Abstract:
A pet toy makes a sound when bitten or squeezed by an animal. The toy contains a resilient shell that substantially surrounds the sound-producing material. The toy also contains a core constructed of an elastic material located beneath the sound-producing material. The sound-producing material is a plastic material such as polyethylene terephthalate, which deforms when external pressure is applied to it, creating sound and vibration. In an embodiment of the invention, air permeates the sound-producing material, the core is hollow, and acoustic ports are located at each end of the toy, all to enhance its sound generating characteristics. In another embodiment, a strand is attached to or passes through the core of the pet toy. In another embodiment, an elastic outer sleeve is attached to the sound-producing material at various locations between their surfaces, to reposition the sound-producing material to its original orientation after an external pressure of force is released.

Description:
RELATED APPLICATION 
     This is a divisional application of co-pending U.S. patent application Ser. No. 13/667,882, filed on Nov. 2, 2012. 
    
    
     FIELD OF THE DISCLOSURE 
     The present invention is directed to a pet toy, and in particular, to resilient pet toys that create a crackling sound and/or generate a vibration, when a pet squeezes or bites down on the pet toy. 
     BACKGROUND OF THE DISCLOSURE 
     Chewable pet toys benefit pets—and, thus, their owners—in various ways. Chewable toys provide enjoyment and distraction for a pet and help to keep the pet occupied when the pet&#39;s owner is unavailable. Such toys also directly provide to pets mastication exercise as well as dental sanitation. Chewable pet toys which are compressible are known to enhance these benefits by incorporating an attractant such as pet treats or noise-makers therein. 
     One known construction of such a noise-making chewable toy incorporates one or more devices that emit sound when the pet chews on or otherwise squeezes the toy due to the passage of air through the devices. These devices, typically known as “squeakers,” are usually made of reeds or other similar devices that vibrate when air is passes through them, with the vibration emitting a sound the animal finds attractive. While squeakers are effective at producing sound, they are less effective at producing a vibration for the animal in response to its squeezing the toy. 
     One known construction of chewable pet toys includes elastic materials that enable the pet toy to be squeezed or bent in response to an animal&#39;s bite without the toy deforming or breaking. After the animal has finished chewing on the pet toy, it returns to its original shape. Such material is useful in pet toys, because it gives the animal a sensation of chewing, without destroying the pet toy. However, elastic materials are not known to make noise or create a vibration for the animal chewing a toy constructed of it. 
     Other materials used in chewable pet toys are not elastic, but rather exhibit plasticity. Such “plastic” materials do not readily break when external force is applied, nor are they elastic. Rather, plastic materials deform with external pressure such as a pet biting down on it. When such deformation occurs, it creates a “crackling” noise and vibration that is attractive to the animal. One such known plastic material is polyethylene terephthalate (PET), commonly used in constructing plastic soda bottles. 
     PET bottles are known to be used in association with pet toys. However, there are several concerns with its use. PET cannot withstand the piercing force of a dog bite, and will readily puncture and break, thus reducing the life of the toy and may further pose a hazard to the animal with exposed edges and shards of PET. It is also preferable to isolate direct exposure with PET from the dog due to potential chemicals in that plastic material. Furthermore, PET must be relatively thin in order to deform to cause the desired noise and vibration of a pet toy. Such thin PET can break if it is not supported by a solid material beneath it, or otherwise secured to a more durable material. While a sealed PET bottle may offer some support through its sealed air pressure, it is insufficient to withstand the repeated biting and chewing by a large dog. Particularly, the PET becomes less and less effective as a sound and vibration generator if it is permitted to migrate, over repeated bites, to a collapsed orientation, without repositioning it back to most of its original pre-bite shape. Further, a sealed PET bottle can be pierced by a strong-enough bite. 
     It would be desirable to provide a pet toy containing a plastic material component that deforms to creates a crackling noise and vibration, yet is protected from an animal&#39;s bite such that the plastic will not puncture or break. At the same time, it is desirable to provide a construction in which the PET is returned to its original orientation, before deformation by an animal&#39;s bite, to enhance repeated sound and vibration generation, in the environment of a dependable, yet safe and durable, pet chew toy. 
     SUMMARY OF THE INVENTION 
     The present invention comprises a sound-producing pet toy apparatus. In one embodiment, the sound-producing pet toy apparatus includes an elastic core having an outside surface, and a crackling member having an inside and an outside surface. The crackling member is positioned with the inside surface of the crackling member substantially adjacent to the outside surface of the elastic core. The sound-producing pet toy apparatus also includes a resilient outer shell member substantially encircling the crackling member and the elastic core, the shell having an inside and an outside surface, the inside surface of the shell being positioned about the outside surface of the crackling member in a first configuration. The apparatus has a second configuration in which at least a portion of the crackling member and elastic core are deformed by a force applied to the resilient outer shell, the crackling member producing at least one of a sound and a vibration upon deformation. Upon release of the applied force, the elastic core reshapes the apparatus toward its first configuration, the crackling member again producing at least some sound and/or vibration, as the elastic core, the crackling material and the shell substantially return to the first configuration. 
     In some preferred embodiments, the resilient outer shell is constructed an elastic material. 
     In some preferred embodiments, the shell and the core are constructed of the same elastic material. 
     In yet other preferred embodiments, air is disposed between the core and shell, adjacent to at least one of the inside and outside surfaces of the crackling member. 
     In some preferred embodiments, the crackling member comprises one or more layers of a sound-producing material. 
     In some preferred embodiments, the one or more layers of sound-producing material comprise polyethylene terephthalate (PET). 
     In some preferred embodiments, the crackling member comprises a sheet of sound-producing material overlapping itself. 
     In other preferred embodiments, the one or more layers of sound-producing material include textured portions to avoid nesting, to, in turn, promote greater sound and vibration. In these embodiments in which one layer of sound-producing material overlaps another layer of sound-producing material, the textured portions substantially space apart the layers of sound-producing material from each other. 
     In some preferred embodiments, the outer shell contains at least one acoustic port. 
     In some preferred embodiments, the core contains at least one acoustic port, the at least one acoustic port in the core being aligned with the at least one acoustic port in the shell. In some preferred embodiments, the shell includes two acoustic ports disposed at opposite ends of the shell. In some preferred embodiments, the core includes two acoustic ports disposed at opposite ends of the core, each of the acoustic ports in the core being aligned with one of the acoustic ports in the shell. In some preferred embodiments, the core includes an inside surface that extends between each of the acoustic ports at opposite ends of the core. 
     In some preferred embodiments, the sound-producing pet toy apparatus further includes a strand operably disposed at least partially within the core. In some of these embodiments, at least a portion of the strand includes one or more filaments of sound-producing material, such as PET, to further generate sound and vibration, upon deformation by a pet. 
     In the preferred embodiments, at least a portion of the crackling member plastically deforms to produce a sound when the shell is deformed. 
     The present invention also comprises a sound-producing pet toy apparatus including an outer shell constructed of an elastic material, the outer shell having an inner surface, and a crackling member constructed of a plastic material, the crackling member having an outer surface which is substantially, restrainably fixed relative to the inner surface of the elastic outer shell. Prior to being chewed by a pet, the outer shell and the crackling member are oriented relative to each other in a first configuration of the apparatus. At least a portion of the crackling member deforms and produces at least one of a sound and a vibration when at least a portion of the inner surface of the outer shell elastically deforms to a second configuration of the apparatus. At least a portion of the crackling member deforms and produces at least one of a sound and a vibration when the elastically deformed portion of the inner surface of the outer shell substantially returns to the first configuration, as prompted by the elasticity of the outer shell. 
     In some preferred embodiments, the sound-producing pet toy apparatus includes a durable, elastic core member positioned within the crackling member for facilitating the return of the crackling member to its first configuration. 
     In some preferred embodiments, the outer shell substantially encases the crackling member, the crackling member substantially restrainably affixed to the outer shell at a plurality of points between the outer surface of the crackling member and the inner surface of the outer shell. 
     In some preferred embodiments, the crackling member is restrainably attached to the outer shell by spot welds or intermittent adhesive attachments. 
     In some preferred embodiments, the crackling member is restrainably attached to the outer shell by one or more extended regions of lamination. In some of these embodiments, the crackling member is restrainably attached to the outer shell by lamination of the outer surface of the crackling member to the inner surface of the outer shell, wherein the lamination is achieved through adhesive or other affixation therebetween. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of the pet toy according to a preferred embodiment of the invention; 
         FIG. 2  is a side view of the pet toy according to the embodiment of  FIG. 1 , laying in a horizontal position. 
         FIG. 3  is an end view of the pet toy according to the embodiment of  FIG. 1 . 
         FIG. 4  is a cross sectional view of the pet toy according to the embodiment of  FIG. 1 , taken along lines  4 - 4  of  FIG. 2 , and looking in the direction of the arrows, showing the core, crackling, and shell layers of the pet toy. 
         FIG. 5  is a cross sectional view of the pet toy according to the embodiment of  FIG. 1 , taken along lines  5 - 5  of  FIG. 2 , and looking in the direction of the arrows, showing the core, crackling, and shell layers of the pet toy. 
         FIG. 6  is a perspective view of the shell layer of the pet toy, in phantom, according to another embodiment of the invention, showing the outer and inner surface of the shell layer. 
         FIG. 7  is a perspective view of the crackling layer of the pet toy according to the embodiment of  FIG. 6 . 
         FIG. 8  is a perspective view of the core layer and strand of the pet toy according to the embodiment of  FIG. 6 , showing the outer and inner surface of the core layer. 
         FIG. 9  is a cross section of the pet toy according to the embodiment of  FIGS. 6 and 8 . 
         FIG. 10  is a cross sectional view of the pet toy, similar to the view of  FIG. 4 , in another embodiment of the invention that includes an elastic shell and a crackling member, with or without the core member shown in phantom. 
         FIG. 11  is a cross sectional view of the pet toy, similar to the view of  FIG. 5 , in another embodiment of the invention, wherein the shell is constructed of a resilient but inelastic material such as a woven fabric. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While this invention is capable of embodiment in many different forms, there is shown and described in the drawings and associated text, specific embodiments, with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments illustrated. 
     The following description and drawings are illustrative and are not to be construed as limiting. Numerous specific details are described herein to provide a thorough understanding of the disclosure. However, in certain instances, well-known or conventional details may not be described in order to avoid obscuring the description. References to one, or an, embodiment in the present disclosure can be, but not necessarily are, references to the same embodiment; and, such references mean at least one of the embodiments. 
     Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments, but not for other embodiments. 
     The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. Certain terms that are used to describe the disclosure are discussed below, or elsewhere in the specification, to provide additional guidance to the practitioner regarding the description of the disclosure. 
     It will be appreciated that same thing can be said in more than one way. Consequently, alternative language and synonyms may be used for any one or more of the terms discussed herein, nor is any special significance to be placed upon whether or not a term is elaborated or discussed herein. Synonyms for certain terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification, including examples of any terms discussed herein, is illustrative only, and in no way limits the scope and meaning of the disclosure or of any exemplified term. Likewise, the disclosure is not limited to various embodiments given in this specification. 
     For purposes of this detailed description, it is envisioned that in one example of use of the invention, a dog will be holding the pet toy in its mouth, and press down on the shell layer of the toy with its teeth. During this process, the dog would bite down on the pet toy, which would then produce a crackling noise in addition to a vibration felt by the dog, to provide both audible and/or tactile feedback to the dog. This description is not meant to limit the scope of the claims, but rather to describe one embodiment of the invention. 
     Pet toy  20 , as shown in  FIGS. 1-5 , comprises core  22 , crackling member or layer  24  and shell  26 . Pet toy  20  may take the form of many different shapes. The embodiment shown in  FIGS. 1-5  is in the shape of a bone. 
     In a preferred embodiment as shown in  FIG. 4 , core  22  has a generally cylindrical, hollow tube shape between first end  40  and second end  42 , defining generally cylindrical outside surface  44  and generally cylindrical inside surface  46 . In some embodiments, outside surface  44  and inside surface  46  are substantially continuous. It should be understood that, according to the principles of the present disclosure, core  22  can have a variety of configurations. While core  22  is shown as hollow in  FIG. 4 , in one particular embodiment, core  22  need not be hollow. Core  22  is constructed of a durable material that may also be resilient such as thermoplastic elastomer, silicone, fluorosilicone, polyethylene or a similar elastic material, and may be molded in one or more parts. Core  22  may also be constructed of materials having varying degrees of deformability. 
     Crackling member or layer  24  comprises one or more substantially flat sheets of plastic material that are rolled, or otherwise situated, about outside surface  44  of core  22 . In should be understood that the cross-sectional view of crackling layer  24  shown in  FIG. 4 , and the similar view of crackling layer  24 ″ in the alternative embodiment illustrated in  FIG. 10 , are each illustrated with the crackling layer having a single, relatively thick layer, to exemplify the structure and configuration of the respective embodiments of the pet toy according to the principles of the present disclosure, and that these exemplary illustrations of these crackling layers are examples of the variety of configurations of crackling layers according to the principles of the present disclosure, which variety also includes the layered configuration illustrated in  FIG. 5 . Alternatively, in other embodiments, such as shown in  FIG. 7 , crackling layer  24 ′ can be formed of textured, ridged, or undulating sound-emitting plastic material. Crackling layer  24  is constructed of one or more layers of a sound-producing material that exhibits plasticity, such that the material will deform when external pressure is applied. One example of such material is polyethylene terephthalate (PET). PET is commonly used as a material for disposable plastic soda bottles. Among its other properties, PET is “plastic,” meaning it will deform when external pressure is applied. When PET is deformed, a crackling sound is made, and a vibration is generated that can be sensed by the animal applying the force that caused the deformation. The PET or other suitable material may be deformed repeatedly, each time generating the desired sound and vibration. Crackling layer  24  may contain one or more layers of PET or other suitable material, that may be wrapped around core  22 . 
     In another preferred embodiment of the invention as shown in  FIG. 5 , the area of the sheet of plastic material used in crackling layer  24  exceeds that of outside surface  44 , such that crackling layer  24  may wrap around itself, outside surface  44 , more than one time. Crackling layer  24  comprises inside surface  50  that may come into contact with outside surface  44  of core  22 , and outside surface  52  that may come into contact with inside surface  64  of shell  26 . 
     Shell  26  substantially encases crackling layer  24 , and is shown in  FIGS. 1-5 . It should be understood that a pet toy according to the principles of the present invention may include additional layers within shell  26 . For example, a toy according to the principles of the present disclosure with the construction illustrated in  FIGS. 1-4  could include additional crackling layers, and other intermediate layers therebetween, to provide a larger toy as well as varying or enhanced sounds and vibrations. 
     Shell  26 , as shown in  FIG. 4 , comprises a first end  60 , second end  62 , an inside surface  64  and an outside surface  66 . Inside surface  64  is shaped in a generally cylindrical manner, mirroring the tube shape of outside surface  44  of core  22 , although with a larger diameter and length, to enable crackling layer  24  and core  22  to substantially fit inside shell  26 . As shown in the preferred embodiment of  FIG. 1 , shell  26  may also comprise additional texture elements, such as ring  27 , located along outside surface  44 . Other rings or ridges  70 ,  71  and  72 , and protrusions  73 ,  74  and  75  can be utilized to stimulate the dog&#39;s gums. 
     Shell  26  may further comprise one or more bone-shaped extremities  68  located at first end  60  and/or second end  62 . Extremities  68  may be arranged in an offset configuration, as illustrated in  FIGS. 1-5 , and may act to keep the remainder of shell  26  from touching the ground, and to inhibit fluids such as dog drool from entering acoustic port  28 , located at first end  60  and/or second end  62 . It should be understood that, a pet toy according to the principles of the present disclosure can have a variety of configurations, including multiple bone-shaped (or otherwise shaped) extremities being aligned or in a coplanar arrangement. 
     Suitable materials of construction for shell  26  include thermoplastic elastomer, silicone, fluorosilicone, polyethylene, or a similar durable and elastically deformable material, that may be molded into one or more parts. Core  22  may be constructed of the same material as shell  26 . When paired with a core component comprising an elastic material, suitable materials of construction of shell  26  also include rope material, woven fabrics, or other durable materials. Indeed, as illustrated in the alternative embodiment of  FIG. 11 , pet toy  20 ′″, shell  26 ′″comprises a different, relatively thinner material than core  22 ′″—such as a woven fabric. 
     Referring again to  FIGS. 1-5 , when external force or pressure, such as that which is expected from a dog&#39;s bite, is applied to pet toy  20  in its initial or first unbitten orientation or configuration while under no force, this bite force comes into contact with outside surface  66  of shell  26 . Resilient shell  26  then dissipates and transfers the force of a piercing bite, such that the bite will not puncture shell  26  or crackling layer  24 . The force of the bite will cause pet toy  20  to have a second orientation or configuration in which inside surface  64  of shell  26  to presses down on outside surface  52  of crackling layer  24 , which in turn causes inside surface  50  of crackling layer  24  to press down on outside surface  44  of core  22 . The force on outside surface  44  of core  22  is, at least in part, returned to inside surface  50  of crackling layer  24 , thus focusing the force from the dog&#39;s bite on crackling layer  24 . The force of the dog&#39;s bite acts to deform a portion of crackling layer  24 , and creates the desired crackling sound and vibration. Shell  26  and core  22  are sufficiently durable to withstand the pressure of a dog&#39;s bite and will transfer at least a portion of the force of the dog&#39;s bite to the crackling layer  24 , rather than absorb all such force. Furthermore, shell  26  acts to prevent a dog&#39;s bite from directly contacting crackling layer  24 , which may cause one or more layers of PET in crackling layer  24  to break, or leech PET chemicals to the dog&#39;s teeth, gums or tongue. Finally, when the bite force is released, as at least one of core  22  and shell  26  is constructed of an elastic material, the memory return functionality of the one or more elastic components operates to return pet toy  20  to the first orientation or configuration. In the return action, the crackling layer  24  again deforms as it returns to the majority of its original orientation to produce yet additional crackling sound and/or vibration. 
     In the preferred embodiment of the invention as shown in  FIGS. 4 and 5 , there is air in between core  22  and shell  26 . It is believed that air assists in transmitting the sound generated by crackling layer  24 . For this reason, additional space between core  22  and shell  26  is provided, to allow air to permeate crackling layer  24 . It should be understood that, in alternative embodiments of a pet toy according to the principles of the present disclosure, the core and shell components may be coupled to each other so as to prevent or inhibit the passage of air therebetween, and that pet toy may be configured without air between those components. 
     In a preferred embodiment of the invention as shown in  FIGS. 4 and 5 , core  22  has inside surface  46 , and is thus substantially hollow. It is believed that a substantially hollow core  22  also assists in transmitting the noise generated by the deformations in crackling layer  24 . In addition, when core  22  is substantially hollow, shell  26  may further comprise one or more acoustic ports  28 . Acoustic port  28  comprises at least one hole in shell  26  and/or core  22 , that also allows sound to travel from crackling layer  24  where it is generated, to the outside where it may be heard, and is shown in particular in  FIGS. 3 and 4 . While acoustic port  28  is shown in combination with a substantially hollow core  22 , it may also be utilized with a solid core  22  in another embodiment of the invention. It is believed that acoustic port  28  enhances the sound produced by crackling layer  24 , such that it generates even more sound and vibration. While acoustic ports  28  may be located anywhere on shell  26  and core  22 , in a preferred embodiment acoustic ports  28  are located at either end of shell  26 . 
     In an alternative embodiment of the invention as shown in  FIG. 6 , shell  26 ′ is in the shape of a small barbell with varying thicknesses along the length of shell  26 ′. In this embodiment, extremities  68 ′ are in the shape of small barbell ends, and, as set forth above with regard to extremities  68 , similarly act to prevent most of shell  26 ′ from touching the ground, and inhibit the flow of any dog drool from entering acoustic port  28 ′. 
     In an embodiment of the invention as shown in particular in  FIG. 7 , the one or more layers of sound-producing PET material of the crackling member or layer  24 ′ are textured, such that when force is applied to deform the sound-producing material, the material may deform in multiple locations among the material, enhancing the noise and vibrations made in the deformation, and enhancing the life of the sound-producing material by allowing for additional places for new deformations in the material, with repeated use. In addition, the textured portions of the sound-producing material of crackling member or layer  24 ′ are less likely to lie flat against one another, as the textured portions space apart the layers of material, and thus assist in enabling air to permeate within crackling layer  24 ′. 
     In an embodiment, as shown in  FIG. 8 , core  22 ′ may be constructed to include a portion of shell  26 ′ in one piece. It should be understood that, in this and other alternative embodiments of a pet toy according to the principles of the present disclosure, the core and shell components may be sealed to one another so as to prevent or inhibit the passage of air therebetween. Furthermore, the pet toy may include strand  30 ′, located at least partially inside core  22 ′. In an embodiment of the invention as shown in particular in  FIGS. 8 and 9 , strand  30 ′ comprises a length of flexible material, which could include one or more filaments of PET or other sound-producing material  32 ′, which passes through and/or attaches to inside surface  46 ′ of core  22 ′. Strand  30 ′ may be used by a person or a dog to pick up, carry or throw a pet toy according to the principles of the present disclosure without touching shell  26 ′, and may also be visually attractive. Suitable materials for strand  30 ′ include, among others, ribbon, cord, rope, or canvas. 
     In another alternative embodiment as shown in  FIG. 10 , a pet toy  20 ″ includes an elastic shell  26 ″ and plastic crackling member  24 ″, with or without a core member  22 ″, illustrated in phantom in  FIG. 10 . Crackling member  24 ″ is fixed relative to elastic shell  26 ″ at attachment points  80 ″, or attachment regions  82 ″,  83 ″ and  84 ″—which can be comprised of one of variety of conventional adhesive attachment points or welds, that may be tacked or tack welded. Alternatively, the PET can be laminated by adhesive or welded to elastic shell  26 ″, by extending attachment regions  82 ″,  83 ″ and/or  84 ″ over a larger region of the surfaces between shell  26 ″ and crackling member  24 ″. According to the principles of the present invention, when elastic shell  26 ″ deforms from a first configuration, under no force—to a second, deformed configuration upon biting, crackling member  24 ″ deforms to produce a sound and/or a vibration. When elastic shell  26 ″ substantially returns to the first configuration after the biting force is removed, elastic shell  26 ″ prompts the shape of crackling member  24 ″ to substantially its original shape as a result of the affixation of crackling member  24 ″ to elastic shell  26 ″. At that time, yet additional crackling sound and/or vibration may be generated. 
     In another embodiment of the invention, a resilient and/or elastic core member can likewise be positioned within the layer of crackling material to enhance the return of the crackling material back to its pre-bite position—while generating yet further sound and/or tactile vibration. 
     The foregoing description and drawings merely explain and illustrate the invention, and the invention is not limited thereto, except as those skilled in the art who have the present disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention.