Abstract:
A method of manufacturing an electrode probe for use on an animal receiver collar, includes the steps of: providing an electrode probe including a base and a tip, the tip extending from the base and having a contacting end; loading a compliant material and the contacting end together, such that a predetermined portion of the tip is embedded within the compliant material; and depositing an insulating material on at least a portion of the probe not embedded within the compliant material.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates to electrode probes for use on an animal receiver collar, and, more particularly, to electrode probes having an outer insulating covering.  
           [0003]    2. Description of the Related Art  
           [0004]    An animal behavior modification system, such as an electrical training system or containment system, typically includes a collar mounted receiver worn by the animal and a wireless transmitter. The transmitter transmits one or more different types of signals to the receiver unit which in turn applies an appropriate stimulus to the animal, such as a good tone-bad tone, electrical stimulation, vibration, citronella spray, etc.  
           [0005]    In the case of a receiver unit which applies an electrical stimulation to the animal, the receiver unit typically includes a pair of electrode probes which are threadingly engaged with threaded terminal posts extending from the receiver unit and through the collar. An electrical potential is applied between the electrode probes resulting in electrical current flowing through the skin of the animal to thereby apply the electrical stimulation to the animal. The particular electrical characteristics of the electrical stimulation which is applied to the animal may vary, depending upon the particular application and/or the signal received from the transmitter.  
           [0006]    Other operating or environmental parameters may also affect the correct application of the electrical stimulation to the skin of the animal. For example, if the animal is in water or the fur of the animal is wet, shunting of the electrical current between the electrode probes may occur, resulting in insufficient electrical stimulation being applied to the skin of the animal. U.S. Pat. No. 5,193,484 (Gonda) discloses that insulation may be applied to the lateral side surfaces of electrode probes to prevent electrical shunting therebetween in a wet environment. However, Gonda specifically teaches that although the lateral side surfaces may be insulated, a large portion of the contacting end must be exposed for the electrode probes to work properly.  
           [0007]    Notwithstanding assertions by Ghanda to the contrary, the inventors of the present invention have found that effective stimulation can be applied to the skin of the animal when only the very distal end of the electrode probe is exposed.  
           [0008]    What is needed in the art is a method of manufacturing an electrode probe in a fast and efficient manner, such that only the distal contacting end of the probe is exposed.  
         SUMMARY OF THE INVENTION  
         [0009]    The present invention provides a method of manufacturing an electrode probe for an animal collar, wherein the probe tip is partially embedded within a compliant material and an insulating material is powder coated on the non-embedded portion of the probe.  
           [0010]    The invention comprises, in one form thereof, a method of manufacturing an electrode probe for use on an animal receiver collar, including the steps of: providing an electrode probe including a base and a tip, the tip extending from the base and having a contacting end; loading a compliant material and the contacting end together, such that a predetermined portion of the tip is embedded within the compliant material; and depositing an insulating material on at least a portion of the probe not embedded within the compliant material.  
           [0011]    An advantage of the present invention is that the electrode probe may be formed with only the very distal end being exposed for contact with the skin of an animal.  
           [0012]    Another advantage is that the insulating material may be quickly and easily applied to the peripheral surfaces of the electrode probe.  
           [0013]    Yet another advantage is that the loading force between the electrode probe and the compliant material may be varied, depending upon the type of compliant material and configuration of the electrode probe tip.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]    The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:  
         [0015]    [0015]FIG. 1 is a plan view of an electrode probe shown with respect to a compliant material;  
         [0016]    [0016]FIG. 2 is another plan view showing the electrode probe tip partially embedded within the compliant material and an insulating material being applied to the peripheral surfaces of the electrode probe; and  
         [0017]    [0017]FIG. 3 is an enlarged fragmentary view of another embodiment of an electrode probe with which the method of the present invention may be carried out. 
     
    
       [0018]    Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0019]    Referring now to the drawings, there is shown an embodiment of an electrode probe  10  which is produced by a method of manufacture of the present invention. Electrode probe  10  generally includes a base  12  and a tip  14 . Probe  10  is used on an animal receiver collar, such as for remote training or confinement.  
         [0020]    Base  12  includes an axially extending, threaded opening (not shown) which screws onto a threaded terminal post extending from a receiver unit (not shown). Hex lands  16  allow probe  10  to be tightened onto the corresponding threaded terminal post of the receiver unit. Curved shoulder  18  defines the transition between hex lands  16  and tip  14 . Shoulder  18  may have a selected radius of curvature, depending upon the particular application.  
         [0021]    Tip  14  extends from shoulder  18  and includes a cylindrical post  20  and a contacting end  22 . End  20  is slightly rounded and includes a perimeter edge adjoining post  20 . Alternatively, contacting end  22  may be flattened, such as by using a grinding process, to provide a flat contact surface against the skin of the animal and thereby better distribute the pressure which is applied to the skin (FIG. 3). If contacting end  22  is flattened, a slight radius of curvature  24  is still provided between contacting end  22  and post  20  to prevent exertion of a line pressure against the skin of the animal.  
         [0022]    The height of hex lands  16  on base  12  may vary, depending upon the desired length of probe  10 . Curved shoulder  18  has a height of aproximently 0.075 inch. Tip  14  also has a diameter of between about 0.10 and 0.20 inch, preferably about 0.140 inch. Base  12  has a diameter of between about 0.20 and 0.40 inch, preferably having a diameter of less than or equal to about 0.275 inch. Tip  14  (including post  20  and contacting end  22 ) has a length of between about 0.075 and 0.40 inch, preferably having a length of about 0.10 inch.  
         [0023]    According to a method of manufacture of the present invention, probe  10  is brought into contact with a compliant material, as indicated by directional arrow  28 . Of course, compliant material  26  may be moved towards probe  10 , or compliant material  26  and probe  10  can be concurrently moved towards each other. Compliant material  26  and probe  10  are loaded against each other such that a predetermined portion of tip  14  at contacting end  22  is embedded within compliant material  26 . The embedded portion of contacting end  22  corresponds to the portion of tip  14  which will not be insulated, and thus acts as the contacting electrode with the skin of the animal. In the embodiment shown, contacting end  22  is embedded within compliant material  26  such that tip  14  has a non-insulated length at contacting end  22  of between about 0.010 and 0.050 inch, preferably about 0.030 inch. In effect, this means only the very distal end of contacting end  22  is exposed as an electrode for contacting the skin and issuing an electrical stimulation to the animal.  
         [0024]    In the embodiment shown, probe  10  is constructed from metal, such as stainless steel, and compliant material  26  is constructed from a material which allows contacting end of probe  10  to be embedded therein. Example of a compliant materials which may be utilized with the method of manufacture of the present invention include rubber, felt, foam, certain plastics, etc.  
         [0025]    With contacting end  22  of probe  10  embedded within compliant material  26 , an insulating material is deposited on at least a portion of probe  10  not embedded within compliant material  26 . Referring to FIG. 2, the insulating material is deposited on the remaining sides of probe  10  not embedded within compliant material  26 , except for the base end opposite tip  14 . The insulating material is a dielectric material which is applied to probe  10  using a deposition powder coating process. Depending upon the type of dielectric material and the type of material from which probe  10  is constructed, the particular parameters of the powder coating process may vary. Powder coating per se is known for other applications, and thus will not be described in more detail hereinafter with regard to temperatures, coating layer thickness, etc. Suffice it to say that in general, during the deposition powder coating process, a spray nozzle  30  deposits a powder coating onto the portion of probe  10  which is not embedded within compliant material  26 . Spray nozzle  30  and/or probe  10  may be rotated during the deposition powder coating process such that the entire peripheral side surfaces of probe  10  are coated with a predetermined thickness of the dielectric material. In the embodiment shown, the dielectric material may be a ceramic or polymeric material (e.g., polyester base, epoxy base or baked on enamel paint), although other dielectric materials may also be utilized.  
         [0026]    In the embodiment of the method of manufacture of the present invention described above, the insulating material is deposited onto the probe using a deposition powder coating process, as described above. However, it is also to be understood that the insulating material can be applied to the probe  10  embedded within compliant material  26  using other suitable deposition techniques, such as dipping, etc.  
         [0027]    While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.