Patent Abstract:
An animal training apparatus including an electrical conductor embedded within a flexible member, and a housing having a through-opening for receiving the electrical conductor therethrough. The flexible member is molded around the electrical conductor and the antenna, while the electrical conductor is positioned such that it extends into the housing through the through-opening. As a result of the molding process, the flexible member shields the housing through-opening, discouraging substances such as water from accessing the interior of the housing via the through-opening.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a divisional of prior application Ser. No. 11/386,413, filed Mar. 22, 2006. 
     
    
     STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0003]    1. Field of Invention 
         [0004]    This invention relates to an external antenna for use with an electronic animal training device. More specifically, the invention relates to an antenna embedded within a flexible collar. 
         [0005]    2. Description of the Related Art 
         [0006]    There is a growing demand for animal collars that incorporate electronic components, such as transmitters, receivers, or transceivers. Generally, such an electronic component is protected by enclosing it in a housing that is integrated into the animal collar. It is well established that transmitters, receivers, and transceivers require an antenna to radiate or receive radio waves effectively. Generally, as the length of an antenna increases, the efficiency of an antenna increases. Lengthening the antenna often is the simplest way of increasing the range of a transmitter, receiver, or transceiver. A relatively long antenna, unlike a relatively short antenna, cannot be enclosed in the housing, however. Instead, such an antenna is external to the housing, and it conductively connects to the electronic component via a through-opening defined by the housing. An animal collar having an external antenna is disadvantaged in at least three respects. First, the antenna, itself, is more susceptible to damage because it protrudes from the housing and, therefore, is exposed to the elements, among other things. Second, the interface of the antenna and the housing, i.e., the through-opening, provides another avenue for water to penetrate the housing and potentially harm any electronic components therein. Finally, an external antenna can impede the movement of an animal in certain environments. For example, underbrush can easily snag an external antenna. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    An antenna enclosed within an animal training apparatus (hereinafter, “improved apparatus”) and three methods for manufacturing certain of its components are provided. One embodiment of the improved apparatus includes a receiver, an antenna in conductive communication with the receiver, and a housing defining an interior and a through-opening. The interior of the housing is adapted to receive the receiver, and the through-opening is adapted to receive the antenna therethrough. This embodiment includes further a flexible member that is formed by molding material around the housing and the antenna, while the antenna is positioned such that it extends through the through-opening. As a result of the molding process, part of the flexible member is bonded to the exterior of the housing, enabling the flexible member to carry the housing. That part of the flexible member, which at least partially encapsulates the housing, also shields the housing through-opening, discouraging substances such as water from accessing the interior of the housing via the through-opening. Additionally, flash resulting from that molding process fills the remainder of the through-opening, plugging it and securing the antenna therein. The flash serves as a secondary seal that further discourages substance such as water from accessing the interior of the housing via the through-opening. Finally, as a result of molding material around the antenna as well, the flexible member encloses and protects the part of the antenna that extends beyond the housing. In this embodiment, the flexible member has the form of a collar, enabling it to releasably secure the improved apparatus to the neck of an animal. 
         [0008]    The improved apparatus of the present invention has three major advantages over a conventional animal training apparatus. First, the improved apparatus is more durable because the antenna is enclosed in the flexible housing and, therefore, is less susceptible to damage. Second, the improved apparatus is less likely than a conventional animal training apparatus to impede the movement of an animal because the antenna is enclosed in the collar, eliminating the chance that the antenna, itself, will be snagged. Third, a seal may be formed more readily at the interface of the antenna and the housing, thereby providing greater protection from the elements. 
         [0009]    As stated previously, three methods for manufacturing certain components of the improved apparatus are provided also. The first method requires a flexible member mold that defines prong pairs. The prong pairs are engineered to grasp the antenna upon its placement in the flexible member mold, in preparation for the molding process that forms the flexible member. Accordingly, the antenna must be placed in the flexible member mold and secured by the prong pairs. This step ensures that the antenna, during the manufacture of the flexible member, remains in proper position relative to the housing and the through-opening. The second method of manufacture uses rigid placeholders to maintain the antenna in proper position in the flexible member mold. The rigid placeholders are formed by molding material around selected parts of the antenna. Thereafter, the antenna, including the attached rigid placeholders, is transferred to the flexible member mold, where the antenna is maintained in proper position by the rigid placeholders. The third method uses a flexible placeholder to maintain the antenna in proper position in the flexible member mold. In one embodiment, the flexible placeholder, itself, is manufactured first by stretching the antenna so that it has no give or slack and suspending it in a flexible placeholder mold. Next, uncured material is injected into the flexible placeholder mold, where it surrounds the desired section of the antenna while assuming the overall form of the flexible placeholder. The material is cured, forming the flexible placeholder, which has a section of the antenna enclosed therein and which defines a plurality of alignment holes and bosses. The flexible placeholder, including the antenna, is transferred to the flexible member mold, where it is maintained in proper position using the alignment holes and bosses, in preparation for the molding process that forms the flexible member. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0010]    The above-mentioned features of the invention will become more clearly understood from the following detailed description of the invention read together with the drawings in which: 
           [0011]      FIG. 1  depicts an animal wearing of an embodiment of the apparatus of the present invention; 
           [0012]      FIG. 2  is a front perspective view of the embodiment of the apparatus of the present invention depicted in  FIG. 1 ; 
           [0013]      FIG. 3  is a top plan view of the embodiment of the apparatus of the present invention depicted in  FIG. 1 ; 
           [0014]      FIG. 4  is an enlarged partial cross-sectional view, taken along lines  4 - 4  of  FIG. 3 , of the apparatus of the present invention; 
           [0015]      FIG. 5  is an enlarged partial cross-sectional view, taken along lines  5 - 5  of  FIG. 3 , of the apparatus of the present invention; 
           [0016]      FIG. 6  is a partial perspective view of the flexible member mold that defines the prong pairs; 
           [0017]      FIG. 7  is a partial view of an embodiment of the apparatus of the present invention that was manufactured using the flexible member mold that defines the prong pairs; 
           [0018]      FIG. 8  is a cutaway of a partial view of the embodiment of the apparatus of the present invention depicted in  FIG. 7 ; 
           [0019]      FIG. 9  is a perspective view of the rigid placeholders, the housing, and the antenna; 
           [0020]      FIG. 10  is a partial view of an embodiment of the apparatus of the present invention immediately following manufacture of the flexible member, using the rigid placeholders depicted in  FIG. 9 ; 
           [0021]      FIG. 11  is a partial view of the embodiment of the apparatus of the present invention depicted in  FIG. 10 , after the exposed sections of the rigid placeholders have been trimmed; 
           [0022]      FIG. 12  is a perspective view of an embodiment of the flexible placeholder of the present invention, the housing, and the antenna; and 
           [0023]      FIG. 13  is an enlarged partial cross-sectional view, taken along lines  13 - 13  of  FIG. 3 , of an embodiment of the apparatus of the present invention manufactured using the flexible placeholder depicted in  FIG. 12 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0024]    An antenna enclosed within an electronic animal training apparatus (hereinafter, “improved apparatus”) is disclosed, as are various methods of manufacture. 
         [0025]      FIG. 1  depicts an animal  108  wearing an embodiment of the improved apparatus  100 , which includes the housing  102  and the flexible attachment member  104 , having one or more flexible members  104   a,    104   b.  The housing  102  is adapted to receive therein an electronic component (not shown) for communicating via radio waves  112  with a remote electronic device  110 , such as a transmitter. The housing  102  is attached to the flexible members  104   a,    104   b,  which, in this embodiment, forms a collar adapted to encircle a neck  106  of an animal  108  and to releasably secure the improved apparatus  100  to the animal  108 . It is worth noting that the electronic component (not shown) is conductively connected to the antenna (not shown), which is not visible in this view because it is enclosed within the flexible attachment member  104 . One skilled in the art will recognize that the flexible attachment member may be adapted to encircle a part of the animal  108  other than the neck  106 . One skilled in the art will recognize also that any of a variety of electronic components may be enclosed in the housing  102 , including a receiver, transceiver, or transmitter. 
         [0026]      FIG. 2  is a front perspective view of the embodiment of the improved apparatus  100  depicted in  FIG. 1 .  FIG. 2  shows that the housing  102  and the flexible member  104  are attached to each other. As set forth in greater detail later in the specification, the flexible member  104  is formed by molding material (e.g., plastic or other polymeric material) around the housing  102  and the antenna (not shown). As a result, the band  202  defined by the flexible member  104  has a form that is complementary to the housing  102 , thereby enabling the flexible member  104  to be attached to, and carry, the housing  102 . Again, it is worth noting that the electronic component (not shown) enclosed in the housing  102  is conductively connected to the antenna (not shown), which is not visible in this view because it is enclosed within the flexible member  104 . One skilled in the art will recognize that the improved apparatus may include components necessary for applying a corrective stimulus to the animal, thereby enabling the improved apparatus to be used in training/ containment/ access applications and in various corrections. Additionally, one skilled in the art will recognize that, in certain applications, the improved apparatus is not advantaged by including such components. For example, in an improved apparatus that is engineered merely to transmit a signal disclosing the location of the animal, such components are unnecessary. 
         [0027]      FIG. 3  is a top plan view of the embodiment of the improved apparatus depicted in  FIGS. 1 ,  2 .  FIG. 3  serves as a reference for the partial cross-sectional views of the improved apparatus depicted in  FIGS. 4 ,  5 , and  13 . 
         [0028]      FIG. 4  is a partial cross-sectional view of the embodiment of the improved apparatus  100 , taken along lines  44  of  FIG. 3 . The housing  102  is composed of a hard material, and it defines an interior  402  and a through-opening  404 . The housing  102  is engineered to enclose at least one electronic component (not shown) in the interior  402 , and the through-opening  404  is engineered to receive the antenna  406  therethrough so that the antenna  406  is able to conductively connect to an electronic component (not shown) enclosed in the housing  102 . One skilled in the art will recognize that an electrical conductor other than an antenna may be suitable for certain applications. The flexible member  104 , which in this embodiment is composed of plastic, completely encloses the antenna  406 , protecting it from damage. Because the flexible member  104  is formed by molding material around the housing  102  and the antenna  406 , the interface  408  between the housing  102  and the first end  410  of the flexible member  104  is sealed, preventing water or another substance from penetrating the housing  102  via the through-opening  404 . Additionally, the seal aids in preventing the water or another substance from harming the antenna  406 . The seal has two components: a primary seal and a secondary seal. The primary seal is effected upon formation of the band  202  of the flexible member  104 . Because the band  202  is formed by molding material around the housing  102 , the interior surface of the band  202  and the exterior surface of the housing  102  bond along the entire interface  408 , significantly reducing the ability of water or another substance to penetrate the interface  408 . The secondary seal is effected upon formation of the flexible member flash  412 , a byproduct of the molding process that forms the flexible member  104 . The through-opening  404  has a diameter selected to enable formation, during the molding process, of the flexible member flash  412 . The flexible member flash  412  fills the through-opening  404 , plugging it, thereby providing a secondary seal for protection in the event that water or another substance breaches the primary seal. One skilled in the art will recognize that the length and thickness of the flexible member flash  412  may be modified by altering the diameter of the through-opening  404 . 
         [0029]      FIG. 5  is a partial cross-sectional view, taken along lines  5 - 5  of  FIG. 3 , of the embodiment of the improved apparatus  100  depicted in  FIG. 4 .  FIG. 5  further discloses the configuration of the housing  102 , the flexible member  104 , the through-opening  404 , the flexible member flash  412 , and the antenna  406 . 
         [0030]      FIG. 6  relates to the first of the three methods presented herein for manufacturing the improved apparatus  100 . The first method requires the flexible member mold  600  that defines the prong pairs  602 . The prong pairs  602  are engineered to grasp the antenna  406  upon its placement in the flexible member mold  600 , in preparation for the molding process that forms the flexible member  104 . Accordingly, the antenna  406  is placed in the flexible member mold  600  and is secured by the prong pairs  602 . Also, the housing  102  is placed in the flexible member mold  600  and is secured in position. These steps ensure that the antenna  406 , during the manufacture of the flexible member  104 , remains in proper position relative to the housing  102 , the through-opening  404 , and the flexible member mold  600 . It is critical to note that the entire flexible member mold  600  is not depicted in  FIG. 6 . Rather, only the part defining the prong pairs  602  is depicted to emphasize their importance to this method of manufacture. After the antenna  406  is secured in position using the prong pairs  602 , uncured material is forced by an injection molding apparatus into the flexible member mold  600 , where it surrounds the antenna  406  and selected parts of the housing  102 . Thereafter, the uncured material is cured, forming the flexible member  102 , within which the antenna  406  is enclosed. 
         [0031]      FIG. 7  depicts a partial view of an embodiment of the improved apparatus  100   a  manufactured using the first method, i.e., the method requiring the flexible member mold  600  that defines the prong pairs  602 .  FIG. 7  shows the flexible member  104   a,  the housing  102 , the antenna  406 , and the through-opening  404 . Additionally,  FIG. 7  shows the cavities  702  defined by the flexible member  104   a.  Each of the cavities  702  has a shape complementary to each of the prongs of the respective prong pairs  602  of the flexible member mold  600 . The cavities  702  form only when the first molding method is used to manufacture the improved apparatus. Thus,  FIG. 7  is useful in clarifying the relationship between the flexible member mold  600  that defines the prong pairs  602  and the resulting embodiment of the improved apparatus  100   a.  It is important to note that the cavities  702  in this embodiment are defined by the interior surface  704  of the flexible member  104   a  and not by the exterior (opposite) surface (not shown) of the flexible member. When an animal is wearing the improved apparatus, the interior surface  704  is adjacent to the surface of the animal and, consequently, is more protected than the exterior surface (not shown). This design aids in preventing water or another substance from damaging the antenna  406  by penetrating the cavities  702 . 
         [0032]      FIG. 8  depicts the same partial view as in  FIG. 7 , except that in  FIG. 8  part of the interior surface  704  has been cutaway to reveal further the configuration of the flexible member  104   a,  the antenna  406 , and the cavities  702 . 
         [0033]      FIG. 9  relates to the second of the three methods presented herein for manufacturing the improved apparatus  100 . The second method requires the rigid placeholders  902  depicted in  FIG. 9 . The rigid placeholders  902  are formed by molding material around selected parts of the antenna  406 . Thereafter, the antenna  406 , including the rigid placeholders  902 , is placed in the flexible member mold (not shown), and the antenna  406  is maintained in position by the rigid placeholders  902 , in preparation for the molding process that forms the flexible member  104 . Also, the housing  102  is placed in the flexible member mold (not shown) and is secured in position. These steps ensure that the antenna  406 , during the manufacture of the flexible member  104 , remains in proper position relative to the housing  102  and the through-opening  404 . After the antenna  406  is secured in position by the rigid placeholders  902 , uncured material is forced by an injection molding apparatus into the flexible member mold (not shown), where it surrounds the antenna  406  and selected parts of the housing  102 . Thereafter, the uncured material is cured, forming the flexible member  102 , within which the antenna  406  is enclosed. 
         [0034]      FIG. 10  depicts a partial view of an embodiment of the improved apparatus  100 b nearing completion of manufacture using the second method, i.e., the method requiring the rigid placeholders  902 . Both of the molding steps already have been completed and, thus, the rigid placeholders  902  and the flexible member  104   b  have been formed.  FIG. 10  shows the flexible member  104   b,  the housing  102 , the antenna  406 , and the through-opening  404 . Additionally,  FIG. 10  shows the exposed sections  1002  of the rigid placeholders  902  as well as the embedded sections  1004  of the rigid placeholders  902 . The exposed sections  1002  are protruding from the interior surface  1006  of the flexible member  104 b and must be trimmed. 
         [0035]      FIG. 11  depicts the same partial view as in  FIG. 10 , except that in  FIG. 11  the exposed sections  1002  of the rigid placeholders  902  have been trimmed and, therefore, no longer are present. The interior surface  1102  of each of the embedded sections  1004  of the rigid placeholders  902  is flush with the interior surface  1006  of the flexible member. 
         [0036]      FIG. 12  concerns the third of the three methods presented herein for manufacturing the improved apparatus  100 . The third method requires the flexible placeholder  1202 . The flexible placeholder  1202  is manufactured by first securing the placeholder section  1204  of the antenna  406  in a flexible placeholder mold (not shown) such that the placeholder section  1204  assumes and maintains the desired position, such as a linear configuration. For example, one way to ensure that the placeholder section  1204  of the antenna  406  maintains a linear configuration is to stretch the antenna  406  so that it has no give or slack and suspend it in the flexible placeholder mold (not shown). After the placeholder section  1204  has assumed the desired position, linear or otherwise, uncured material (e.g., rubber or other polymeric material) is injected into the flexible placeholder mold (not shown), where it surrounds the placeholder section  1204  of the antenna  406  while assuming the overall form of the flexible placeholder  1202 . Thereafter, the uncured material is cured, forming the flexible placeholder  1202 , within which the placeholder section  1204  of the antenna  406  is enclosed. 
         [0037]    The flexible placeholder  1202 , as shown in the embodiment illustrated in  FIG. 12 , defines alignment holes  1206  to allow for securing it in proper position in the flexible member mold (not shown), in preparation for the molding process that forms the flexible member  102 . The flexible placeholder  1202  defines also a plurality of bosses, such as those depicted at  1208 . The bosses  1208  provide support for the flexible placeholder  1202  so that, upon its  1202  placement in the flexible member mold (not shown), there are gaps between a majority of the surface of the flexible placeholder  1202  and the interior surface of the flexible member mold (not shown). During the next molding process, which forms the flexible member  104   c  and is described in the following paragraph, these gaps serve as channels for the uncured material, enabling it to envelop the flexible placeholder  1202 . 
         [0038]    The next step is to place the flexible placeholder  1202 , including the antenna  406 , in the flexible member mold (not shown). The antenna  406  is maintained in position by the flexible placeholder  1202 , which is maintained in position by the bosses  1208  and by projections (not shown), defined by the flexible member mold (not shown), that engage the alignment holes  1206 . Also, the housing  102  is placed in the flexible member mold (not shown) and is secured in position. These steps ensure that the flexible placeholder  1202  (and, hence, the antenna  406 ) remains in proper position relative to the housing  102  and the through-opening  404  during the manufacture of the flexible member  104 . Next, uncured material is forced by an injection molding apparatus into the flexible member mold (not shown), where it surrounds the flexible placeholder  1202 , the antenna  406 , and selected parts of the housing  102 . Thereafter, the material is cured, forming the flexible member  102 c, within which the flexible placeholder  1202  and the antenna  406  are enclosed, and to which the housing  102  is attached. 
         [0039]      FIG. 13  is a partial cross-sectional view, taken along lines  13 - 13  of  FIG. 3 , of an embodiment of the improved apparatus  100   c  that was manufactured using the third method, i.e., the method requiring the flexible placeholder  1202 .  FIG. 13  discloses the configuration of the housing  102 , the flexible member  104   c,  the flexible placeholder  1202 , the through-opening  404 , the flexible member flash  412 , and the antenna  406 . 
         [0040]    One skilled in the art will recognize that certain applications may require enclosing an electrical conductor other than an antenna in the flexible member or flexible placeholder. Depending on the nature of the application, that electrical conductor either may replace, or coexist with, the antenna. For example, in still another embodiment of the improved apparatus, only the middle section of an electrical conductor is embedded in the flexible placeholder, leaving both ends available for insertion into housings via through-openings. In this embodiment, the electrical conductor forms a conductive connection between two electronic components, each of which is enclosed in its own housing. This embodiment aids in distributing more evenly the weight and bulk of two or more electronic components around the neck or other part of an animal. 
         [0041]    While the present invention has been illustrated by description of several embodiments and while the illustrative embodiments have been described in detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional modifications will readily appear to one skilled in the art. For example, one skilled in the art will recognize that, in some instances, it may be preferable, when manufacturing the flexible member or flexible placeholder, to use molding methods other than injection molding, such as extrusion molding, transfer molding, or compression molding. Thus, the invention in its broader aspects is not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant&#39;s general inventive concept.

Technology Classification (CPC): 8