Process for manufacturing dog chew toys of tire sidewalls

A die is utilized to cut chew toy bases from tire sidewalls extracted from used tires. The chew toy bases are initially soaked in a cleansing solution of bleach and a detergent, and are subsequently cleaned by scrubbing them with a brush and rinsing with water. The chew toy bases are placed on a drying rack, and are then soaked in a conditioning solution of a silicone-based rubber beautifier and a scenting and/or flavoring agent. The chew toy based are then polished and screened utilizing a metal detector to identify if there is any metal within the new toy bases. The chew toy bases are suitable for use as dog chew toys and, depending on the particular design of the chew toy bases, may be assembled to other chew toy bases to manufacture a composite dog chew toy.

BACKGROUND OF THE INVENTION 
This invention relates generally to the manufacture of rubber articles. 
More specifically, the present invention relates to a process for 
manufacturing dog chew toys of the tire sidewalls of used tires. 
The benefits of recycling rubber are well known. Much work has been done to 
devise methods of recycling rubber through reclaiming and the use of 
various chemical additives to revulcanize the recycled rubber. See, for 
example, U.S. Pat. No. 4,579,871 and the discussion of prior rubber 
reclaiming methods therein. Furthermore, there is produced each year vast 
quantities of ground cured rubber from operations such as the grinding of 
used tires and the grinding and buffing of various rubber articles such as 
transmission belts, conveyer belts and tire carcasses in recapping 
operations. 
The disposal and/or reprocessing of used tires in an environmentally safe 
manner has proven to be a relatively expensive proposition. There has been 
a need, therefore, for improved methods for utilizing components of used 
tires in an environmentally safe manner, which the consumer finds 
beneficial. In this regard, advantageous use of used tire components to 
manufacture new articles should require a minimum of processing of the 
used tire components to create a product pleasing to the senses and 
functionally viable. A potential market for such products is in the pet 
care industry. 
Accordingly, there has been a need for a novel process for manufacturing 
useful articles of tire components, which process may be utilized to 
efficiently manufacture such articles in great quantities at relatively 
low cost. As there is a need in the pet care industry for dog chew toys, 
there is a need to develop a process to utilize tire components to 
manufacture such toys. The present invention fulfills these needs and 
provides other related advantages. 
SUMMARY OF THE INVENTION 
The present invention resides in the process for manufacturing dog chew 
toys of tire sidewalls removed from used tires. The process comprises, 
generally in regard to a first preferred form of the invention, the steps 
of cutting a chew toy base from a tire sidewall, and cleaning and 
polishing the chew toy base within a cleaning tumbler utilizing sand and 
gravel. Once the chew toy base is removed from the cleaning tumbler, it is 
rinsed to remove residual sand therefrom, and then placed within a final 
treatment tumbler to flavor the chew toy base with a flavoring agent. 
Additionally, the chew toy base may be beautified with a conditioning 
agent simultaneously with the step of flavoring the chew toy base within 
the final treatment tumbler. 
More specifically, the entire sidewall is cut from a used tire prior to the 
step of cutting the chew toy base from the tire sidewall. The step of 
cutting the sidewall from the tire includes the steps of utilizing a 
stationary knife to effect the cutting while rotating the tire. 
Next, the chew toy base is cut from the sidewall into a desired 
configuration utilizing a die. The die is preferably fit to a press, and 
then the tire sidewall is placed adjacent to the die which is then 
activated to cut the chew toy base from the tire sidewall. The chew toy 
base is removed from the die, the tire sidewall is rotated to place an 
unused portion adjacent to the die, and then the press is activated to cut 
another chew toy base. This cutting process continues until substantially 
the entire sidewall is consumed in creating chew toy bases. 
The chew toy bases are placed into a cleaning tumbler containing sand and 
gravel, and the cleaning tumbler is rotated to clean and polish the chew 
toy bases. They are then removed from the cleaning tumbler and placed into 
a rinsing tumbler containing water. The rinsing tumbler is rotated to 
remove residual sand and dirt from the chew toy bases. Afterwards, the 
chew toy bases are removed from the rinsing tumbler and placed onto drying 
racks. 
Once dry, the chew toy bases are placed into a final treatment tumbler 
containing porous media having flavoring and beautifying/conditioning 
agents applied thereto. The flavoring agents may include salt, animal fat, 
smoke flavor, and other flavor variations. The preferred beautifying agent 
is Armor All. The chew toy bases and the porous media are rotated within 
the final treatment tumbler to bring the chew toy bases into contact with 
the porous media to effect a transfer of the flavoring agent and the 
beautifying agent to the chew toy bases. 
In regard to a second preferred form of the invention, the process 
comprises generally the steps of cutting a chew toy base from a tire 
sidewall and cleaning the chew toy base by scrubbing it with a brush and 
rinsing it with water. Once cleaned, the chew toy base is then soaked in a 
conditioning solution containing a rubber beautifier and a scenting agent. 
More specifically, like in the previously described process, the entire 
sidewall is cut from a used tire prior to the step of cutting the chew toy 
base from the tire sidewall. The step of cutting the sidewall from the 
tire includes the steps of utilizing a stationary knife to effect the 
cutting while rotating the tire. However, as it is well understood by 
those in the art, any suitable process may be utilized to cut the tire 
sidewall from the tire. 
Next, the chew toy base is cut from the sidewall into a desired 
configuration utilizing a die in the same manner as described above. 
Either a die/backing plate that is mounted into a press may be utilized, 
or a hand-held cutting die may be advantageously utilized for lower 
production volume pieces. 
Prior to the scrubbing step, the chew toy base is soaked in a cleansing 
solution comprising bleach and a detergent. After being subsequently 
scrubbed and rinsed, the chew toy base is placed on a drying rack prior to 
being placed within the conditioning solution. The conditioning solution 
comprises a silicone-based rubber beautifier and means for scenting the 
chew toy base. 
Next, the chew toy base is polished and, if necessary, at least a portion 
of an exterior surface of the chew to base may be removed utilizing a 
grinder. The prepared chew toy base is then screened utilizing a metal 
detector to identify if there is any metal within the chew toy base. 
It is sometimes desirable to manufacture chew toy bases having different 
configurations that may be assembled to one another to form a composite 
dog chew toy. In such cases it is often desirable to punch additional 
apertures within the chew toy base subsequent to the step of utilizing a 
die to cut the chew toy base into a desired configuration. Such apertures 
may be created within the previously cut chew toy base using an arbor 
press. 
The resulting product is a dog chew toy of a quality that may be sold on 
the retail market. The dog chew toys may be easily shipped in bulk 
packaging without degrading the quality thereof. 
Other features and advantages of the present invention will become apparent 
from the following more detailed description, taken in conjunction with 
the accompanying drawings which illustrate, by way of example, the 
principles of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
As shown in the drawings for purposes of illustration, the present 
invention is concerned with a novel process for manufacturing dog chew 
toys (generally designated in FIG. 11 by the reference number 20) from the 
sidewalls 22 of used tires 24 (see FIGS. 1 and 2). 
In accordance with the present invention and with reference initially to 
FIGS. 1 and 2, the process involves obtaining used tires 24 from tire 
scrap yards, tire shops and other locations where used tires are 
accumulated. A tire sidewall 22 is extracted from the used tire 24 by use 
of a hand held knife 26 or by means of a knife positioned on a rotating 
arm pivoting at a center point. The purpose is to separate the tire 
sidewall 22 from the tire tread 28. Two tire sidewalls 22 may be extracted 
from one tire 24 (FIG. 2). 
With reference to FIGS. 3-5, the tire sidewall 22 is then placed in either 
a mechanical punch press 30 or a similar die cut press such as a hydraulic 
clicker press. In this regard, mechanical punch presses are ideal for die 
cutting chew toy bases 32 (FIG. 5) since they have a fast cycle, low 
maintenance, low cost for used presses, and are easily obtainable. Such 
presses 30 typically are manufactured to have a vertical stroke whereby 
the material to be cut is placed on a lower stationary platform 34. An 
upper moving portion 36 of the punch press 30 is fitted with a die 38 
attached to a backing plate 40 (FIG. 3). The lower stationary platform 34 
is fitted with a hard plastic punch base 42 which is designed to provide a 
solid cutting surface while not damaging the cutting die 38. The plastic 
punch base 42 is preferably fabricated with vacuum holes and a vacuum 
apparatus (not shown). The vacuum plate will remove the cut chew toy bases 
32 out of the cutting die 38 so that the cut sidewall 22 can be easily 
removed from the punch press 30. 
The cutting die 38 is preferably made of hardened steel rule material. The 
steel rule is bent to form a desired shape. Exemplary shapes include the 
bone shape illustrated, airplanes, throw balls, ball and chains, fire 
hydrants, letters and numbers. The steel rule is available in both 
straight edge (as shown) and serrated edge. The serrated edge offers 
better cutting performance. The cutting die 38 is then mounted on the 
backing plate 40 which gives the cutting die rigidity for added cutting 
performance and die longevity. 
With the tire sidewall 22 placed over the lower stationary platform 34 
directly over the plastic punch base 42 as shown in FIG. 4, the mechanical 
punch press 30 is activated to displace the die 38 downwardly (as 
illustrated in phantom) to cut a chew toy base 32 from the tire sidewall. 
The cut chew toy base 32 is then removed from the die 38 and the plastic 
punch base 42. The remaining unused tire sidewall 22 is rotated to where 
an unused portion of the tire sidewall is under the die 38. The press 38 
is again activated, and the entire process is repeated until substantially 
the entire sidewall 22 is consumed in creating chew toy bases 32. 
The chew toy bases 32 are then placed into a first or cleaning tumbler 44 
which contains cleaning sand and gravel 46 (FIG. 6). The cleaning tumbler 
44, which is similar to a concrete mixer, is rotated to tumble the cut 
chew toy bases 32, and the cleaning sand and gravel removes dirt and grime 
from the surfaces of the chew toy bases. The tumbling action also polishes 
the rubber. 
Next, the cleaned and polished chew toy bases 32 are placed into a second 
or rinsing tumbler 48 which contains water 49 (FIG. 7). As the rinsing 
tumbler 48 is rotated, residual sand and dirt are removed from the 
surfaces of the chew toy bases. 
The chew toy bases 32 are removed from the rinsing tumbler 48 and placed on 
a drying rack 50 (FIG. 8). 
As shown in FIGS. 9 and 10, porous media such as sponges 52 and cloths 54 
are sprayed with a flavoring agent (i.e., salt, animal fat, smoke flavor, 
or other flavor variations and scents) 56 and a conditioning or rubber 
beautifying agent (Armor All) 58 prior to being placed within a third or 
final treatment tumbler 60. The dried chew toy bases 32 are removed from 
the drying rack 50 and placed into the final treatment tumbler 60 with the 
porous media having the flavoring and beautifying/conditioning agents 56 
and 58 applied thereto, and the final treatment tumbler 60 is rotated to 
bring the chew toy bases 32 into contact with the porous media 52 and 54 
to effect a transfer of the flavoring agent 56 and the beautifying agent 
58 to the chew toy bases 32. The porous media (sponges 52 and cloths 54) 
are preferably saturated with the flavoring agent 56 and the beautifying 
agent 58 prior to being placed within the final treatment tumbler 60. 
The beautified and flavored chew toy bases 32, when removed from the final 
treatment tumbler 60, are now suitable for sale as dog chew toys 20. They 
are then quality inspected, touched up if required, and placed in 
packaging 62 for shipment (FIG. 11). 
FIGS. 12-29 illustrate another preferred process for manufacturing dog chew 
toys of tire sidewalls. In so far as possible, the same reference numbers 
utilized in connection with the foregoing description will be maintained. 
It will be appreciated that aspects of the second preferred process to be 
described below may be utilized in connection with the first preferred 
form of the invention described above, and vice versa. 
FIGS. 12-14 illustrate a second die system that may be utilized to cut chew 
toy bases 32' from a cut tire sidewall 22. The second die system comprises 
a hand-held cutting die 64 that includes a die 38' attached to a backing 
plate 40, and a rod 66 that extends from the backing plate. A handle 68 
extends perpendicularly from the rod 66 to facilitate manually placing the 
backing plate-supported die 38' into a mechanical punch press 30. 
The cutting die 38' is, once again, preferably made of hardened steel rule 
material. The steel rule is bent to form a desired shape (illustrated in 
the shape of an airplane propeller). The steel rule is available in both 
straight edge (as shown) and serrated edge. The serrated edge offers 
better cutting performance. The cutting die 38' is then mounted on the 
backing plate 40 which gives the cutting die rigidity for added cutting 
performance and die longevity. 
As illustrated in FIG. 13, the hand-held cutting die 64 is placed within 
the mechanical punch press 30 so that the backing plate 40 is placed 
directly over the lower stationary platform 34. The cut tire sidewall 22 
is then placed over the die 38' prior to activating the press. When 
utilizing the hand-held cutting die 64, the hard plastic punch base 42 is 
fitted to the upper moving portion 36 of the punch press 30. Thus, when 
the mechanical punch press 30 is activated to displace the plastic punch 
base 42 downwardly, the upwardly facing die 38' causes a chew toy base 32' 
to be cut from the tire sidewall 22. The die 38' may then be removed from 
the punch press 30 and the stamped part (the chew toy base 32') may be 
removed from the die. Hand-held dies 64 are less expensive and are 
appropriate for lower production volume pieces. 
Referring to FIGS. 15, 16 and 26-29, some chew toy bases 32' require 
insertion apertures 70. By way of example, FIG. 26 illustrates three 
different chew toy bases that may be separately stamped from a cut tire 
sidewall 22 and then processed (either separately or together) and 
assembled to form a composite airplane-like dog chew toy 72. In 
particular, the airplane toy 72 may be assembled of the propeller chew toy 
base 32', an airplane wing base 74 and an airplane body base 76. The 
insertion apertures 70 in the propeller base 32' and the airplane body 76 
permit the various components of the airplane toy 72 to be assembled to 
one another as shown, generally, in FIG. 25. 
By way of further example, the composite dog chew toy that may be 
manufactured utilizing the processes of the present invention may take 
other forms, as illustrated in FIGS. 28 and 29. There a composite dog chew 
toy in the form of a dinosaur 78 is shown. The dinosaur toy 78 is 
manufactured of three separate chew toy bases, namely a body portion 80, a 
front leg portion 82 and a rear leg portion 84. Insertion apertures are 
provided in both the front and rear leg portions 82 and 84 to permit those 
portions to be assembled to the body portion 80. Additional apertures 86 
may be provided for aesthetic purposes. 
The insertion apertures 70 and the additional apertures 86 may be formed by 
simply punching the chew toy bases 32 utilizing a manual arbor press 88. 
As shown in FIGS. 15 and 16, the chew toy base 32' is placed on a 
supporting base 90, the arbor press 88 is aligned with the area to be 
stamped and then simply driven through the underlying portion of the chew 
toy base 32'. The removed portion 92 of the chew toy base 32' is discarded 
following the procedure. 
After the chew toy bases 32' have been cut from the tire sidewalls 22 and 
modified, if necessary, by cutting additional apertures 70 or 86, they are 
placed into a container 94 of bleach 96 and a detergent 98 and soaked for 
several house (FIG. 17). After soaking, the chew toy bases 32' are cleaned 
utilizing a cleaning brush 100 and by rinsing them with water 102. More 
specifically, with reference to FIGS. 18 and 19, the chew toy base 32' is 
placed on a yoke 104 and then inserted into a cleaning chamber 106. The 
yoke 104 comprises a rod 108 having a handle 110 at one end and a clamp 
112 at another. The clamp 112, which includes a pivoting handle 114, a 
stationary handle 116 and a linkage 118, is designed to securely hold the 
chew toy base 32' on the yoke 104 during the brushing and rinsing 
procedure. After the chew toy base 32' has been properly mounted onto the 
yoke 104, the portion of the yoke supporting the chew toy base 32' is 
inserted through an aperture 120 of an enclosure 122 that defines the 
cleaning chamber 106. The chew toy base 32' is brought into contact with a 
rotating polishing/cleaning brush 100 that serves to scrub, as it rotates, 
the exterior surfaces of the chew toy base 32'. A water conduit 124 
extends through the enclosure 122 to provide a spay of water 102 directly 
onto the brush chew toy base 32'. The enclosure 122 serves as a water 
reservoir 126 and, if desired, the water within the reservoir 126 may be 
recycled. 
Once cleaned, the chew toy base 32' is removed from the yoke 104 and placed 
on a drying rack 128. The drying rack 128 may have multiple levels and be 
provided with an air blower 130 to facilitate drying of the previously 
cleaned chew toy bases 32' (FIG. 20). 
The cleaned and dried chew toy bases 32' are then placed into a container 
132 filled with a solution 134 for conditioning the chew toy bases. The 
solution 134 preferably contains a conditioning or rubber beautifying 
agent such as Armor All or another similar silicone based rubber 
conditioning and/or beautifying agent and/or a flavoring and/or scenting 
agent (i.e., salt, animal fat, smoke flavor, liquid smoke, or other flavor 
variations and scents) (FIG. 21). The solution 134 conditions the rubber 
of the cleaned chew toy bases 32' by beautifying, scenting and/or 
flavoring the bases 32'. 
After the chew toy bases 32' have been allowed to soak in the conditioning 
solution 134, they are subsequently polished utilizing a polishing brush 
136 (FIG. 22). For some parts that have dirty white sidewalls after the 
initial cleaning process, a grinder 138 may be utilized to shave the dirty 
exterior layer sidewall off the chew toy base 32'. This grinding process 
produces a clean fresh layer of whitewall (FIG. 23). 
The processed chew toy base 32' is next screened using a highly sensitive 
metal detector 140 (such as the Goldmaster metal detector by Whites 
Electronics) to identify if there is any metal in the base 32' (FIG. 24). 
For composite or multiple part dog chew toys, such as the airplane toy 72 
and the dinosaur toy 78, the component parts are assembled utilizing a 
bench-mounted vise 142 that holds a part without the insertion aperture 
(for example, the airplane wing 74), while the other part with an 
insertion aperture 70 (the airplane body 76) is pulled onto the wing. 
The cleansed, conditioned and, if desired, assembled chew toy bases are now 
suitable for sale as dog chew toys 20. Once they are quality inspected and 
touched up if required, they are placed in packaging 62 for shipment (FIG. 
11). 
From the foregoing it will be appreciated that the process set forth herein 
for manufacturing dog chew toys of tire sidewalls, provides a means for 
economically utilizing used tires to fashion a commercially useful 
product. The process is easy to implement and utilizes abundantly 
available materials and tools. 
Although two particular embodiments of the invention have been described in 
detail for purposes of illustration, various modifications of each may be 
made without departing from the spirit and scope of the invention. 
Accordingly, the invention is not to be limited, except as by the appended 
claims.