevational view thereof;

(5) FIG. 4 is a right side elevational view thereof;

(6) FIG. 5 is a top plan view thereof;

(7) FIG. 6 is a bottom plan view thereof;

(8) FIG. 7 is a cross sectional view taken along line XII-XII of FIG. 1; and

(9) FIG. 8 is a flowchart showing an exemplary method for manufacturing the ball of FIG. 1 through FIG. 6;

(10) FIG. 9 is a photograph showing an otherwise conventional tennis ball 150 according to the PRIOR ART, depicted in a damaged condition as the result of animal interaction.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(11) The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within the Figures. It should be understood that the legal scope of the description is defined by the words of the claims set forth at the end of this patent and that the detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims.

(12) It should also be understood that, unless a term is expressly defined in this patent there is no intent to limit the meaning of that term, either expressly or by implication, beyond its plain or ordinary meaning, and such term should not be interpreted to be limited in scope based on any statement made in any section of this patent (other than the language of the claims). To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term by limited, by implication or otherwise, to that single meaning. Finally, unless a claim element is defined by reciting the word “means” and a function without the recital of any structure, it is not intended that the scope of any claim element be interpreted based on the application of 35 U.S.C. § 112, sixth paragraph.

(13) The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within the Figures.

(14) 1. Detailed Description of the Figures

(15) Referring generally to FIG. 1 through FIG. 7, an animal toy, generally noted as 100, is shown according to the preferred embodiment of the present invention. The animal toy 100 is preferably constructed from a latex or natural rubber material and formed into a ball 102. The ball 102 may be formed of an aggregate of particulate material 104 that are bound together to form a substantially non-hollow construction. According to an alternate embodiment, it is envisioned that a portion of the center of the ball may form a cavity 110 (as shown in FIG. 7). However, such an alternate configuration is envisioned as being formed to facilitate an alternate manufacturing method, such as rotational molding or the like, but in any configuration it is desired that the ball 102 have a substantially filled internal section 106 that is substantially greater than any cavity 110. By way of example, and not meant as a limitation, an internal cavity 110 having a diameter of D1 which should be no greater than half the overall diameter D2 of the entire ball 102.

(16) The ball 102 may be different sizes such as, for example, golf ball, baseball, or softball size, depending on the size of the animal, typically a dog, that is to use toy. In available commercial embodiments as provided under the WUNDERBALL™ brand available under authority through Wacky Walk'r of Hatfield, Pa., the balls 102 are formed to accommodate various sized dogs, including small dogs (1-20 pound) that has an approximate general diameter D2 of 1.5 inches, medium dogs (21-60 pounds) that has an approximate general diameter D2 of 2.35 inches, or large dogs (61-200 pounds) having an approximate general diameter D2 of 2.9 inches. For purposes of comparison, a conventional standard tennis ball 150 as shown in FIG. 9 has an outer diameter of 2.7 inches.

(17) The toy 100 may be of various colors through the addition of pigment or dye or through the use of pre-colored rubber aggregate 104.

(18) Referring now in conjunction with FIG. 8, a flowchart 200 is providing depicting an exemplary method for manufacturing the animal toy 100. In FIG. 2, in step 202, a solution of calcium nitrate or other suitable salt and water in a ratio of about 30 lbs (about 13.6 kg) of water to about 1 lb (about 0.45 kg) of calcium nitrate is formed. It should be apparent to one having ordinary skill in the relevant art, in light of the present teachings, that other chemical salts that are functionally similar to or equivalent with calcium nitrate within the present method may be substituted. In step 204, liquid latex and/or natural rubber is placed into the solution. Optionally, in step 201, it is desired that, prior to adding the calcium nitrate to the water, the water is filtered through a water softener.

(19) While in the solution, in step 206, the pieces of latex are joined together to form balls 102. The balls 102 can be constructed by hand or, alternatively, pressed into molds. By constructing the balls 102 by hand, no two balls 102, even balls 102 of similar size, are identical. Also, because the balls 102 are made by hand, each ball has irregular surfaces 103.

(20) It has been found that, depending on the size of the balls 102, about 80-100 balls 102 can be formed using the solution of about 30 lbs of water to about 1 lb of calcium nitrate as described above.

(21) In step 208, the newly formed balls 102 are leached in tanks with water at a temperature of between about 85 degrees and about 100 degrees Celsius for about two hours. In step 209, the balls 102 are then removed from the tank and placed on a mesh support at room temperature of about 72 degrees Fahrenheit (about 23 degrees Celsius) for at least 48 hours to remove moisture.

(22) In step 210, balls 102 are cured in an oven or dryer at a temperature of at least 200 degrees Fahrenheit (about 93 degrees Celsius) for about 2 hours, or until the internal temperature of balls 102 reaches about 180 degrees Fahrenheit (about 83 degrees Celsius), at which temperature the latex bonds solidify balls 102.

(23) After the balls 102 are dry, the balls 102 can be packed and shipped. The balls 102 can be used as an animal chew toy and can clean the animal's teeth. Also, because of its latex/rubber nature, balls 102 can bounce and, because of their irregular surfaces 103, when the balls 102 bounce, the balls 102 do so erratically, allowing the animal to chase the balls 102 in different directions, allowing ball 100 to be treated as a fetch toy.

(24) 2. Operation of the Preferred Embodiment

(25) In operations, the toy 100 has an application as an animal fetch/chew toy. Used as an alternative to an otherwise conventional tennis ball 150 as shown in conjunction with FIG. 9, the toy 100 is more durable and, in the event that particulates are released they would be of a size, shape and consistency that is nonhazardous to an animal. This is in contrast to a conventional tennis ball 150, in which the narrow sidewall 152 can tear and degrade into larger, irregularly shaped shards 154 that can be a choking hazard to a pet.

(26) It should be apparent to those skilled in the art, in light of the present teachings, that such a toy 100 can also be used by humans as a throw/catch toy as well.

(27) The foregoing descriptions of specific embodiments of the present invention are presented for purposes of illustration and description. The Title, Background, Summary, Brief Description of the Drawings and Abstract of the disclosure are hereby incorporated into the disclosure and are provided as illustrative examples of the disclosure, not as restrictive descriptions. The embodiments are chosen and described in order to best explain principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and its various embodiments with various modifications as are suited to the particular use contemplated. It is intended that a scope of the invention be defined broadly by the Drawings and Specification appended hereto and to their equivalents. Therefore, the scope of the invention is in no way to be limited only by any adverse inference under the rulings of Warner-Jenkinson Company, v. Hilton Davis Chemical, 520 US 17 (1997) or Festo Corp. v. Shoketsu Kinzoku Kogyo Kabushiki Co., 535 U.S. 722 (2002), or other similar case law or subsequent precedent should not be made if any future claims are added or amended subsequent to this Patent Application.