Patent Publication Number: US-2015083053-A1

Title: Contact unit for an animal training system

Description:
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable 
     BACKGROUND OF THE INVENTION 
     Various animal training systems are known in the art. Typically, in such systems, a contact unit has a pair of conductive probes that extend from an RF receiver housing and are retained against the skin of an animal via a collar that is secured around the neck of the animal. A stimulus in the form of an electric shock may be provided to the animal via the conductive probes of the contact unit in response to undesired behaviors to train the animal not to engage in such behaviors. 
     In one form of animal training system, an antenna wire is buried in the ground or otherwise disposed so as to define an area in which an animal, such as a pet or livestock, is/are to be constrained or to define an area from which an animal is to be excluded. The antenna wire is energized to provide an RF field in the vicinity of the wire. When the animal approaches the antenna wire and the strength of the RF signal received by the RF receiver exceeds a specified threshold, the RF receiver may generate a stimulus in the form of an electric shock that is conveyed to the animal via the conductive probes. By providing the animal with an electrical stimulus when it approaches the antenna wire, the animal is trained not to approach the antenna wire and thus remains within or outside of the defined area. 
     In another form of animal training system, a trainer controls a transmitter that is capable of producing an RF signal. The RF signal is received by an RF receiver secured around the neck of the animal via a collar. In response to the receipt of the RF signal, the RF receiver conveys an electrical stimulus to the animal via the conductive probes. By applying an electrical stimulus to the animal when the trainer observes undesirable behaviors by the animal, the animal can be trained not to engage in such behaviors. 
     RF receivers that include replaceable metallic probes and that are mountable to a collar worn by a pet are known. RF receivers are also known that include conductive plastic probes which are molded into the base of an RF receiver housing. The replacement of the conductive plastic probes in this embodiment disadvantageously requires disassembly of the RF receiver housing and replacement of the entire base portion of the housing which includes the conductive probes, or alternatively, replacement of the entire housing for the RF receiver. 
     It would therefore be desirable to have a contact unit that was distinct from the RF receiver housing to permit replacement of the contact unit should such be required without replacement of all or a part of the RF receiver housing. Additionally, it would be desirable to provide a contact unit that was manufacturable in high volume and at low cost and that could be produced in various sizes to accommodate animals of different size and hair configurations. 
     BRIEF SUMMARY OF THE INVENTION 
     A contact unit includes two or more electrically conductive contact probes and one or more non-conductive base portions. The electrically conductive contact probes are molded into the one or more electrically non-conductive base portions. The contact unit is mountable to a housing of an RF receiver via at least one fastener to releasably secure the contact unit to the housing and to electrically interconnect the conductive contact probes to conductive contacts mounted to the RF receiver housing. The conductive contacts are electrically coupled to stimulus generating circuitry within the RF receiver. 
     The contact probes are integrally formed single piece molded components. Each contact probe includes a probe tip portion for making conductive contact with the skin of an animal and an interconnection portion for conductively coupling the respective contact probe to a corresponding conductive contact on the RF receiver housing. 
     In one embodiment, the interconnection portion includes an opening sized to receive a fastener that is used to secure the interconnection portion of the contact probe to the conductive contact mounted to the RF receiver housing. Additionally, the fastener may be conductive and serve to electrically interconnect the interconnection to a corresponding conductive contact by engagement of the conductive fastener with the interconnection portion and the conductive contact. 
     The interconnection portion may be conductively coupled to the probe tip portion via a stem portion that extends between the interconnection portion and the probe tip portion. 
     In another embodiment, the contact unit is releasably secured to the RF receiver housing via a non-conductive fastener. The interconnection portion of the contact probe is disposed in conductive abutting relation with a corresponding conductive contact that is mounted to the RF receiver housing when the contact unit is mounted to the housing. The non-conductive fastener serves to maintain the interconnection portion in conductive abutting relation with a corresponding conductive contact mounted in the RF receiver housing. 
     The contact unit may be fabricated by molding the contact probes in a first molding operation and then molding one or more contact probes into one or more base portions. The contact probes are molded into the base portion(s) in a second molding operation using insert or over-molding techniques. 
     Alternatively, the contact unit may be fabricated by first molding one or more non-conductive base portions and then molding one or more of the contact probes in each base portion in a second molding operation. 
     The contact unit may be molded in various sizes and probe tip configurations to accommodate animals of different sizes and hair characteristics. 
     In addition to the use of the contact unit in conjunction with an RF Receiver as described above, the contact unit may be employed with a controller that produces an electrical stimulus in response to an audible, pressure, vibration, linear or rotary motion input or any other suitable input. 
     Other features, advantages and aspects of the presently disclosed contact unit will be apparent to those skilled in the art in view of the drawings and detailed description that follows. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The invention will be more fully understood by reference to the following Detailed Description of the Invention in conjunction with the drawings of which: 
         FIG. 1A  is a perspective view of a contact unit having a molded non-conductive base portion and molded spaced contact probes in accordance with the present invention; 
         FIG. 1B  is an exploded perspective view illustrating the molded contact probes and the base portion that form the contact unit of  FIG. 1A ; 
         FIG. 2  is a perspective view of a conductive contact probe employed in the contact unit of  FIG. 1 ; 
         FIG. 3  is a perspective view of the molded non-conductive base portion in the contact unit of  FIG. 1 ; 
         FIG. 4  is a cross-sectional cutaway view through a longitudinal centerline through the contact unit of  FIG. 1A ; 
         FIG. 5  is an exploded assembly drawing illustrating the mounting of the contact unit of  FIG. 1A  to a collar and RF receiver in accordance with one embodiment of the invention; 
         FIG. 6  is another embodiment of a contact unit in accordance with the present invention that includes two base portions with one contact probe in each base portion; 
         FIG. 7  is an exploded assembly drawing of another embodiment of a contact unit in accordance with the present invention that employs a single fastener for securing the contact unit to a RF receiver housing; 
         FIG. 8  is another embodiment of a contact unit in accordance with the present invention that includes a single base portion and four contact probes molded therein; and 
         FIG. 9  is another embodiment of a contact unit in accordance with the present invention that includes two opposing base portions and two contact probes in each base portion. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In accordance with the present invention, a molded contact unit for use in an animal training system is disclosed. Referring to  FIGS. 1A-5 , the contact unit  100  includes a pair of spaced electrically conductive molded contact probes  102  disposed in a nonconductive molded base portion  104 . The contact probes  102  in the illustrated embodiment include a probe tip portion  102   a  and an interconnection portion  102   b . The contact probes also include a stem portion  102   c  extending from and conductively coupling the interconnection portion  102   b  to the probe tip portion  102   a . The probe tip portion  102   a  has a generally dome shaped upper surface for making contact with the skin of animal. The interconnection portion has a bottom surface that is configured to abut and conductively mate with corresponding conductive contacts  108  mounted in the RF receiver housing  110 . In the embodiment illustrated in  FIGS. 1A-5 , the interconnection portion  102   b  includes an opening  102   d  sized to accommodate a fastener that is used to secure the contact unit  102  to an RF receiver  110  ( FIG. 4 ) as subsequently discussed. In the exemplary illustrated embodiment, the interconnection portion  102   b  is a generally washer shaped portion that includes a side section extending from one side thereof which is generally V-shaped. The stem portion  102   c  of the contact probe  102 , in the illustrated embodiment, extends upward from the interconnection portion  102   b  to the probe tip portion  102   a . As illustrated in  FIG. 1B , wings  102   e  extend outward from the stem portion  102   c  and confront surfaces of the passages  104   c  in the base portion  104 . 
     The contact probes  102  are formed of an electrically conductive moldable polymer such as a conductive plastic, a conductive rubber or any other suitable moldable conductive material. It is recognized that the electrical conductively may be achieved via the addition of additives to an otherwise non-conductive polymeric material and the reference to a conductive polymer herein includes polymers that are conductive by reason of the addition of additives, such as carbon black, fine metal particles or other additives that impart conductive characteristics to otherwise non-conductive materials. By way of example, and not limitation, the contact probes  102  may be fabricated from Nylon 66 which is available from DuPont™ with a conductive additive such as carbon black or fine metal particles. 
     In the illustrated embodiment, the base portion  104  is formed of an electrically nonconductive moldable polymer such as an electrically nonconductive plastic, an electrically nonconductive rubber or any other suitable moldable non-conductive material. By way of example, and not limitation, the base portion  104  may be fabricated from Nylon 66 available from DuPont™. The base portion  104 , as illustrated, is an elongated member having a pair of through-holes  104   a  located at opposing ends and a pair of upwardly extending spaced pedestals  104   b  disposed inwardly of the through-holes  104   a . The upper surface of each pedestal  104  is in the form of a plateau which, in the exemplary embodiment is generally planar. The probe tip portions  102   a  extend upward from the two upstanding pedestals  104   b  formed in the base portion  104 . The center portion of the passages  104   c  extend through the pedestals  104   b . Surfaces of the upper portion of the passages  104   c  define slots in the base portion  104  which also define the outer surface of the wings  102   e . The wings  102   e  extending from the stem portions  102   c  provide added support and stability for the contact probes  102  molded within the base portion  104 . 
     The contact unit  100  is formed in first and second molding operations in which the contact probes  102  are first formed in one or more first molds in a first molding operation. The contact probes  102  are then inserted into a second mold and spaced and aligned such that the open areas of the second mold correspond to the structure of the base portion  104  to be formed. A nonconductive moldable polymeric material is then injected into the second mold to form the base portion  104  around the contact probes  102  and thereby produce the contact unit  100 . 
     Alternatively, the contact unit  100  may be formed in first and second molding operations in which the base portion  104  is first molded and the contact probes are formed in a secondary molding operation. In the first molding operation, the base portion  104  is formed of a moldable nonconductive polymeric material in a first mold. The base portion  104  is then inserted and aligned in a second mold that is configured such that the open areas within the mold correspond to the structure of the contact probes  102 . An electrically conductive polymeric material is then injected into the second mold to form the contact probes  102  and produce the finished contact unit  100  as depicted in  FIG. 1A . 
     In the illustrated embodiment, the contact unit  100  is releasably mountable to conductive contacts  108  of an RF receiver  110  via fasteners  112 , such as screws, as illustrated in  FIG. 5 . The fasteners  112 , may be conductive or nonconductive fasteners and extend through the openings  102   d  (see  FIG. 2 ) in the interconnection portion  102   b . When conductive fasteners  112  are employed, they provide an electrical connection between the contact probes  102  and the electrical contacts  108  of the RF receiver  110  by abutting engagement with the interconnection portion and engagement with the conductive contacts  108  mounted in the RF receiver housing. The conductive contacts  108  in turn are coupled to the electrical stimulus generating circuitry (not shown) within the RF receiver  110 . RF receivers and stimulus generating circuitry of the type herein employed are generally known in the art and therefore not discussed in further detail herein. 
     The fasteners  112  in the illustrative embodiment thus releasably secure the contact unit  100  to the RF receiver  110  and electrically interconnect the contact probes  102  of the contact unit  100  to the conductive contacts  108  mounted in the housing of the RF receiver  110 . The contact probes  102  may thereby be energized by the electrical stimulus generating circuitry within the RF receiver  110 . 
     The fasteners  112  may also be nonconductive fasteners which secure the contact unit  100  to the RF receiver housing. When nonconductive fasteners  112  are employed, the undersurface of the interconnection portion  102   b  is configured to mate with the conductive contacts  108  in abutting relation. The nonconductive fasteners  112  serve to secure the undersurface of the interconnection portions  102   b  in conductive abutting relation with the upper surface of corresponding conductive contacts  108 . 
     A collar  114 , that is configured to be secured around the neck of an animal, has through-holes  116  spaced so as to align with the openings  102   d  of the contact probes  102 . The collar  114  may be disposed between the contact unit  100  and the RF receiver  110  as illustrated in  FIG. 4 . In this embodiment, the conductive fasteners  112  extend through the openings  102   d  of the contact probes  102  and through the through-holes  116  of the collar  114  and engage the electrical contacts  108  of the RF receiver  110  to releasably secure the contact unit  100  and the RF receiver  110  to the collar  114 . 
     Alternatively, it should be recognized that a collar may be mounted to the RF receiver  110  housing or extend through strap retaining members formed in the housing rather than being disposed between the contact unit  100  and the RF receiver  110  as depicted in  FIG. 5 . 
     While  FIGS. 1A-5  depict a contact unit in which two contact probes are molded into a single base portion, one or more contact probes may be formed within a single base portion and two or more base portions may be employed to form the contact unit. In this circumstance, each base portion of the contact unit is releasably mounted to the RF receiver housing with the interconnection portion of each contact probe electrically interconnected to a corresponding electrical contact mounted to the RF receiver housing. 
       FIG. 6  illustrates an embodiment of a contact unit  600  in which a contact probe  102  is provided in each of two separate molded base portions  604 . This embodiment provides some flexibility in that the spacing between the base portions  604  may be varied when mounting the base portions to a receiver housing to accommodate animals having different neck sizes and hair configurations. It is recognized that the mounting of base portions  604  to the receiver housing requires adjustment in the spacing of the conductive contacts of the RF receiver housing or other means for interconnecting the interconnection portions to the conductive contacts. Such means may include, by way of example, at least one movable conductive contact in the receiver housing that accommodates the adjustable spacing of the interconnection portions. 
       FIG. 7  illustrates another embodiment of a contact unit  700  in which the interconnection portions and the ends of the base portion do not include through-holes. In this embodiment, the undersurface of the interconnection portions of the contact probes are configured so as to substantially conform to the surface of the conductive contacts  708  of the RF receiver housing  710  and abut the conductive contacts  708  in electrically conductive relation when the contact unit  700  is secured to the RF receiver housing  710 . In the illustrated embodiment, a single fastener  712  is employed to secure the contact unit  700  to the receiver housing  710 . More specifically, the fastener  712 , which is a threaded screw in the illustrated embodiment, extends through an opening in the base portion and mechanically engages a threaded member  714  to secure the contact unit  700  to the receiver housing  710 . In the illustrated embodiment, the fastener  712  serves to urge the undersurface of the interconnection portions of the contact probes against the upper surface of the conductive contacts  708  to maintain the interconnection portions in electrically conductive relation with the conductive contacts  708 . It should be recognized that multiple fasteners may also be employed to secure the contact unit  700  to the receiver housing  710  that extend through the base portion but do not extend through the interconnection portions of the contact probes. 
     Other embodiments may include more than two contact probes. For example,  FIG. 8  illustrates an embodiment of a contact unit  800  in which four contact probes  802  are molded into a single base portion  804 . The use of more than two contact probes  802  can be advantageous to improve the conductive contact of the probes to the skin of an animal and thereby more reliably impart an electrical stimulus to the animal upon activation of the stimulus generator. The contact probes  802  may be molded individually as illustrated in  FIG. 2  or alternatively, a single molded electrically conductive structure for a contact probe may be provided that includes multiple probe tips. 
     In yet another embodiment of a contact unit  900 , illustrated in  FIG. 9 , two contact probes  902  are molded into each of two separate base portions  904 . The contact probes  902  in each base portion may be formed as separate contact probes as depicted in  FIG. 2  or molded as an integral unit having one interconnection portion and multiple probe tips. By forming the base portions  904  as separate units, the distance between the contact probes  902  in opposed base portions  904  may be varied when mounting the base portions  904  to the RF receiver housing. The ability to vary the spacing between the base portions and thus the probe tips allows the contact unit configuration to be adjusted to accommodate animals of different size and hair texture. While two contact probes are illustrated in each of the opposed base portions  904 , it should be appreciated that one or more contact probes may be provided in each of the two opposed base portions  904 . 
     While several embodiments of contact units have been illustrated, it should be appreciated that the contact units may be formed with other numbers of contact probes. Additionally, other base configurations are contemplated that are distinct from and mountable to an RF receiver housing. 
     The interconnection portions of the contact probes may be electrically interconnected to the conductive contacts of the RF receiver housing in various ways. For example, a conductive fastener may be used to releasably secure and electrically interconnect the interconnection portion to a corresponding electrical contact of the RF receiver housing as previously described. Alternatively, the interconnection portions of the contact probes and the conductive contacts of the RF receiver housing may be configured and cooperative so as to abut one another in electrically conductive relation when the respective base portion is secured to the RF receiver housing via an electrically conductive or non-conductive fastener. In such an embodiment, it should be recognized that the interconnection portion of the contact probes need not have an opening therethrough for fastening the base portion to the RF receiver housing. 
     In the foregoing manner a contact unit is provided that is releasably securable to an RF receiver and that may be fabricated using high volume and low cost manufacturing techniques. The contact unit of the present invention thus permits the replacement of only the contact unit should replacement of just the contact unit become necessary. 
     The contact units, as described above, are employed in conjunction with an RF receiver in animal containment/exclusion systems in which an animal is provided an electrical stimulus when it approaches an antenna wire as noted previously, or in remote to remote activation by a trainer via an RF transmitter. In these applications, a controller that is operative to generate an electrical stimulus includes the RF receiver within a controller housing. It should be recognized that the contact units presently described may also be employed with controllers that contain electrical stimulus generating circuitry responsive to other inputs. For example, the contact units may be employed in conjunction with a controller that generates an electrical stimulus in response to an audible input, such as barking. Additionally, the presently described contact units may be employed with controllers that generate an electrical stimulus in response to a pressure input, linear or rotary motion, a vibration input or any other suitable input that is employed to initiate the generation of an electrical stimulus that is conveyed to the contact probes of the contact unit. 
     It will be appreciated by those of ordinary skill in the art that modifications to and variations of the above described contact unit and associated methods for making and using the same may be made without departing from the inventive concepts disclosed herein. Accordingly, the invention should not be viewed as limited except by the scope and spirit of the appended claims.