Abstract:
A toy for people or animals, especially for dogs, is provided. The disc-shaped or component ring toy has a body having optional recesses on an outer surface thereof. The body comprises a ring core of a first, hard polymeric material, and a covering of a second, soft polymeric thermosetting material, natural rubber, or mixture of a thermosetting and non-thermosetting material which may be frictionally connected, thermally and chemically bonded, or otherwise mechanically interconnected to the first polymeric material.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims the priority of German application 10152070.0 filed Oct. 25, 2001 and is a continuation-in-part of abandoned application Ser. No. 10/213,870 filed Aug. 6, 2002 and pending application Ser. No. 10/858,220 filed Jun. 1, 2004. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     Chew toys for animals, especially dogs, are well-known in the art. Toys comprised of elastic polymers and/or having recesses and grooves such as those disclosed in U.S. Pat. No. 4,802,444 and U.S. Reissue Pat. 34,352, are also well-known. Further, a simple disc-shaped toy for animals is well-known in the art, as disclosed in U.S. Pat. Nos. 3,359,679; 4,132,030; 4,196,540; 4,204,357; 4,456,265; 4,737,128; 4,889,347; 4,919,083; 4,955,842; 5,676,581; 5,934,966; 5,984,753; and 6,672,253. Other chew toy shapes are known in the art, such as rope toys having loops at opposing ends to a knotted center. Such toys serve not only for keeping the animal busy and entertained, but also are used for caring for the animal&#39;s teeth. Therefore, for hygienic reasons, it is desirable for the animal to occupy itself frequently with the toy.  
         [0003]     Additionally, it is well-known that animals which are stimulated and occupy themselves by playing with toys are often better behaved and pose less of a nuisance through typical “boredom” behaviors, such as barking, trying to escape yards or homes, and chewing on undesirable items such as shoes. Therefore, there is a deep-seated need to provide toys to animals to improve their hygiene and behavior.  
         [0004]     Further, flying disc toys are well-known in the art for human use as well, showing different design elements including animal appendages, display screens, collapsible designs, extra-lift producing designs, such as those shown in U.S. Pat. Nos. 6,860,783; 6,695,666; 6,599,162; 6,595,823; 6,585,552; 6,390,879; 6,200,185; 5,816,879; 5,611,720; 5,348,509; 5,261,846; 5,032,098; 4,869,699; 4,915,661; 4,290,226; 4,212,131; 4,183,168; 449,082; D387,817; D346,626; D345,586; D295,429; and D293698.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0005]     This object, and other objects and advantages of the present invention, will appear more clearly from the following specification in conjunction with the accompanying schematic drawings, in which:  
         [0006]      FIG. 1  is a partially cross-sectioned end view of one exemplary embodiment of the inventive toy for animals;  
         [0007]      FIG. 2  is an end cross-sectional view through the toy of  FIG. 1  depicting the cross-section of side wall  16  enclosing solid core ring  18 , particularly cross-sectional configuration  20  of core ring  18 ;  
         [0008]      FIG. 3  is an end cross-sectional view through the toy of  FIG. 1  depicting the cross-section of side wall  16  enclosing hollow core ring  18  having outer section  22  and interior space  24 ;  
         [0009]      FIG. 4  is a longitudinal cross-section view through side wall  16 , particularly depicting covering  18  circumferentially disposed within wall  16 ;  
         [0010]      FIGS. 5   a  &amp;  5   b  are an embodiment utilizing surface grooves  25  and ridges  29  as indentation/extension combinations for hygienic purposes; and  
         [0011]      FIGS. 6, 6   a,    6   b  are a partially cross-sectioned view and partial views of an additional embodiment of the invention, showing a version similar in overall shape to a typical rope toy, but utilizing the more durable materials of the invention and the inventive connections between the materials.  
     
    
     SUMMARY OF THE INVENTION  
       [0012]     The toy of the present invention is characterized primarily in that it comprises at least one core ring of a hard polymeric, preferably thermoplastic material with a covering of a soft polymeric material, especially a rubber-like or rubber-feeling, elastic polymeric material. The toy of the present invention is also characterized by use of a thermosetting material, natural rubber, or mixture of thermosetting and non-thermosetting materials as the soft polymeric material. Further, the harder core may be hollow which may be helpful to prevent damage to the toy. Finally, the utilization of the softer thermosetting polymer material with a hard core provides a better compression dynamic than prior art toys, thereby providing a toy that is more stimulating to the animal.  
         [0013]     As a consequence of the inventive configuration of the toy, an animal utilizing the toy has the chewing sensation of a bone that is covered with meat, whereby the core can be hollow in order to imitate a hollow marrow-filled bone, and possibly, as an optional benefit, to hold treats, and more preferably, acoustical or optical effects, etc. A scented and/or flavored insert to stimulate an animal to play with the toy would also be possible. The toy thus on the one hand has a shape that is comfortable and stimulating for the animal and on the other hand is easy to manufacture, as described herein.  
         [0014]     When a toy is utilized by a person, with or without an animal, the inventive hard ring and soft covering give a comfortably soft yet firm grip. This improved gripping can improve both throwing catching. Further, the softer outer surface provides cushioning which may lessen injury when one is inadvertently struck by the disc.  
         [0015]     The material of the covering is a thermosetting material, natural rubber, or a mixture of a thermosetting material and a non-thermosetting material such as natural rubber. The outside surface of the core ring is formed or revised mechanically after forming to provide a rough surface texture. The covering material is then formed around the ring without it being necessary to dispose an additional layer of a binder, an adhesive or the like between the core ring and the covering. Alternatively, some mechanical interconnection can be used, for example via undercuts and/or over-molding, or thermally achieved chemical interconnection between the hard plastic core and the outer rubber-like coating may be used.  
         [0016]     The harder material of the core may be a thermoplastic that is particularly suitable for forming this chemical bond. Such materials include but are not limited to a polyamide (PA) or a modified polyphenylene ether (PPE). With such a combination of materials, it is possible to provide the animal with a chewing sensation of a bone that is covered with meat, but one which is more durable and stable against external forces that tend to attack and destroy it. Further, it is easy to manufacture.  
         [0017]     The hard core ring, which is preferably fixedly connected with the covering through the mechanical bond between the thermosetting material and the roughened surface of the thermoplastic material (or other suitable materials) improves the durability and stability of the toy. Unlike prior art hard or soft disc toys, the combination of the hard core with the elastic covering ensures that the toy jumps or rebounds well when it falls upon a hard surface, and thus enables an entertaining and exciting toy for the animal. Further, the use of the softer covering and harder core make it easier for an animal to pick up the disc—a formerly frustrating endeavor for an animal engaged in disc play.  
         [0018]     In an alternate embodiment with a hollow internal structure of the core ring, it is possible to dispose therein an electronic device that produces musical tones, acoustical effects, or light effects, and/or releases scents or flavors, thus exerting a particular fascination for the animal or person. The electronic device can be embodied in such a way that it produces different effects depending upon how the animal or person manipulates the toy.  
         [0019]     Further specific features of the present invention will be described in detail subsequently.  
         [0020]     It is an object of the present invention to improve the toy of the aforementioned general type such that it is particularly interesting to an animal and stimulates the animal to occupy itself with the toy  
       DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0021]     Referring now to the drawings in detail, an embodiment of the toy of the invention is shown in  FIG. 1 . Toy  10  in the first embodiment is shown as having a primarily disc-shaped configuration, formed from covering  11  and core ring  18 .  
         [0022]     Disc shape toy  10  is round in circumference (as shown in  FIG. 1 ), having a convex upper surface  12  that functions as an air foil, and a concave underside  13  surrounded by a circumferential rim/side wall  16 , that provides gyroscopic action as the disc is tossed through the air with a backspin. Upper surface  12 , concave underside  13 , and side wall  16  are composed of covering material  11 . Core ring  18  is disposed within rim  16 , preferably extending the entire circumference of rim  16 , as shown in  FIGS. 1-3 . Core ring  18  preferably has a cross-sectional diameter, x (as shown in  FIG. 2 ) much smaller than its ring diameter, y (as shown in  FIG. 4 ). However, it is envisioned that the core ring may have larger cross-sectional diameters than pictured, especially when utilizing optional electronic devices.  
         [0023]     As shown in  FIG. 2 , core ring  18  may comprise a solid thermoplastic material in any suitable cross-sectional configuration  20 , including, but not limited to rectangular, circular, oval, square, and any known polygonal shape. As shown in  FIG. 3 , core ring  18  of toy  10  may also comprise a hollow ring formed of thermoplastic material in any suitable cross-sectional configuration  20 , including, but not limited to rectangular, circular, oval, square, or any known polygonal shape, having outer section  22  and interior space  24 .  
         [0024]     Alternate embodiments, as shown in  FIGS. 5   a  and  5   b,  may utilize peripherally extending grooves, dimples, and/or bumps or other similar indentation/extension combinations known in the art. When the toy is in use for an animal, for example a dog, which plays with the inventive toy, the teeth of the animal penetrate or enter into grooves  25  when the animal grasps toy  10  with its mouth. The animal&#39;s teeth and/or gums beneficially rub against interior walls  27  of the grooves  25  or against upper surfaces  29  of ridges  31 . In so doing, the teeth and/or gums are cleaned of food residue, coatings on the teeth, etc. Further, such indention/extension combinations can provide a gripping surface, thereby improving a person&#39;s throwing and catching ability with the disc.  
         [0025]     In preferred embodiments of the invention, toy  10  has core ring  18  and sheathing or covering  11 , wherein the core and the covering preferentially comprise different materials, as shown in  FIGS. 1-3 . Covering  11  is comprised of a natural rubber, thermosetting polymeric material, or mixture of a thermosetting material and a non-thermosetting material which is softer than core ring  18 , and preferably having elastic, rubber-like qualities.  
         [0026]     Preferably, covering  11  comprises either an unmixed composition of a particular thermosetting material or a composition having a mixture of materials including at least one thermosetting material known in the art, such as but not limited to natural rubber (NR), styrene-butadiene rubber (SBR), isoprene rubber (IR), ethylene propylene diene terpolymer rubber (EPDM), nitrile terpolymer rubber (NBR), hydrogenated nitrile terpolymer rubber (HNBR), carboxylated nitrile terpolymer rubber (XNBR), polyurethane (PU), fluorocarbon rubber (FPM), flurosilicone rubber (MVQ), and/or modified flurorosilicone rubber (FMVQ).  
         [0027]     More preferably, natural rubber (NR), isoprene rubber (IR) and/or styrene-butadiene rubber (SBR) are utilized in their unmixed form or in a mixture with other thermosetting materials and/or other polymeric materials as the covering of the present invention. Other thermosetting materials, including but not limited to those listed above may also be utilized in their unmixed form or in mixtures with other thermosetting materials and/or other polymeric materials as well.  
         [0028]     Preferably, the material of covering  11  will have a hardness between approximately 20 and approximately 80 Shore A [DIN 53505 and ASTM 22140]. More preferably, the hardness will be between approximately 30 and approximately 70 Shore A. Most preferably, the hardness will be between approximately 35 and approximately 65 Shore A.  
         [0029]     Use of thermosetting materials provide a surprisingly useful advantage in that the materials of the covering may be chemically bonded by a thermally derived bond to the material of the core, thereby providing a fixed, stable combination of covering and core which need not utilize less stable mechanical interconnections to arrive at the combination, or worse, utilize potentially unstable and sometimes hazardous binders to arrive at such a connection. Thermosetting materials are particularly useful in providing a thermally derived chemical bond since a thermosetting polymer “sets” upon heating and cannot be re-melted, unlike thermoplastics known in the art which may be softened again if the toy becomes heated. This, in turn, would make connections of a thermoplastic less stable and less durable than the connections of the thermosetting material of the present invention.  
         [0030]     Further, the use of the thermosetting cover to chemically bond to the core provides additional versatility in designs and other structure for the toys. In prior art devices, mechanical interconnections and/or use of binders (which are typically dark in color, most usually black) prevented flexibility in design elements. For example the apparatus of the present invention can have different colors for the core and for the covering where in prior art mechanical devices, the interconnection would, in most cases, have been visible given the necessary protrusion of one element into another to provide the interconnection. In the prior art devices utilizing binders, the unsightly binder between layers would prevent any ornamentation-oriented showing of an inner layer because of concurrent display of the unsightly binder. In the present invention however, ornamental cuts or partial covering of the inner layer (the core—or additional colored layers of core or covering) can be achieved without display of unsightly mechanical interconnections or binders.  
         [0031]     Further, use of the thermosetting bond to a hollow core is beneficial in allowing the manufacturer to utilize less material than in preparing a solid core toy and also reduces the amount of cure time necessary for the core to set. Therefore, the use of a hollow core is also more cost- and time-effective to a manufacturer.  
         [0032]     Core ring  18  comprises a material that is necessarily harder than the material of covering  11 . Preferably, the core material comprises a thermoplastic such as, but not limited to polyamide (PA), polyphenylene ether (PPE), polypropylene (PP), polystyrene (PS), acrylonitrile-butadine-styrene (ABS), acetal polyoxymethene (POM), polycarbonate (PC), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyvinyl chloride (PVC) and modifications thereof, wherein such resins preferably have a melting point of approximately 400° F. or greater. Most preferably, the core material comprises a thermoplastic such as a PA or modified PPE. Thermosetting materials and mixtures of thermoplastics and thermosetting materials with an appropriate hardness (greater than the hardness of the covering) may be utilized. However, other materials known in the industry and/or thermoplastics or thermosetting materials with a hardness of preferably at least 50 on the Shore D scale and a tensile strength of at least 100 N/mm 2  may also be utilized. More preferably, the core material will have a hardness of between approximately 55 and approximately 90 on the Shore D scale and a tensile strength of at least 1500 N/m 2 , and preferably, at least 2700 N/m 2 .  
         [0033]     If a chemical bond is utilized, it is achieved in a two component injection molding system with a one-step integral operation wherein the hard thermoplastic component is first molded and then the soft thermosetting component is injection molded around (or partially around) the thermoplastic core, but may be alternately done in a two-step process, utilizing typical injection molding and curing techniques for thermosetting and thermoplastic materials, respective of the type of thermosetting materials used, as is well-known in the art for each material. However, another preferred method of connection between the ring and the covering requires either forming (for example, press molding) the ring to have a roughened surface  38 , as shown in  FIGS. 2 and 6  or, alternatively, mechanically roughening the surface after forming the ring, for example, by sanding the surface with a rough grit sander. The covering material is then formed around the ring and as a result, enters into the indentations and around the extrusions formed by mechanically roughening or molding the surface to be rough. Friction holds the two surfaces, hard and soft, together.  
         [0034]     Core ring  18  is optionally hollow, having an outer wall  22  and an interior space  24  as is depicted in  FIG. 3 . In particular, core ring  18  of the embodiment as shown in  FIG. 3  comprises a cylindrical tube with relatively thick walls wherein the end faces of the core may be left open. Thus, the toy, while disc-shaped, has the sensation off a hollow, marrow bone that is covered with soft meat for an animal. The use of a hollow or latticed embodiment is a great improvement over all configuration prior art toys comprising multiple hardness layers since the harder, hollow core allows the toy to deform and return to its prior non-depressed state with greater ease and less chance of breakage or permanent deformation.  
         [0035]     The inventive toy has somewhat surprising superiority in bounce over prior art toys with the hollow thermoplastic core/thermosetting covering combination of the present invention. Hard prior art toys (such as solid polyamide discs) have very little bounce because of lack of compression/deformation in the material. On the other hand, soft prior art toys, such as non-reinforced rubber or cloth discs deform too greatly, such that most of the kinetic energy introduced by a fall is lost as heat. The amount of bounce, or the “work” performed is calculated by the force (for example, from a fall or drop) which is force is converted into potential energy in the resulting deformation of the toy and which is then released again as kinetic energy plus energy lost as heat.  
         [0036]     Work, W, is calculated as 
        W=F×D def          
 
         [0038]     Wherein F=force, 
        D def =distance of deformation in the toy. 
 
 In the hard prior art toys, there is little work or bounce which comprises the work since there can be little deformation of the toy. In the soft prior art toys, while there was great potential for increased work as a bounce, there was also a great loss of energy as heat. With the present art invention, it is believed that the resilience offered by the strengthening of the toy with its hard core provides sufficient resilience to prevent the major loss of energy found with prior art toys and that the soft covering provides the necessary deformation to provide the desired work in the form of a bounce. And, particularly with the embodiments utilizing ridges, the ridges act somewhat in the manner of a spring to store the potential energy (by their deformation) and release them and recoil (conversion to kinetic energy) given the resilience of the core. 
       
 
         [0040]     In conjunction with  FIG. 3 , an embodiment of the inventive toy may be utilized that is provided with an additional unit in the form of electronic device that sends out acoustical or optical signals, and thus provides an additional attraction or fascination for the animal to encourage it to play with the toy. The electronic device can, for example, be provided with a light emitting diode that is supplied from a small battery and constantly blinks. However, in an alternate embodiment, the electronic device can also be provided with sensors that establish if the animal is manipulating the toy and possibly with what effort, and in conformity therewith can emit signals, such as musical notes and noises. Such sensors can, for example, react to pressure, shaking, or during throwing and/or striking of the toy on the ground. It is possible, but not necessary, that such electronic devices are replaceable component units wherein, for instance, electronic devices whose battery has been depleted through play may be removed from the inventive toy and replaced with a new electronic unit.  
         [0041]     The electronic device is preferably disposed within a pressure-tight capsule or shell that is sealed against moisture as described in related U.S. patent application Ser. No. 10/888,220, filed Jun. 1, 2004, and that is inserted into a tubular ring core.  
         [0042]     The embodiments described herein can also be provided with optional grooves on at least part of the surface of the covering  11 . These optional grooves can be in the form of shallow grooves or ribs.  
         [0043]     An embodiment as shown in  FIG. 4 , can also have a dispensing/holding hole  32 , preferably at one location only. Treats for animals can be inserted into the hollow interior of the toy through this hole  32 . Flaps or retaining elements  34  can also be provided on the covering  11 , and can project into the area of the hole  32 , to hold treats and to prevent them from being released too easily. To provide an emergency breathing passage in the event that the toy gets stuck in the throat of an animal, and blocks its natural breathing process, another portion of the covering  11 , such as the opposite end of the toy, can optionally be provided with a small ventilation hole  36  which is not intended to hold treats.  
         [0044]     It is understood that similar effects could be achieved by using multiple ring-shaped cores stacked above one another for a deeper disk. Alternatively, another embodiment of the invention as depicted in  FIG. 6  shows multiple ring cores  18   a,b  with covering  11  disposed thereon and joined by an interior panel  40 . Interior panel  40  preferably comprises the same categories of materials used for covering  11 . However, it should be noted that the covering and panel need not comprise exactly the same materials for any particular embodiment of the invention. Alternately, panel  40  may comprise a material such as those disclosed for core ring  18  supra. Interior panel  40  joins rings  18   a,b  preferably by enclosing rings  18   a,b  within the material of panel  40  by utilizing the methods of molding or mechanical interconnection described for enclosing ring  18  within covering  11  as disclosed above. However, any other suitable mechanical interconnection of the rings with a central portion  40  may be utilized. Further, it should be understood that central portion  40  need not utilize a flat panel shape as depicted in  FIG. 6 , but could include other shapes known in the art, for example spheres or other three-dimensional shapes. Additionally, surface protrusions or indentations may also cover the at least a portion of the surface of central joining portion  40 . Further, it should be understood that additional embodiments of the invention are anticipated and claimed herein in that additional rings and joining portions can be utilized to extend the toy. Core rings  18   a,b  are disposed within loops  38   a,b,  preferably extending the entire circumference of loops  38   a,b,  as shown in  FIG. 6 . Core rings  18   a,b  preferably have cross-sectional diameter, x (as shown in  FIG. 6   a ) much smaller than their ring diameter, y (as shown in  FIG. 6   a ). However, it is envisioned that the core rings may have larger cross-sectional diameters than pictured, especially when utilizing optional electronic devices.  
         [0045]     As discussed supra core rings  18   a,b  may comprise a solid thermoplastic material in any suitable cross-sectional configuration, including, but not limited to rectangular, circular, oval, square, and any known polygonal shape. Core rings  18   a,b  may also comprise a hollow ring formed of thermoplastic material in any suitable cross-sectional configuration, including, but not limited to rectangular, circular, oval, square, or any known polygonal shape, having an outer section and interior space. Additionally, lattice techniques known in the art and as shown on a reverse side of toy  10  in  FIG. 6   b  may be utilized. As shown in  FIG. 6   b,  an upper surface  50  of rings  18   a,b  is solid while a lower surface  52  forms a lattice  54 . Such a lattice may be continual around a ring or interspersed with solid portions of ring  18 , particularly solid portions may be useful under coverings  11  usable as a handle.  
         [0046]     Further it is understood that the core could be contained within the covering without mechanical or chemical interconnection, however, for such embodiments it is preferred that the ring be completely or substantially disposed within the covering to ensure it&#39;s position is not disturbed.  
         [0047]     The specification incorporates by reference the disclosure of German priority document 101 52 070.0 filed 25 Oct. 2001 and U.S. application Ser. No. 10/213,870 filed Aug. 2, 2002, and U.S. application Ser. No. 10/858,220 filed Jun. 1, 2004.  
         [0048]     The present invention is, of course, in no way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims.