U.S. patent application number 10/692626 was filed with the patent office on 2004-05-13 for toy figure with articulating joints.
This patent application is currently assigned to C.J. Associates, Ltd.. Invention is credited to Kwan, Chiu Keung, Lee, James S. W..
Application Number | 20040092203 10/692626 |
Document ID | / |
Family ID | 23985050 |
Filed Date | 2004-05-13 |
United States Patent
Application |
20040092203 |
Kind Code |
A1 |
Lee, James S. W. ; et
al. |
May 13, 2004 |
Toy figure with articulating joints
Abstract
A toy figure having multiple articulating limbs connected to the
torso by pivot joints that are molded in a vertical injection
molding step that forms and pivotally interconnects, in situ, one
member of the pivot joint to a second, pre-formed member of the
pivot joint.
Inventors: |
Lee, James S. W.; (Long
Island, NY) ; Kwan, Chiu Keung; (Hong Kong,
HK) |
Correspondence
Address: |
MICHAEL BEST & FRIEDRICH LLC
401 NORTH MICHIGAN AVENUE
SUITE 1700
CHICAGO
IL
60611-4212
US
|
Assignee: |
C.J. Associates, Ltd.
Hong Kong
HK
|
Family ID: |
23985050 |
Appl. No.: |
10/692626 |
Filed: |
October 24, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10692626 |
Oct 24, 2003 |
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09499380 |
Feb 7, 2000 |
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6333382 |
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09499380 |
Feb 7, 2000 |
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09088385 |
Jun 1, 1998 |
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6089950 |
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Current U.S.
Class: |
446/268 |
Current CPC
Class: |
C08L 37/00 20130101;
C08L 23/16 20130101; C08L 23/10 20130101; C08L 23/142 20130101;
C08L 55/02 20130101; C08L 2666/24 20130101; C08L 2666/22 20130101;
C08L 2666/02 20130101; C08L 2666/24 20130101; C08L 2314/06
20130101; C08L 71/02 20130101; C08L 23/10 20130101; C08L 23/10
20130101; C08L 2205/03 20130101; C08L 45/00 20130101; C08L 51/06
20130101; A63H 3/46 20130101; C08L 23/16 20130101; C08L 23/142
20130101; C08L 23/0815 20130101; C08L 27/06 20130101; C08L 53/025
20130101 |
Class at
Publication: |
446/268 |
International
Class: |
A63H 003/00 |
Claims
We claim:
1. A toy comprising a head and body: the head having an interior
space and a bottom surface with an opening therein in communication
with the interior space; an internal pivot pin formed within the
interior space; a lever arm having a distal end and a proximal end,
the distal end being pivotally mounted within the head by the
internal pivot pin and the proximal end adapted for connection to
the body to enable the lever arm to move relative to the body.
2. The toy of claim 1 wherein the lever comprises a first material
having a first melting point and the internal pivot pin comprises a
second material having a second melting point lower than the first
melting point.
3. The toy of claim 2 wherein the proximal end extends from the
opening in the bottom surface of the head.
4. The toy of claim 3 wherein the opening in the bottom surface of
the head is a slot accommodating pivotal movement of the lever
arm.
5. The toy of claim 2 wherein the proximal end of the lever arm is
connected to the body.
6. The toy of claim 5 wherein the proximal end of the lever arm is
rotatably connected to the body.
7. The toy of claim 6 wherein a rotational member is disposed on
the proximal end of the lever arm and the torso comprises an
interior space sized and shaped to capture said rotational member
so that the head is capable of rotating relative to the body.
8. The toy of claim 1 wherein the rotational member is a disk.
9. The toy of claim 2 wherein the distal end of the lever arm
defines an aperture and the pivot pin engages the aperture to
pivotally mount the proximal end of the lever arm within the
head.
10. The toy of claim 2 wherein the head comprises the second
material having a melting point lower than the first melting
point.
11. The toy of claim 2 wherein the second melting point is at least
30.degree. C. lower than the first melting point.
12. The toy of claim 10 wherein the second material is a
thermoplastic material.
13. The toy of claim 10 wherein the first material is selected from
the group consisting of nylon, acrylonitrile butadiene styrene, and
polyoxymethylene resins, and the second material is selected from
the group consisting of PVC and strene butadiene.
14. A method for making a toy figure having a head pivotally
connected to a lever arm, the head housing an internal pivot pin
and having a bottom surface with an opening therein, the lever arm
having a distal end defining an aperture and the internal pivot pin
extending through the aperture to pivotally mount the lever arm to
the head, the method comprising the steps of: (a) inserting the
lever arm into an injection mold having inner walls defining a
cavity for forming the head, the lever arm being formed from a
material having a given melting point and being positioned in the
injection mold so that the distal end is within the cavity; and (b)
injecting a sufficient quantity of a first thermoplastic material
into the cavity of the mold under injection molding conditions
permitting the thermoplastic material to fill the cavity to form
the head and to fill the aperture to form the pivot pin, the
injecting step being carried out at a temperature that is less than
the given melting point of the lever arm.
15. A method according to claim 14 wherein the first thermoplastic
material has a melting point that is about 30.degree. C. to about
200.degree. C. less than the given melting point of the pivot
pin.
16. A method according to claim 15 wherein the melting point of the
first thermoplastic material is about 70.degree. C. to about
140.degree. C. less than the given melting point of the pivot
pin.
17. A method according to claim 14 wherein the lever arm material
is selected from the group consisting of nylon, acrylonitrile
butadiene styrene, and polyoxmethylene resins, and the first
thermoplastic material is selected from the group from the group
consisting of PVC and styrene butadiene.
18. A method according to claim 14 wherein the injection mold is
connected to a vertical injection molding apparatus.
19. A method according to claim 14 wherein the lever arm has a
proximal end and the lever arm is positioned in the injection mold
so that proximal end of the lever arm is outside of the cavity.
20. A method according to claim 19 wherein the opening in the
bottom surface of the head is a slot accommodating pivotal movement
of the lever arm.
21. A method for making an articulating limb comprising a first
limb segment, a second limb segment and an elongate member having a
first end and a second end, the first limb segment having a distal
end connected to the first end of the elongate member and the
second limb member having a proximal end connected to the second
end of the elongate member, the method comprising the steps of: (a)
inserting the elongate member into an injection mold having inner
walls defining a first cavity for forming the first limb segment
and a second cavity for forming the second limb segment, the
elongate member being formed from a material having a given melting
point and being positioned in the injection mold so that the first
end is within the first cavity and the second end is within the
second cavity; and (b) injecting a sufficient quantity of a first
thermoplastic material into the first and second cavities of the
mold under injection molding conditions permitting the
thermoplastic material to fill the first and second cavities and
form the first limb segment and the second limb segment, thereby
connecting the distal end of the first limb segment to the first
end of the elongate member and the proximal end of the second limb
member to the second end of the elongate member, wherein the
injecting step is carried out at a temperature that is less than
the given melting point of the elongate member.
22. A method according to claim 21 wherein the distal end of the
first limb segment is pivotally connected to the first end of the
elongate member.
23. A method according to claim 22 wherein the first end of the
elongate member defines a first aperture and the distal end of the
first limb segment comprises a first pivot pin integrally formed
therewith and extending through the first aperture of the elongate
member, a sufficient quantity of the first thermoplastic material
being injected into the first cavity to fill the first aperture to
form the first pivot pin.
24. A method according to claim 21 wherein the distal end of the
first limb segment is rotatably connected to the first end of the
elongate member.
25. A method according to claim 24 wherein the elongate member has
a rotational member at its first end and the distal end of the
first limb member defines an interior space sized and shaped to
capture the rotational member.
26. A method according to claim 25 wherein the rotational member
comprises a disk.
27. A method according to claim 21 wherein the first thermoplastic
material has a melting point that is about 30.degree. C. to about
200.degree. C. less than the given melting point of the elongate
member.
28. A method according to claim 27 wherein the melting point of the
first thermoplastic material is about 70.degree. C. to about
140.degree. C. less than the given melting point of the elongate
member.
29. A method according to claim 26 wherein the elongate member
material is selected from the group consisting of nylon,
acrylonitrile butadiene styrene, and polyoxmethylene resins, and
the first thermoplastic material is selected from the group from
the group consisting of PVC and styrene butadiene.
30. A method according to claim 26 wherein the injection mold is
connected to a first vertical injection molding apparatus.
31. A method according to claim 26 wherein the first vertical
injection molding apparatus communicates with the first cavity and
a second vertical injection molding apparatus communicates with the
second cavity.
32. A method according to claim 21, 22 or 24 wherein the proximal
end of the second limb segment is pivotally connected to the second
end of the elongate member.
33. A method according to claim 32 wherein the second end of the
elongate member defines a second aperture and the proximal end of
the second limb segment comprises a second pivot pin integrally
formed therewith and extending through the second aperture of the
elongate member, a sufficient quantity of the first thermoplastic
material being injected into the second cavity to fill the second
aperture to form the second pivot pin.
34. A method according to claim 21, 22 or 24 wherein the proximal
end of the second limb segment is rotatably connected to the second
end of the elongate member.
35. A method according to claim 34 wherein the elongate member has
a rotational member at its second end and the proximal end of the
second limb member defines an interior space sized and shaped to
capture the rotational member.
36. A method according to claim 35 wherein the rotational member
comprises a disk.
37. A method for making an articulating limb adapted to be
connected to a body part, the articulating limb comprising a first
limb segment, an elongate member having a first end, and a
connecting member having a body-part end adapted to be connected to
the body part and a limb end; the first limb segment having a
distal end connected to the first end of the elongate member and a
proximal end connected to the limb end of the connecting member;
the method comprising the steps of: (a) inserting the elongate
member into an injection mold having inner walls defining a first
cavity for forming the first limb segment, the first cavity having
a distal end and a proximal end and the elongate member being
formed from a material having a first melting point and being
positioned in the injection mold so that the first end of the
elongate member is within the distal end of the first cavity; (b)
inserting the limb end of the connecting member into the injection
mold, the connecting member being formed from a material having a
second melting point and being positioned in the injection mold so
that the limb end is within the proximal end of the first cavity;
and (c) injecting a sufficient quantity of a thermoplastic material
into the first cavity of the mold under injection molding
conditions permitting the thermoplastic material to fill the first
cavity and form the first limb segment, thereby connecting the
distal end of the first limb segment to the first end of the
elongate member and the proximal end of the first limb segment to
the limb end of the connecting member, the injecting step being
carried out at a temperature that is less than the lower of the
first and second melting points.
38. A method according to claim 37 wherein the distal end of the
first limb segment is pivotally connected to the first end of the
elongate member.
39. A method according to claim 38 wherein the first end of the
elongate member defines a first aperture and the distal end of the
first limb segment comprises a first pivot pin integrally formed
therewith and extending through the aperture of the elongate
member, a sufficient quantity of the first thermoplastic material
being injected into the first cavity to fill the first aperture to
form the first pivot pin.
40. A method according to claim 37 wherein the distal end of the
first limb segment is rotatably connected to the first end of the
elongate member.
41. A method according to claim 40 wherein the elongate member has
a rotational member at its first end and the distal end of the
first limb member defines an interior space sized and shaped to
capture the rotational member.
42. A method according to claim 41 wherein the rotational member
comprises a disk.
43. A method according to claim 37 wherein the thermoplastic
material has a melting point that is about 30.degree. C. to about
200.degree. C. less than the lower of the first and second melting
points.
44. A method according to claim 43 wherein the melting point of the
thermoplastic material is about 70.degree. C. to about 140.degree.
C. less than the lower of the first and second melting points.
45. A method according to claim 42 wherein the elongate member
material is selected from the group consisting of nylon,
acrylonitrile butadiene styrene, and polyoxmethylene resins, and
the thermoplastic material is selected from the group from the
group consisting of PVC and styrene butadiene.
46. A method according to claim 42 wherein the injection mold is
connected to a first vertical injection molding apparatus.
47. A method according to claim 37, wherein the elongate member has
a second end, the articulating limb further comprises a second limb
segment connected to the second end of the elongate member, the
injection mold has inner walls defining a second cavity for forming
the second limb member, the method further comprising the steps of
positioning the elongate member in the injection mold so that the
second end of the elongate member is within the second cavity, and
injecting a sufficient quantity of the thermoplastic material into
the second cavity at a temperature that is less than the lower of
the first and second melting points and under injection molding
conditions permitting the thermoplastic material to fill the second
cavity to form the second limb segment, thereby connecting the
second limb segment to the second end of the elongate member.
48. A method according to claim 47 wherein a first vertical
injection molding apparatus communicates with the first cavity and
a second vertical injection molding apparatus communicates with the
second cavity.
49. A method according to claim 38 or 40 wherein the elongate
member has a second end, the articulating limb further comprises a
second limb segment pivotally connected to the second end of the
elongate member, the injection mold has inner walls defining a
second cavity for forming the second limb member, the method
further comprising the steps of positioning the elongate member in
the injection mold so that the second end of the elongate member is
within the second cavity, and injecting a sufficient quantity of
the thermoplastic material into the second cavity at a temperature
that is at least 30.degree. C. less than the lower of the first and
second melting points and under injection molding conditions
permitting the thermoplastic material to fill the second cavity to
form the second limb segment, thereby connecting the second limb
segment to the second end of the elongate member.
50. A method according to claim 49 wherein the second end of the
elongate member defines a second aperture and the second limb
segment comprises a pivot pin integrally formed therewith and
extending through the second aperture of the elongate member, a
sufficient quantity of the first thermoplastic material being
injected into the second cavity to fill the second aperture to form
the pivot pin of the second limb segment.
51. A method according to claim 40 wherein the elongate member has
a second end, the articulating limb further comprises a second limb
segment rotatably connected to the second end of the elongate
member, the injection mold has inner walls defining a second cavity
for forming the second limb member, the method further comprising
the steps of positioning the elongate member in the injection mold
so that the second end of the elongate member is within the second
cavity, and injecting a sufficient quantity of the thermoplastic
material into the second cavity at a temperature that is at least
30.degree. C. less than the lower of the first and second melting
points and under injection molding conditions permitting the
thermoplastic material to fill the second cavity to form the second
limb segment, thereby connecting the second limb segment to the
second end of the elongate member.
52. A method according to claim 51 wherein the elongate member has
a rotational member at its second end and the proximal end of the
second limb member defines an interior space sized and shaped to
capture the rotational member.
53. A method according to claim 37 wherein the first melting point
is about equal to the second melting point.
54. A method according to claim 37 wherein the limb end of the
connecting member is pivotally connected to the proximal end of the
first limb segment.
55. A method according to claims 54 wherein the limb end of the
connecting member defines an aperture and the proximal end of the
first limb segment comprises a pivot pin integrally formed
therewith and extending through the aperture of the connecting
member, a sufficient quantity of the first thermoplastic material
being injected into the first cavity to fill the connecting member
aperture to form the pivot pin of the proximal end of the first
limb member.
56. A method according to claim 37 wherein the limb end of the
connecting member is rotatably connected to the distal end of the
first limb segment.
57. A method according to claim 56 wherein the connecting member
has a rotational member at its limb end and the distal end of the
first limb member defines an interior space sized and shaped to
capture the rotational member of the connecting member.
58. A method according to claim 57 wherein the rotational member of
the connecting member comprises a disk.
59. A method according to claim 37 wherein the body part end of the
connecting member is adapted to be pivotally connected to the body
part.
60. A method according to claim 59 wherein the body part end of the
connecting member defines an aperture.
61. A method according to claim 37 wherein the body part end of the
connecting member is adapted to be rotatably connected to the body
part.
62. A method according to claim 61 wherein the body-part end of the
connecting member comprises a disk.
63. A toy figure having a trunk comprising: an upper torso member
having a reduced-diameter lower end, a middle section and an upper
end; a lower torso member having a substantially circular opening
at its upper end for seating the reduced-diameter lower end of said
upper torso member; and a ball joint having a body member and a
ball member pivotally and rotatably mounted in the body member, the
ball member comprising a shaft extending therefrom, the body member
of the ball joint being mounted in the upper torso and being shaped
and sized so as to occupy a substantial portion of the interior of
the middle section of the upper torso, and the shaft of the ball
joint being mounted in the lower torso such that the upper torso
member is seated for pivoting and rotating in the substantially
circular opening of the lower torso member.
64. A toy figure having a trunk comprising: an upper torso member
having a reduced-diameter lower end; a lower torso member having an
upper end, a lower end, and a substantially circular opening at its
upper end for seating the reduced-diameter lower end of said upper
torso member; and a ball joint having a body member and a ball
member pivotally and rotatably mounted in the body member, the ball
member comprising a shaft extending therefrom, the body member of
the ball joint being mounted in the lower torso and being shaped
and sized so as to occupy a substantial portion of the upper end of
the lower torso, and the shaft of the ball joint being mounted in
the upper torso such that the upper torso member is seated for
pivoting and rotating in the substantially circular opening of the
lower torso member.
65. A toy figure comprising: a trunk; a shaft member connected to
the trunk and having a first end projecting from the trunk, the
first end comprising a first substantially spherical ball member;
and a first limb member having a proximal end defining a cavity for
capturing the first spherical ball member to rotationally connect
the first limb member to the shaft member, the proximal end of the
first limb member further defining an arcuate opening to
accommodate pivotal movement of the shaft member relative to the
first limb member.
66. The toy figure of claim 65 wherein the shaft member has a
second end projecting from the trunk and comprising a second
substantially spherical ball member, the toy figure further
comprising a second limb member having a proximal end defining a
cavity for capturing the second spherical ball member to
rotationally connect the second limb member to the shaft member,
the proximal end of the second limb member further defining an
arcuate opening to accommodate pivotal movement of the shaft member
relative to the second limb member.
67. The toy figure of claim 65 wherein the proximal end of first
limb member comprises a pair of complimentary shells.
68. The toy figure of claim 65 wherein the trunk defines a cavity
and a portion of the shaft member between the first end and the
second end sits in the cavity defined by the trunk.
69. The toy figure of claim 68 wherein the portion of the shaft
member between the first end and the second end comprises a
projection and the cavity defined by the trunk captures the
projection.
70. An articulating limb of a toy figure, the articulating limb
being rotatable at two spaced-apart locations along a single member
and comprising: an elongate member having a first end comprising a
first rotational member and a second end comprising a second
rotational member; a first limb segment having a distal end
defining an interior space sized and shaped to capture the first
rotational member; and a second limb segment having a proximal end
defining an interior space sized and shaped to capture the second
rotational member.
71. The articulating limb of claim 70 wherein the first rotational
member comprises a disk.
72. The articulating limb of claim 71 wherein the second rotational
member comprises a disk.
73. An articulating limb of a toy figure, the articulating limb
being rotatable at one of two spaced-apart locations along a single
member and pivotable at the other of the two spaced-apart
locations, the articulating limb comprising: an elongate member
having a first end comprising a rotational member and a second end
defining an aperture; a first limb segment having an end defining
an interior space sized and shaped to capture the rotational
member; and a second limb segment having an internal pivot pin
formed within the second limb segment and adapted to engage the
aperture.
74. The articulating limb of claim 73 wherein the rotational member
comprises a disk.
Description
[0001] This is a continuation-in-part application of pending U.S.
patent application Ser. No. 09/088,385, filed Jun. 1, 1998. The
present invention generally relates to jointed toy figures and more
specifically relates to toy figures with an unusually large number
of unique articulating parts which give the figures a particularly
realistic look and feel.
FIELD OF THE INVENTION
Background of the Invention
[0002] Toy figures with articulating limbs are generally known. Toy
figures having a large number of articulating limbs are not widely
available because of expenses associated with manufacturing and
assembling the completed toy figure. Additionally, as the toy
figures decrease in size below about 10-12 inches in overall
length, the costs of manufacture and assembly increase considerably
because of difficulty in constructing and attaching small limbs
with multiple movable joints. A further problem in providing
relatively small toy figures with multiple articulating parts
concerns producing small joints that are durable and have the close
tolerances necessary to provide sufficient friction between the
moveable surfaces of the joints necessary for proper operation of
the joints. Also, it has long been a goal to combine realistically
articulating limbs with adjacent body parts in a manner which
minimizes any undesirable gaps so that the outer surface of the
articulating figure has a relatively continuous, life-like
appearance.
[0003] It would therefore be very desirable to provide a toy figure
with multiple articulating limbs having improved joint construction
with increased durability for manipulation through a variety of
realistic poses. It would also be desirable to provide methods
which reduce the amount of time and labor needed for assembling toy
figures of various sizes, including small sizes, having
articulating limbs. It would also be very desirable to provide toy
figures, especially toy figures with an overall length less than
about 10 inches, that provide improved joint operation.
Furthermore, it would be very desirable to enable the manufacture
of toy figures with realistic articulating limb and torso parts
having outer surfaces free of screws or other visible fasteners and
having reduced gaps between the connected parts.
SUMMARY OF THE INVENTION
[0004] The present invention provides toy figures having
articulating limbs with a large number of joints. The toy figures
of the present invention include one or more pivotally connected
parts having a first joint member made of a first material,
preferably a first thermoplastic material, and a second joint
member made of a second thermoplastic which has a melting point
that is less than that of the first material. The first and second
joint members are advantageously pivotally connected to one another
in an in situ injection molding method of the invention. Thus, in
another of its aspects, the present invention includes a method of
connecting a first joint member and a second joint member in an in
situ injection molding process, wherein the first joint member is
formed of a first material and the second joint member is formed of
a second material which is a thermoplastic material, wherein the
first joint member is inserted in a predetermined position into an
injection mold, as an insert part, and the second thermoplastic
composition is injected to form the second joint member around the
first joint member, pivotally connecting the two. In a presently
preferred embodiment, the first thermoplastic composition is an
acrylonitrile butadiene styrene (ABS) and the second thermoplastic
composition is a polyvinylchloride (PVC) composition having a
melting point of about 160.degree. C. and the difference in melting
points is at least about 70.degree. C.
[0005] In another of its aspects, the present invention includes a
method for making an articulating limb having first and second limb
segments connected by an elongate member. The elongate member is
formed of a first material and the first and second leg segments
are formed from a second material having a melting point lower than
the melting point of the first material. In this method, the
elongate member is placed into an injection mold having a cavity
for forming the first limb segment and a cavity for forming the
second limb segment. The elongate member is positioned in the
injection mold such that one end of the elongate member is within
the first cavity and the other end of the elongate member is within
the second cavity. The second material is then injected into the
mold at a temperature equal to or higher than the melting point of
the second material but lower than the first material's melting
point. In this manner, the first and second limb segments are
formed around the elongate member, the first limb segment being
connected to one end of the elongate member, and the second limb
segment being connected to the elongate member's other end.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a front elevation view, partially in
cross-section, depicting a toy figure having features of the
present invention;
[0007] FIG. 2 is an exploded perspective view of the toy figure of
FIG. 1 illustrating the head, torso and left limbs of the toy
figure, it being understood that the right limbs are corresponding
mirror-images of the left limbs;
[0008] FIG. 3 is an exploded perspective view of the component
parts of the toy figure of FIG. 1 which comprise a left arm
subassembly extending from the shoulder to the elbow just prior to
assembly and ultrasonic welding in an ultrasonic welding device as
depicted in this FIG.;
[0009] FIG. 4 is an exploded perspective view of the upper torso,
head/head joint, left and right arm assemblies and the body joint
of the toy figure of FIG. 1 prior to assembly and ultrasonic
welding;
[0010] FIG. 5 is an exploded view of the upper torso produced in
the assembly step depicted in FIG. 4, the lower torso, and left and
right leg assemblies prior to assembly and ultrasonic welding to
complete the toy figure of FIG. 1;
[0011] FIG. 6 is a perspective view of a first joint member used as
an insert part in the in situ injection molding process, wherein
the insert part is pivotally connected to a second joint member to
form the pivoting left shoulder of the toy figure of FIG. 1;
[0012] FIG. 7 is an elevation view of the insert part of FIG. 8 in
conjunction with the second joint member, including a pivot pin, as
formed in an injection mold, with part of the mold cut away for
purposes of illustration;
[0013] FIG. 8 is a perspective view of the pivotally connected
first and second joint members made by injection molding, as in
FIG. 7, showing in phantom lines the position and connection of the
insert part (first joint member) depicted in FIG. 6;
[0014] FIG. 9 is a perspective view of an insert part which
provides the ball member of a ball and socket joint of the
invention which corresponds to the body joint of the toy figure of
FIG. 1;
[0015] FIG. 10 is an elevation view of the insert part of FIG. 9 in
conjunction with a socket member, as formed in an injection mold,
with part of the mold cut away for purposes of illustration;
[0016] FIG. 11 is a perspective view of the ball and socket joint
made by injection molding, as in FIG. 10, showing in phantom lines
the position and connection of the insert part (first joint member)
depicted in FIG. 9 to the body of the socket member (second joint
member) of the ball and socket joint;
[0017] FIG. 12 is a perspective view of an insert part used in the
hand/wrist of the toy figure of FIG. 1;
[0018] FIG. 13 is an exploded perspective view of the finger
members and pivot pin used (in combination with the insert part of
FIG. 12) to form a left hand according to a method of the present
invention;
[0019] FIG. 14 is a perspective view of the finger members of a
left hand of a figure of the present invention with the finger
members pivotally mounted on a pivot pin prior to the injection
molding step to complete the left hand;
[0020] FIG. 15 is a perspective view of a left hand of the toy
figure of the FIG. 1 made by a molding method of the present
invention;
[0021] FIG. 16 is an elevation view of the insert parts of FIGS. 12
and 14 in conjunction with a left hand of the toy figure of the
present invention, as formed in an injection mold, with part of the
mold cut away for purposes of illustration;
[0022] FIG. 17 is a front elevational view, partially exploded,
illustrating the head, torso and left limbs of another toy figure
having features of the present invention, it being understood that
the right limbs are corresponding mirror-images of the left
limbs;
[0023] FIG. 18 is a front elevational view, partially exploded, of
the toy figure of FIG. 17;
[0024] FIG. 19 is an elevation view, in partial cross-section, of
the left arm of the toy figure of FIG. 17 as formed in an injection
mold;
[0025] FIG. 20 is a perspective view of the left arm of the toy
figure of FIG. 17, showing in phantom lines the position and
connection of the elongate member and the connecting member;
[0026] FIG. 21 is a perspective view of the connecting member of
the left arm of the toy figure of FIG. 17;
[0027] FIG. 22 is a perspective view of the elongate member of the
left arm of the toy figure of FIG. 17;
[0028] FIG. 23 is an exploded perspective view, partially in
cross-section, of another embodiment of the elongate member of the
left arm in association with the first arm segment;
[0029] FIG. 24 is a perspective view of another embodiment of the
left arm, showing in phantom lines the position and connection of
the elongate member of FIG. 23 and the connecting member;
[0030] FIG. 25 is a perspective view of the elongate member of the
left leg of the toy figure of FIG. 17;
[0031] FIG. 26 is an elevation view, in partial cross-section, of
the left leg of the toy figure of FIG. 17 as formed in an injection
mold;
[0032] FIG. 27 is a perspective view of the left leg of the toy
figure of FIG. 17, showing in phantom lines the position and
connection of the elongate member of FIG. 25;
[0033] FIG. 28 is a perspective view, partially exploded, of the
left leg and hip segment of the toy figure of FIG. 17;
[0034] FIG. 29 is an exploded perspective view, partially in
cross-section, of another embodiment of the elongate member of the
left leg in association with the first leg segment;
[0035] FIG. 30 is a perspective view of another embodiment of the
left leg, showing in phantom lines the position and connection of
the elongate member of FIG. 29;
[0036] FIG. 31 is a perspective view of the lever arm of the head
of the toy figure of FIG. 17;
[0037] FIG. 32 is a perspective view of the head of the toy figure
of FIG. 17, showing in phantom lines the position and connection of
the lever arm of FIG. 31;
[0038] FIG. 33 is an elevation view, in cross-section, of the head
of the toy figure of FIG. 17 as formed in an injection mold;
[0039] FIG. 34 is a front elevational view, in partial
cross-section, depicting another embodiment of the torso mounting
structure of a toy figure of the present invention;
[0040] FIG. 35 is an elevation view, in partial cross-section, of
the embodiment of the left arm of FIG. 24 as formed in an injection
mold;
[0041] FIG. 36 is an elevation view, in partial cross-section, of
the embodiment of the left leg of FIG. 30 as formed in an injection
mold;
[0042] FIG. 37 is an exploded perspective view, partially in
cross-section, of another embodiment of the elongate member of the
left arm in association with the first arm segment;
[0043] FIG. 38 is a perspective view of another embodiment of the
left arm, showing in phantom lines the position and connection of
the elongate member of FIG. 37 and the connecting member;
[0044] FIG. 39 is an elevation view, in partial cross-section, of
the embodiment of the left arm of FIG. 38 as formed in an injection
mold;
[0045] FIG. 40 is a perspective view of another embodiment of the
elongate member of the left arm;
[0046] FIG. 41 is a perspective view of another embodiment of the
left arm, showing in phantom lines the position and connection of
the elongate member of FIG. 40 and the connecting member;
[0047] FIG. 42 is an elevation view, in partial cross-section, of
the embodiment of the left arm of FIG. 41 as formed in an injection
mold;
[0048] FIG. 43 is a perspective view of another embodiment of the
elongate member of the left leg;
[0049] FIG. 44 is a perspective view of another embodiment of the
left leg, showing in phantom lines the position and connection of
the elongate member of FIG. 43;
[0050] FIG. 45 is an elevation view, in partial cross-section, of
the embodiment of the left leg of FIG. 44 as formed in an injection
mold;
[0051] FIG. 46 is an exploded perspective view, partially in
cross-section, of another embodiment of the elongate member of the
left leg in association with the first leg segment;
[0052] FIG. 47 is a perspective view of another embodiment of the
left leg, showing in phantom lines the position and connection of
the elongate member of FIG. 46; and
[0053] FIG. 48 is an elevation view, in partial cross-section, of
the embodiment of the left leg of FIG. 47 as formed in an injection
mold.
DETAILED DESCRIPTION OF THE INVENTION
[0054] Reference is made to FIG. 1 of the drawings which depicts a
toy figure designated by reference numeral 10. Toy FIG. 10 includes
a torso 12 and limbs including a left arm 14, a right arm 16, a
left leg 18, and a right leg 20, as well as a head 22.
[0055] In a preferred embodiment, left arm 14 and right arm 16,
which are shown in different orientations in FIG. 1, comprise a
plurality of arm segments designated by numerals 24, 42, 58, 66, 80
and 102. These arm segments are interconnected at joints 14a, b, c,
d, e and f and 16a, b, c, d, e and f, respectively, to provide
articulating left and right arms 14 and 16. Since the two arms 14
and 16 and the two legs 18 and 20, as well as the component parts
thereof, are mirror-images of each other, we will describe the
details of left arm and left leg 14 and 18, it being understood
that the corresponding right arm and right leg 16 and 20 are
comprised and assembled identically.
[0056] With reference to FIGS. 1 and 2, first arm segment 24 has a
generally spherical top portion 26 with a short trunk 26a depending
therefrom and integrally formed therewith to give the appearance of
a left shoulder and approximately the upper 1/3 of the upper arm.
Spherical body 26 has an arcuate opening 27 into the interior of
first arm segment 24. A joint member 25 having a lever arm 28 is
pivotally attached to first arm segment 24 at joint 14a. Lever arm
28 terminates at one end in a disk 30 and at the other end in a
ring 31 Ring 31 has a bore for mounting joint member 25. Ring 31 of
lever arm 28 extends through arcuate opening 27 and is pivotally
mounted on pivot pin 33 formed in the first arm segment as
described below.
[0057] This mounting of joint member 25 inside trunk 12 permits
first arm segment 24 to pivot at joint 14a through an arc A of
approximately 90.degree.. Thus, when first arm segment 24 is
mounted to trunk 12, as described more fully below, arm segment 24
is capable of pivoting within the arm hole 36 of the trunk such
that the gap between the outer surface of body 26 of the first arm
segment and the circular edge 38 of arm hole 36 is small at all
positions of first arm segment 24 along arc A.
[0058] First arm member 24 further comprises a disk 32 spaced apart
from a bottom surface of body 26a by a short shaft 34, by way of
which first arm segment 24 is rotatingly connected to second arm
segment 42. As best seen in FIG. 2, second arm segment 42 has
complementary second arm segment shells 42a and 42b which are
attached by way of a cylindrical pin 50 in second arm segment shell
42a having a bore 52 therein for receiving assembly pin 54
extending from the inside surface of second arm shell 42b. When
these second arm segment shells are assembled, disk 32 of the first
arm segment is seated in a corresponding circular interior space 46
with shaft 34 extending through a bore in top wall 44 of second arm
segment 42, the bore being formed by complementary semi-circular
cut-outs 48a and 48b in top wall 44. With disk 32 positioned in
interior space 46 and resting against the interior surface 44a of
top wall 44, second arm segment 42 is capable of rotating
360.degree. about the axis of shaft 34 at joint 14b with respect to
first arm segment 24. Additionally, second arm shell 42 has an
arcuate opening 56 extending along the curved body surface of
second arm segment 42 adjacent pin 50 which permits movement at
joint 14c, as explained below.
[0059] Left arm 14 further comprises a third arm segment 58 which
acts as a double pivot member comprising. Third arm segment 58 has
a plate 60 with bores 62 and 64 extending transversely therethrough
at the opposite ends of the plate. Third arm segment 58 is
connected through bore 62 to pin 50 in second arm segment 42 to
provide joint 14c, a pivot joint.
[0060] Left arm 14 further includes a fourth arm segment 66 which
is pivotally connected to third arm segment 58 at joint 14d. Fourth
arm segment 66 comprises complementary fourth arm segment shells
66a and 66b. Fourth arm segment shell 66a is provided with a pivot
pin 68 which passes through bore 64 to provide pivoting motion. Pin
68 has a bore 70 therein to mate with complementary assembly pin 71
in fourth arm segment shell 66b. As will be appreciated from an
inspection of FIGS. 1 and 2, fourth arm segment 66 is analogous in
structure and function to second arm segment 42, albeit shorter in
overall length and inverted with respect to the orientation of
second arm segment 42. Thus, fourth arm segment 66 has a circular
interior space 72 (analogous to circular interior space 46) and a
bottom wall 74 defining semi-circular cut outs 74a and 74b defining
a bore 76 in communication with interior space 72.
[0061] Fourth arm segment 66 thus is connected to third arm segment
58 by inserting pin 68 through bore 64 of the third arm segment 58
to provide joint 14d. Thus it will be appreciated that third arm
segment 58 provides a double pivot member which allows second arm
segment 42 and fourth arm segment 66 to independently pivot with
respect to third arm segment 58 at joints 14c and 14d,
respectively.
[0062] When the second arm segment and fourth arm segment are
pivoted toward each other, each of the respective arm segments are
capable of pivoting through an arc of about 90.degree. (represented
by B and C) such that the second and fourth arm segments may be
pivoted a total of approximately 180.degree. with respect to one
another with the third arm segment thus functioning as an elbow
joint. Because the third arm segment 58 uses a double pivot
arrangement whereas a natural human elbow joint has a single pivot
point, the second and fourth arm segments are spaced apart from
each other.
[0063] As best seen in FIG. 1, when left arm 14 is fully extended
lengthwise, third arm segment 58 abuts end wall 56a of arcuate
opening 56 in the bottom of second arm segment 42 and end wall 78a
defining arcuate opening 78 of the fourth arm segment to provide a
continuous outer arm surface. Third arm segment 58 is provided with
wing-like extensions 80 which extend outwardly and curve slightly
downwardly from the outer edge 83 to fill in the gaps caused by the
pivotal attachment of second and fourth arm segments 42 and 66 at
opposite ends of third arm segment 58, as needed to assure that
articulating left arm 14 has a full range of motion about third arm
member 58. The wing-like extensions thus allow arm 14 to exhibit a
relatively continuous outer arm surface where second and fourth arm
segments 42 and 66 are joined to third arm segment 58 without
interfering with the pivoting arm segments.
[0064] Left arm 14 further comprises a fifth arm segment 80 which
is rotatingly connected to fourth arm segment 66 at joint 14e by
lower arm joint member 82. Joint member 82 comprises a disk 84 and
a plate 86 spaced apart from each other by a short shaft 88. Fifth
arm segment 80 comprises complementary shells 80a and 80b having a
pivot pin 90 with a bore 92 therein with complementary fifth arm
segment shell 80b having an assembly pin 94 extending therefrom to
fit within bore 92. Fifth arm segment 80 also has a circular
interior space 96 and a top wall 98 with a bore 100 therethrough in
communication with interior space 96. As will be appreciated from
an inspection of FIGS. 1 and 2, fifth arm segment 80 and fourth arm
segment 66 are essentially identical in structure and operation but
are of different respective dimensions. When fourth and fifth arm
segments 66 and 88 are rotatingly connected at joint 14e by lower
arm joint member 82, fourth and fifth arm segments 66 and 80 are
mated at their respective walls 74 and 98 with shaft 88 extending
through bores 76 and 100 and with disk 84 seated on the interior
surface of wall 74 and plate 86 seated on the interior surface of
wall 98. Thus fourth and fifth arm segments 66 and 80 are capable
of rotating with respect to one another 360.degree. about shaft 88,
with disk 84 rotating in interior space 72.
[0065] Left hand 102, which is discussed in detail below, includes
a ring 104 with a central bore 106. Ring 104 is spaced apart from
the bottom wall 108 of left hand 102 by shaft 110. Left hand 102 is
pivotally connected at joint 14f to fifth arm segment 80 by way of
the mounting of ring 104 on pivot pin 90, with shaft 110 extending
through an arcuate opening 91 in arm segment 80. Left hand 102
therefore pivots on pivot pin 90.
[0066] In another embodiment shown in FIGS. 17-22 and particularly
suitable for toy figures three inches or less in overall height,
left arm 14 comprises a first arm segment 500, a second arm segment
505, and an elongate member 510. As shown in FIGS. 17-21, first arm
segment 500 has a proximal end 515 and a distal end 520, second
limb segment 505 has a proximal end 525 and a distal end 530, and
elongate member 510 (as shown in FIG. 22) has a first end 535 and a
second end 540.
[0067] Proximal end 515 of first arm segment 500 is adapted to be
connected to upper torso 250 of the toy figure. In the preferred
embodiment, connecting member 565 (shown in FIG. 21) connects
proximal end 515 to upper torso 250. Connecting member 565 has a
body-part end 590 comprising a disk 575, and a limb end 595
comprising a ring 580 defining an aperture 585. Proximal end 515 of
first arm segment 500 comprises an integrally formed interior pivot
pin 600 (see FIG. 19) and defines a slot 560. A pivotal connection
between arm segment 500 and connecting member 565 is formed with
ring 580 extending through slot 560 into the interior of arm
segment 500 and pivot pin 600 extending through aperture 585.
Body-part end 590 of connecting member 656 is rotatably connected
to upper torso 250 by seating disk 575 within a mounting structure
analogous to the mounting structure described in more detail below
with respect to disk 30.
[0068] Distal end 520 of first arm segment 500 is connected to
first end 535 of elongate member 510. In the embodiments shown in
FIGS. 17, 19, 20, 22, 41, and 42, distal end 520 of first arm
segment 500 is pivotally connected to first end 535 of elongate
member 510, with first end 535 comprising a ring 542 defining an
aperture 545 and distal end 520 comprising pivot pin 550 extending
through aperture 545. A perspective view of an embodiment of such
an elongate member 510 is shown in FIG. 40. In the embodiments
shown in FIGS. 23, 24, 25, 37, 38 and 39, distal end 520 of first
arm segment 500 is rotatably connected to first end 535 of elongate
member 510, with first end 535 comprising disk 251 and distal end
520 defining a circular interior space 560 capturing disk 251.
[0069] Proximal end 525 of second arm segment 505 is connected to
second end 540 of elongate member 510. In the preferred
embodiments, the second arm segment's proximal end 525 is either
pivotally (see FIGS. 19, 20, 22, 23, 24 and 35) or rotatably (see
FIGS. 37, 38, 39, 40, 41 and 42) connected to the elongate member
using a pivot pin or a disk, respectively, in a manner analogous to
that described above with respect to distal end 520.
[0070] In one embodiment, left leg 18 comprises a plurality of leg
segments which are interconnected at a series of joints to provide
the articulating leg whose structure and movement correspond to arm
14 described above. Thus, leg 18 comprises first, second, third,
fourth and fifth leg segments 124, 142, 158, 166, and 180 which are
analogous to the left arm segments 24, 42, 58, 66 and 80, as well
as to the right arm segments 24r, 42r, 58r, 66r and 80r and right
leg segments 124r, 142r, 158r, 166r and 180r.
[0071] With reference to FIGS. 1 and 2, first leg segment 124 has a
generally spherical top portion 126 with a short trunk 126a
depending therefrom and integrally formed therewith to give the
appearance of a left hip and approximately the upper 1/3 of the
upper leg. Spherical body 126 has an arcuate opening 127 into the
interior of first leg segment 124. A joint member 125 having a
lever leg 128 is pivotally attached to first leg segment 124 at
joint 18a. Lever arm 128 terminates at one end in a disk 130 and at
the other end in a ring 131. Ring 131 has a bore for mounting joint
member 125. Ring 131 of lever leg 128 extends through arcuate
opening 127 and is pivotally mounted on pivot pin 133 formed in the
first leg segment as described below.
[0072] This mounting of joint member 125 inside trunk 12 permits
first leg segment 124 to pivot at joint 18a through an arc D of
approximately 90.degree.. Thus, when first leg segment 124 is
mounted to trunk 12, as described more fully below, leg segment 124
is capable of pivoting with respect to trunk 12 such that the gap
between the outer surface of body 126 of the first leg segment and
the circular edge 138 of leg hole 136 is small at all positions of
first leg segment 124 along arc D.
[0073] First leg member 124 further comprises a disk 132 spaced
apart from a bottom surface of body 126a by a short shaft 134, by
way of which first leg segment 124 is rotatingly connected to
second leg segment 142. As best seen in FIG. 2, second leg segment
142 has complementary second leg segment shells 142a and 142b which
are attached by way of a cylindrical pin 150 in second leg segment
shell 142a having a bore 152 therein for receiving assembly pin 154
extending from the inside surface of second leg shell 142b. When
these second leg segment shells are assembled, disk 132 of the
first leg segment is seated in a corresponding circular interior
space 146 with shaft 134 extending through a bore in top wall 144
of second leg segment 142, the bore being formed by complementary
semi-circular cut-outs 148a and 148b in top wall 144. With disk 132
positioned in interior space 146 and resting against the interior
surface 144a of top wall 144, second leg segment 142 is capable of
rotating 360.degree. about the axis of shaft 134 at joint 18b with
respect to first leg segment 124. Additionally, second leg shell
142 has an arcuate opening 156 extending along the curved body
surface of second leg segment 142 adjacent pin 150 which permits
movement at joint 18c, as explained below.
[0074] Left leg 18 further comprises a third leg segment 158 which
acts as a double pivot member comprising. Third leg segment 158 has
a plate 160 with bores 162 and 164 extending transversely
therethrough at the opposite ends of the plate. Third leg segment
158 is connected through bore 162 to pin 150 second leg segment 142
to provide joint 18c, a pivot joint.
[0075] Left leg 18 further includes a fourth leg segment 166 which
is pivotally connected to third leg segment 158 at joint 18d.
Fourth leg segment 166 comprises complementary fourth leg segment
shells 166a and 166b. Fourth leg segment shell 166a is provided
with a pivot pin 168 which passes through bore 164 to provide
pivoting motion. Pin 168 has a bore 170 therein to mate with
complementary assembly pin 171 in fourth leg segment shell 166b. As
will be appreciated from an inspection of FIGS. 1 and 2, fourth leg
segment 166 is analogous in structure and function to second leg
segment 142, albeit slightly shorter in overall length and inverted
with respect to the orientation of second leg segment 142. Thus,
fourth leg segment 166 has a circular interior space 172 (analogous
to circular interior space 146) and a bottom wall 174 defining
semi-circular cut outs 174a and 174b (shown with phantom lines)
defining a bore 176 in communication with interior space 172.
[0076] Fourth leg segment 166 thus is connected to third leg
segment 158 by inserting pin 168 through bore 164 of the third leg
segment 158 to provide joint 18d. Thus it will be appreciated that
third leg segment 158 provides a double pivot member which allows
second leg segment 142 and fourth leg segment 166 to independently
pivot with respect to third leg segment 158 at joints 18c and 18d,
respectively.
[0077] As best seen in FIG. 1, when left leg 18 is fully extended
lengthwise third leg segment 158 abuts end wall 156a of arcuate
opening 156 in the bottom of second leg segment 142 and end wall
178a defining arcuate opening 178 of the fourth leg segment to
provide a continuous outer leg surface.
[0078] When second leg segment and fourth leg segment are pivoted
toward each other, each of the respective leg segments are capable
of pivoting through an arc of about 90.degree. (analogous to arcs C
and D) such that the second and fourth leg segments may be pivoted
a total of approximately 180.degree. with respect to one another
with the third leg segment thus functioning as an elbow joint.
Because the third leg segment 158 uses a double pivot arrangement
whereas a natural human elbow joint has a single pivot point second
and fourth leg segments are spaced apart from each other. To fill
the gap in the outer surfaces of the second and fourth leg segments
142 and 166 where they attach to third leg segment 158, third leg
segment 158 is provided with wing-like extensions 180 which extend
outwardly and curve slight downwardly from the outer edge 183 of
third leg member 158 to fill in the gaps between second and fourth
leg segments 142 and 166 which are needed to assure that
articulating left leg 18 has a full range of motion about third leg
member 158. The wing-like extensions thus allow leg 18 to exhibit a
relatively continuous outer leg surface where second and fourth leg
segments 142 and 166 are joined to third leg segment 158.
[0079] Left leg 18 further comprises a fifth leg segment 181 which
is rotatingly connected to fourth leg segment 166 at joint 18e by a
disk 184 spaced apart from fifth leg segment 180 by a short shaft
188. Fifth leg segment 181 has a bore 190 extending therethrough at
its lower end. When fourth and fifth leg segments 166 and 181 are
rotatingly connected at joint 18e by inserting disk 184 into
interior space 172 of fourth leg segment 166, fourth and fifth leg
segments 166 and 181 are mated at their respective walls 174 and
198 with shaft 188 extending through bores 176 and with disk 184
seated on the interior surface of wall 174. Thus fourth and fifth
leg segments 166 and 181 are capable of rotating with respect to
one another 360.degree. about shaft 188, with disk 184 rotating in
interior space 172.
[0080] Left foot 202 includes L-shaped left foot shells 202a and
202b. Left foot shell 202a has a pivot pin 204 having a bore 206
therein positioned at the upper portion of the "L" and a pivot pin
208 having a bore 210 therein positioned at the terminal end of the
base of the L. Foot 202 further comprises large toe member 210 and
smaller toe member 212, which have respective proximal ends 210a
and 212a, and bores 210b and 212b extending transversely
therethrough. Toe members 210 and 212 are pivotally mounted on
pivot pin 206 and fifth leg segment 181 is mounted to pivot pin
204. Left foot shell 202b connects to foot shell 202 by mating
assembly pins 214 and 216 which fit in bores 206 and 210.
[0081] In another embodiment shown in FIGS. 17, 18, 26 and 27 and
particularly suitable in toy figures three inches or less in
overall length, leg 18 comprises a first leg segment 605, a second
leg segment 610, and an elongate member 615. First leg segment 605
has a proximal end 620 and a distal end 625, and second leg segment
610 has a proximal end 630 and a distal end 635. Elongate member
615 (see FIG. 25) has a first end 640 and a second end 645.
[0082] Proximal end 620 of first leg segment 605 is adapted to be
connected to lower torso 252. In a preferred embodiment, shown in
FIGS. 17, 18 and 28, proximal end 620 is rotatably connected to hip
segment 660, which in turn is connected to lower torso 252. In this
embodiment, proximal end 620 of first leg segment 605 comprises a
disk 655 captured by an internal space 665 formed by hip segment
660. Hip segment 660 is connected to lower torso 252 in a manner
described below.
[0083] Distal end 625 of first leg segment 605 is connected to
first end 640 of elongate member 615. In the embodiments shown in
FIGS. 17, 26, 27, 44, and 45, distal end 625 is pivotally connected
to first end 640, with first end 640 comprising a ring 647 defining
an aperture 650 and distal end 625 comprising pivot pin 652
extending through aperture 650. (A perspective view of an
embodiment of such an elongate member 615 is shown in FIG. 43.) In
the embodiments shown in FIGS. 29, 30, 36, 46, 47 and 48, distal
end 625 of first leg segment 605 is rotatably connected to first
end 640, with first end 640 of elongate member 615 comprising disk
642 and distal end 625 defining a circular interior space 632
capturing disk 642.
[0084] Proximal end 630 of second leg segment 610 is connected to
second end 645 of elongate member 615. In preferred embodiments,
the second leg segment's proximal end 630 is either pivotally (see
FIGS. 17, 26, 27, 29 30, and 36) or rotatably (see FIGS. 43, 44,
45, 46, 47, and 48) connected to the elongate member 615 using a
pivot pin or a disk, respectively, in a manner analogous to that
described above with respect to distal end 625.
[0085] With further reference to FIGS. 1 and 2, trunk 12 comprises
an upper torso 250 and a lower torso 252 pivotally and rotatingly
connected to one another at joint 12a. As best seen in FIG. 1,
upper torso 250 has a reduced lower end 256 which is defined by a
gently tapering wall 258 having a collar which is partially seated
in upper opening 260 in lower torso 252. Upper opening 260 thus
forms a substantially circular seat to meet with the reduced end
256 of upper torso 250 such that trunk 12 is capable of
articulating when upper torso 250 and lower 252 are connected by
body joint 254. In a particularly preferred embodiment, upper torso
is capable of pivoting left to right with respect to the lower
torso over an arc of about 30.degree. (e.g., 15.degree. to each
side) of an upright position and is capable of pivoting front to
back by approximately 30.degree. (5.degree. back and 25.degree.
forward) to simulate a range of motion about the waist of a human
being. Body joint 254, which is more fully described below with
reference to FIGS. 9-11, functions as a ball and socket joint.
[0086] In one embodiment, the head 22 of toy FIG. 10 is
substantially hollow and cast of a thermoplastic resin such as PVC,
preferably using a rotational molding technique as known in the
art. The base 261 of the head has an involuted hemispherical bottom
wall 262 defining a cavity 263 with a bore 264 therethrough at the
top of the hemisphere. Head 22 is attached to upper torso 250 by a
head joint member 266 which has a generally spherical body with an
upper portion 267 supporting a mushroom-shaped attachment member
270 which is sized and shaped to snap-fit through bore 264 and be
retained within the interior space of head 22 with the upper
surface 267 of head joint 266 residing in cavity 263. Joint 266 has
a second attachment disk 269 (analogous to disk 30 of joint member
25) which is pivotally connected inside of joint member 266 via
lever arm 274 in an analogous manner to the slot 280 connecting
lever arm 25 and first arm segment 24 as discussed below. When head
22 is connected to trunk 12, head 22 is capable of pivoting about a
pivot joint located in head joint 266 (analogous to the pivot joint
in first arm segment 24) as well as rotating about disk 269. Thus,
head 22 is capable of swiveling and nodding relative to torso
250.
[0087] In another embodiment shown in FIGS. 17, 32 and 33 and
particularly suitable in toy figures three inches or less in total
length, head 22 is attached to upper torso 250 by lever arm 670. As
shown in FIGS, 31-33, lever arm 670 has a proximal end 690 and a
distal end 685.
[0088] Proximal end 690 of lever arm 670 is adapted to be attached
to upper torso 250. In a preferred embodiment, proximal end 690
extends through slot 700 formed in the bottom of head 22 and
comprises a disk 695. Disk 695 is rotatably captured within slot
280 in the same manner as disk 39 described below.
[0089] Distal end 685 of lever arm 670 is located within the
interior of head 22 and, in a preferred embodiment comprises a ring
675 defining an aperture 680. Head 22 has an internal pivot pin 705
extending through aperture 680 to pivotally connect head 22 to
lever arm 670.
[0090] Torso 250 includes slots 280 for the rotational attachment
of left arm 14, right arm 16 and head 22. Attachment of left arm 14
will now be described, it being understood that right arm 16 and
head 22 are similarly attached. See FIG. 4. Left arm 14 is
connected to upper torso 250 at arm hole 36 by seating disk 30
within a mounting structure comprising a slot 280 defined by
vertical upstanding, parallel spaced walls 282 and 284. Wall 284
has a semi-circular cut-out 286 along its exposed edge and the
opposite wall 282 has a horizontal upstanding ridge 288 formed on
its inner surface 290. Disk 30 of first arm member 24 is provided
with a groove 37 which is complementary to ridge 288 and acts as a
detent when a disk 30 is rotated within slot 280. Torso shell 250a
is provided with a complementary mounting structure (not shown).
Thus, when complementary upper torso shells 250a and 250b are mated
edgewise, the open ends of the complementary mounting structures
including particularly their respective upstanding walls abut to
form a retention seat for disk 30 of first arm segment 24 with
shaft 28 of arm joint 24 extending through the abutting
semi-circular cut-outs 286 in the abutting wall such that left arm
member 24 and thus left arm 14 is rotatingly attached to upper
torso 250. A disk attached to a shaft member (e.g., disk 30
attached to shaft 28) and a retention seat (e.g., slot 280 with
wall 284 having a bore therethough to rotatingly seat disk 30) are
an example of complementary joint members or attachment means which
comprise a rotational joint which may be used to connect adjacent
body parts of toy FIG. 10.
[0091] Upper torso 250 and lower torso 252 are connected at joint
12a by a body joint member 254 having a rectilinear portion 300
with a pair of laterally-extending rails 302 extending from the
side walls 304 of body 300. Body joint member 254 further comprises
a ball-member 306, rotatingly and pivotally mounted in body 300 and
having a shaft 308 depending therefrom and connected to a plate
310.
[0092] Portion 300 of body joint member is seated within torso 250
using a mounting structure 281 that is different than previously
described for seating disk 30 of first arm segment 24 in slot 280.
Thus, mounting structure 281 has a bottom wall 312 having a
semi-circular cut-out 314. Bottom wall 312 is connected to a pair
of upstanding parallel spaced side walls 316, which side walls have
complementary rectangular cut-outs 318. Body 300 of body joint 254
is seated on bottom wall 312 with notches 318 engaging rails 302 of
the body joint and shaft 308 extending through cut-out 314 and
through the opening at the bottom of upper torso 250. In an
embodiment shown in FIGS. 17 and 34 and particularly suitable in
toy figure is three inches or less in overall length, portion 300
is sized so as to occupy a substantial portion of the upper torso
250.
[0093] Lower torso 252 has yet another type of mounting structure,
designated by reference numeral 283, which includes an upper plate
320 having a semi-circular cut-out 322 at its edge. Top plate 320
has a pair of parallel reinforcing side walls 324 to add structural
support to top wall 320. Complementary top plate and reinforcing
side plates are formed on lower torso shell 252a which
complementary walls abut when the shells 252a and 252b of lower
torso 252 are mated edgewise to capture plate 310 beneath top wall
320. As will be appreciated, the length of shaft 308 is
predetermined so that when body 300 is seated on bottom wall 312
and plate 310 is seated beneath top wall 320, the reduced end 256
of upper torso is pivotably and rotatably seated in substantially
circular opening 260 of lower torso 252.
[0094] Turning to FIG. 3, assembly of action FIG. 10 proceeds with
step-wise connection of the components of the limbs and torso of
action FIG. 10 using an ultrasonic welding apparatus. The
ultrasonic welding apparatus comprises base 350 and an ultrasonic
horn 352 that resonates at a sufficiently high frequency, for
example 20 kHz-40 kHz, with power output of from 1000 watts to
about 4000 watts to heat the surfaces of parts which are housed
within the ultrasonic welding apparatus and causes the surfaces of
the plastic parts to be welded together edgewise. As known in the
art, the duration of power of the ultrasonic welding apparatus may
be controlled to assure a good weld of the intended abutting
surface.
[0095] Referring to FIGS. 3-5, in a presently preferred embodiment
of the present invention, the ultrasonic welding assembly is
carried out in a series of steps to join the limb segments into
articulating limb subassemblies and attach the limb subassemblies
to one another to form a completed limb, and then to connect the
completed limbs to the upper and lower torsos 250 and 252 and the
upper and lower torsos 250 and 252 to each other.
[0096] As shown in FIG. 3, arm shell 42a is inserted into
ultrasonic base 350 and connected to first arm segment 24 by
inserting disk 32 into receptacle 46. Third arm segment 58 is
connected to the pin 50 of arm shell 42a through the bore 62 in
plate 60 and arm shell 42b is mated edgewise with complementary arm
shell 42a with assembly pin 54 being received in bore 52 of pin 50.
When arm shells 42a and 42b are mated, disk 32 (and thus first arm
segment 24) is rotationally captured in interior space 46 of second
arm segment 42 and third arm segment 58 is captured and pivotally
mounted on pivot pin 50 of second arm segment 42. Then, ultrasonic
energy is applied to weld arm shells 42a and 42b (preferably formed
of ABS) edgewise without adversely affecting the above-described
rotational and pivotal connections. The assembly so formed is a
first left arm subassembly.
[0097] In the next step of assembling the left arm, arm shells 66a
and 66b of the fourth arm segment 66 are brought together for
ultrasonic welding with attaching pin 71 being received in bore 70
after connecting the first left arm subassembly (completed in the
prior ultrasonic welding step) by connecting pin 68 through bore 64
of third arm segment 58 extending from the first left arm
subassembly and by inserting disk 84 of lower arm joint 82 into
receptacle 72. After completion of the second ultrasonic welding
step, a second left arm subassembly is provided which is connected,
in a third ultrasonic welding, to fifth left arm segment 80 and
left hand 102. In this third ultrasonic welding step arm shells 80a
and 80b are mated edgewise and welded essentially as described
above to capture plate 86 of lower arm joint 82 in receptacle 96
and to capture ring 104 pivotally mounted on pin 90. After the
third ultrasonic welding step the left arm 14 is complete.
[0098] The left leg is assembled in essentially the same manner
using three ultrasonic welding steps as described above for
assembly of the left arm. Thus, referring to FIGS. 1 and 2, in step
(1), left first leg segment 124, left leg shells 142a and 142b and
third left leg member 158 are joined in an ultrasonic welding step
to provide a first leg subassembly; in step (2), a further
ultrasonic welding step, the first leg subassembly is pivotally
connected by way of bore 164 in the portion of third leg member
158, extending from the first leg subassembly to pin 168 of leg
shell 166a and to fifth leg segment 180 by inserting disk 184 into
a receptacle 172 to form a second leg subassembly; and in step (3),
toe members 210 and 212 are pivotally mounted on pin 208 and pin
204 is pivotally mounted through bore 190 of fifth leg segment 180
and the foot shells 202a and 202b are brought together edgewise
with assembly pins 214 and 216 being received in bores 206 and 210,
respectively, prior to ultrasonic welding to capture second leg
subassembly via bore 190 and to capture toe members 210 and 212 to
complete left leg 18.
[0099] Right arm 16 and right leg 20 are assembled in the same
manner as left arm 14 and left leg 18.
[0100] Referring now to FIG. 4, the left arm 14 and right arm 16
are connected to upper torso 250 by inserting disks 30 into slots
280. The head 22 (previously joined to head joint 266) is connected
by inserting disk 269 into slot 280. And, body 300 of body joint
254 is seated on bottom plate 312 with rails 302 received in
notches 318 of side plates 316. Then upper torso shells 250a and
250b are aligned edgewise with complementary slots located near the
respective arm holes and opening at the top and bottom of the torso
for the head joint 266 and body joint 254 abutting to capture disks
30 (arms 14 and 16) and 269 (head 22) and rails 302 (body joint
254), followed by ultrasonic welding to provide an upper torso 250
having a left arm 14, a right arm 16, a head 22 and a body joint
254.
[0101] With reference to FIG. 5, the leg assemblies and lower torso
are attached to the completed upper torso (1) by seating plate 310
beneath upper wall 320 so that shaft 308 extends through
semi-circular cut-out 322, and (2) by positioning disks 130 in the
interior space 330 defined by lower torso walls 332 and 334 with
shafts 128 extending through cut-outs 332 and 334 of lower torso
252. In this orientation, the spherical outer walls 126 and 126r of
first leg segment 124 and 124r are flush against the concave
sidewalls 336 and 338 of lower torso 252. Then lower torso shells
252a and 252b are mated edgewise and connected by ultrasonic
welding to capture upper torso 250 and left and right legs 18 and
20, thereby completing the assembly of action FIG. 10.
[0102] In another embodiment shown in FIGS. 17, 18 and 28 and
particularly suitable for use in toy figures three inches or less
in overall length, the leg and hip assemblies are attached to lower
torso 252 by means of shaft member 710. Shaft member 710 is
captured within a cavity 715 formed by lower torso 252. Shaft
member 710 has a first end 720 and a second end 725 projecting from
lower torso 252, each end comprising a substantially spherical ball
member 730.
[0103] Hip segment 660 of each leg and hip assembly 737 comprises a
pair of complimentary shells 745 and 750 defining a cavity 735 for
capturing spherical ball member 730, thereby rotatably connecting
hip segment 660 to shaft member 710. Hip segment 660 also defines
slot 740 to accommodate the pivotal movement of shaft member 710 in
relation to hip segment 660. In the preferred embodiment, a
projection 755 is situated on shaft member 710 and is captured by
cavity 715 to keep shaft member 710 from rotating or moving
laterally within cavity 715.
[0104] In yet another of its aspects, the present invention entails
an injection molding method for producing a joint in which a first
joint member is pivotally connected to a second joint member. This
method comprises the steps of:
[0105] (i) inserting a first joint member having a first portion
with a substantially circular bore into an injection mold having
inner walls defining a cavity for forming at least the second joint
member, so that the first joint member is positioned in the
injection mold so that the first portion is maintained in spaced
relation to the walls of the mold and a second portion of the first
joint member is outside of the mold cavity; and
[0106] (ii) injecting a thermoplastic composition into the cavity
of the mold under suitable injection molding conditions so that the
thermoplastic composition fills the cavity and engulfs the first
portion of the first joint member and fills the bore to form in
situ a joint including a second joint member with a molded-in-place
pivot pin pivotally connecting the first joint member to the second
joint member, wherein the injecting step is carried out under
injection molding conditions that do not adversely affect the shape
and structural integrity of the first joint member.
[0107] In another of its aspects, the present invention includes a
method for making an articulating limb having first and second limb
segments connected by an elongate member. The elongate member is
formed of a first material and the first and second leg segments
are formed from a second material having a melting point lower than
the melting point of the first material. In this method, the
elongate member is placed into an injection mold having a cavity
for forming the first leg segment and a cavity for forming the
second limb segment. The elongate member is positioned in the
injection mold such that one end of the elongate member is within
the first cavity and the other end of the elongate member is within
the second cavity. The second material is then injected into the
mold at a temperature equal to or higher than the melting point of
the second material but lower than the first material's melting
point. In this manner, the first and second limb segments are
formed around the elongate member, the first leg segment being
connected to one end of the elongate member, and the second limb
segment being connected to the elongate member's other end.
[0108] In another of its aspects, the present invention entails an
injection molding method for making a ball and socket joint for
pivotally connecting a first joint member to a second joint member
comprising the steps of:
[0109] (i) inserting a joint member having a first portion with a
substantially spherical ball member into an injection mold having
inner walls defining a cavity for forming at least the second joint
member, the first joint member is positioned in the injection mold
so that the major portion of the ball member is maintained in
spaced relation to the walls of the mold and a minor portion of the
ball member of the first joint member is outside of the mold
cavity; and
[0110] (ii) injecting a thermoplastic composition into the cavity
of the mold under suitable injection molding conditions so that the
thermoplastic composition fills the cavity and engulfs the major
portion of the ball member of the first joint member to form the
second joint member including a socket pivotally connecting the
first joint member to the second joint member, wherein the
injecting step is carried out under injection molding conditions
that do not adversely affect the first joint member.
[0111] The term "suitable injection molding conditions" means
temperature, time and pressure conditions as known in the art which
allow a flowable thermoplastic composition to be introduced into
the cavity of an injection mold so as to fill the cavity. As will
be appreciated by those of ordinary skill in the art, such suitable
injection molding conditions may be routinely determined depending
upon the selected thermoplastic material. Also, by the phrase
"injection molding conditions that do not adversely affect the
first joint member," it is meant temperature, time and pressure
conditions less than those which would cause either the first joint
member having a bore therethrough or the first joint member
comprising a ball member of a ball and socket joint, to melt,
distort or fuse to the second joint member so that the first and
second joint members are unable to pivot properly with respect to
each other.
[0112] In the methods of the present invention for pivotally
connecting a first joint member to a second joint member, it is
preferred to use a vertical injection machine because of the
relative ease with which an insert part may be oriented and held in
the mold during the molding process. However, other injection
molding apparatus, including conventional horizontal injection
molding machines, may be used with suitably designed molds.
[0113] In the injection molding process of the invention, a first
rigid joint member is made of a first material which has a higher
melting point than the second joint member. The first material may
be any suitable material for an insert part including plastic,
metal or the like, so long as the first material has a melting
point sufficiently above the melting point of the second
thermoplastic material used in the claimed process. It is presently
preferred, however, that both the first joint member and the second
joint member be made of first and second thermoplastic materials,
respectively. Also, it is preferred that the first joint member be
injection molded.
[0114] In a particularly preferred embodiment, the first
thermoplastic material will have a melting temperature that is at
least about 30.degree. C. higher than the second thermoplastic
material. The first thermoplastic composition more preferably will
have a melting point which is from about 50.degree. C. to about
300.degree. C. higher than the second thermoplastic material, and
most preferably about 70.degree. C. to about 140.degree. C. higher
than that of the second thermoplastic material. Suitable first
thermoplastic materials may have a melting point in the range of
200.degree. C. to 350.degree. C. and suitable second thermoplastic
compositions may have a melting point in the range of 140.degree.
C. to 180.degree. C. or more. Presently preferred first
thermoplastic compositions include polycarbonate having a melting
point of about 300.degree. C., nylon having a melting point of
about 300.degree. C., acrylonitrile-butadiene-styrene (ABS) having
a melting point of about 230.degree. C., polyoxymethylene resin
(POM), (e.g., POM known by the brand name Celcon), having a melting
point of about 260.degree. C., and the like. Presently preferred
second thermoplastic compositions include polyvinylchloride or
Kraton (a brand name of styrene butadiene, a synthetic rubber
composition) having a melting point of about 160.degree. C. In
particularly preferred embodiments of the invention, the first
plastic composition is ABS and the second plastic composition is
PVC.
[0115] It has been surprisingly found that where the second plastic
composition is relatively soft compared to the first plastic
composition a sufficient coefficient of friction between the first
and second joint members results to permit relative movement while
insuring that, once moved, the members will remain in their new
relative positions. This applies as well to other pairs of joint
members (including joint members formed separately and then
assembled) used to form a pivot joint or a rotational joint of toy
FIG. 10.
[0116] Referring to FIGS. 6-8, one embodiment of the molding method
of the present invention is illustrated. FIG. 6 shows an insert
piece 25' comprising ring 31 having a bore 35 transversely
therethrough and a disk 30' having notches 380 cut in the
circumferential edge 30e of the disk. Ring 31 and disk 30' are at
either end of lever arm 28. Ring 35 has keys 382 protruding
inwardly towards the center of bore 35. Keys 382 serve to increase
pivotal friction between ring 31 and a pivot pin 33 formed
therethrough in the molding method of the present invention.
Notches 380 serve to prevent relative rotation between disk 30' and
disk 30 formed over disk 30' in the molding process.
[0117] With reference to FIG. 7, first joint member 25' (preferably
made of ABS) is placed in a vertical injection mold 388 which parts
along line 389 so that a portion of lever arm 28 and ring 31 extend
into a first cavity 390 of the mold 388 and a portion of lever arm
28 and the notched disk portion extend into a second cavity 392 of
the mold 388. As shown in this figure, an intermediate portion of
the lever arm is held in mold 388 so that it is not in
communication with either first cavity 390 or second cavity 392. As
will be understood by those skilled in the art, the second
thermoplastic composition used to fill first cavity 390 and second
cavity 392 is injected under injection molding conditions using
runner 391, which is in communication with the first cavity and a
second runner (not shown) which is in communication with the second
cavity.
[0118] FIG. 8 shows the first arm segment 24 after completion of
the injection molding process with a portion of ring 31 and disk
30' shown in phantom lines encased in the second thermoplastic
composition used in the injection step. As best seen in FIG. 7,
pivot pin 33 is formed in situ through bore 35 of ring 31.
[0119] It will be appreciated that right arm segment 24r, left leg
segment 124 and first right leg segment 124r are formed in an
analogous manner.
[0120] An embodiment of the molding process of the present
invention for producing a ball and socket body joint 254 is
illustrated in FIGS. 9-11. Body joint 254 comprises a first joint
member 450 (shown in FIG. 9) and a second joint member 300 which
are capable of pivoting and swiveling relative to one another.
First joint member 450 includes a ball member 306 and a plate 310
spaced at either end of a shaft 308. First joint member 450 is made
of a first thermoplastic composition, preferably ABS. As shown in
FIG. 10, first joint member 450 is inserted into mold 460 so that a
major portion of ball member 306 (at least greater than half of its
surface area and preferably more than 75% of its surface area) is
positioned within mold cavity 462 and a minor portion of ball
member 306 (less then half of its surface area) as well as shaft
308 and plate 310 are positioned within mold 460 so that they are
outside of communication with mold cavity 462. In an injection
molding step, a second thermoplastic material is injected into mold
cavity 462 to establish second joint member 300 which has an
interior surface which is formed around the outer surface of ball
306 to establish the socket of body joint 254. FIG. 11 shows the
completed body joint 254 with a major portion of ball 306 (shown in
phantom lines) residing within body 300 of body joint 254.
[0121] An embodiment of the molding process of the present
invention for making an articulating arm having first and second
arm segments connected by an elongate member is illustrated in
FIGS. 19, 35, 39 and 42. The elongate member 510 is formed of a
first material and the first and second arm segments 500 and 505
are formed from a second material having a melting point lower than
the melting point of the first material. In this method, the
elongate member is placed into an injection mold 800 having a
cavity 805 for forming the first arm segment 500 and a cavity 810
for forming the second arm segment 505. The elongate member 510 is
positioned in the injection mold such that elongate member's first
end 535 is within the first cavity 805 and the elongate member's
second end 540 is within the second cavity 810. The second material
is then injected into the mold 800 in the manner described above at
a temperature equal to or higher than the melting point of the
second material but lower than the first material's melting
point.
[0122] In this manner, the first and second arm segments are formed
around the elongate member. In one embodiment, shown in FIG. 19,
the first arm segment 500 forms pivot pin 550 within aperture 545
of the first end of the elongate member 510, and the second arm
segment 505 forms a pivot pin 803 within aperture 807 of the second
end 540 of the elongate member 510. In another embodiment, shown in
FIG. 39, first end 535 of elongate member 510 comprises disk 251
and first arm segment 500 forms circular interior space 560
capturing disk 251, while second end 540 of elongate member 510
comprises disk 900 and second arm segment 505 forms circular
interior space 905 capturing disk 900. In other embodiments, first
end 535 of elongate member 510 comprises a disk and second end 540
of the elongate member comprises a ring defining an aperture (see
FIG. 35) or vice versa (see FIG. 42).
[0123] A variation of the molding process described above, can be
used to make an articulating arm as described above and further
comprising a connecting member 565 having a body-part end 590
adapted to be connected to the body part and a limb end 595
attached to the distal end 515 of first arm segment 500. The
connecting member 565 can be made from either the same material as
the elongate member 510 or a third material having a melting point
higher than the second material's melting point. In this method,
the connecting member 565 is, like the elongate member 510,
inserted into the injection mold 800 but is positioned in the
injection mold 800 so that the limb end 585 is located within the
first cavity 805. The second material is then injected into the
first and second cavities 805 and 810 of the mold 800 under
injection molding conditions permitting the second material to fill
the first and second cavities 805 and 810 and form the first arm
segment 500 and the second arm segment 505. The distal end 520 of
the first arm segment 500 is then formed around the first end 535
of the elongate member 510, the proximal end 515 of the first arm
segment 500 is formed around the limb end 595 of the connecting
member 565, and the proximal end 525 of the second arm member 505
is formed around the second end 540 of the elongate member 510.
Where the connecting member 590 is made from the first material,
the injecting step is carried out at a temperature lower than first
material's melting point but higher than the second material's
melting point. Where the connecting member 590 is made from a third
material, the injecting step is carried out at a temperature below
the lower of the first and third material's melting points but
higher than the second material's melting point.
[0124] Another embodiment of the molding process of the present
invention for making an articulating leg having first and second
leg segments connected by an elongate member is illustrated in
FIGS. 26, 36, 45 and 48. The elongate member 615 is formed of a
first material and the first and second leg segments 605 and 610
are formed from a second material having a melting point lower than
the melting point of the first material. In this method, the
elongate member 615 is placed into an injection mold 815 having a
cavity 820 for forming the first leg segment 605 and a cavity 820
for forming the second leg segment 610. The elongate member 615 is
positioned in the injection mold 815 such that the elongate
member's first end 640 is within the first cavity 820 and the
elongate member's second end 645 is within the second cavity 825.
The second material is then injected into the mold at a temperature
equal to or higher than the melting point of the second material
but lower than the first material's melting point.
[0125] In this manner, the first and second leg segments are formed
around the elongate member 615. In one embodiment, shown in FIG.
26, the first leg segment 605 forms a pivot pin 652 within aperture
650 of the first end 640 of the elongate member 615, and the second
leg segment 610 forms a pivot pin 830 within aperture 835 of the
second end 645 of the elongate member 615. In an alternate
embodiment, shown in FIG. 48, first end 640 of elongate member 615
comprises disk 642 and first leg segment 605 forms circular
interior space 632 capturing disk 642 while second end 645 of
elongate member 615 comprises disk 910 and second leg segment 610
forms a circular interior space 915 capturing disk 910.
[0126] In other embodiments, first end 640 of elongate member 615
comprises a disk and second end 645 of elongate member 615
comprises a ring defining an aperture (see FIG. 36) or vice versa
(see FIG. 45).
[0127] Another aspect of the inventive molding process, a method
for making a head that is pivotally connected to a lever arm, is
illustrated in FIGS. 31-33. The lever arm 670 has a distal end 685
defining an aperture 680 and the head 22 has an internal pivot pin
700 extending through the aperture 680 to pivotally mount the lever
arm 670 to the head 22. The method comprises the steps of first
inserting the lever arm 670 into an injection mold 830 having inner
walls defining a cavity 835 for forming the head 22. The lever arm
670 is formed from a material having a given melting point and is
positioned in the injection mold so that the distal end 685 is
located within the cavity 835. Next, a sufficient quantity of a
first thermoplastic material is injected into the cavity 835 mold
under injection molding conditions permitting the thermoplastic
material to fill the cavity 835 to form the head 22 and to fill the
aperture 680 to form a pivot pin 705 extending through the aperture
680. This injecting step is carried out at a temperature that is at
least 30.degree. C. less than the given melting point of the lever
arm.
[0128] In another of its aspects, the present invention entails a
method for making a body part having pivotable digits, such as a
hand 102 of a toy FIG. 10 having pivotable finger members 400, 402,
and 404. Referring to FIGS. 12-16, this embodiment of the invention
uses injection molding to incorporate into an articulable joint, in
situ, an insert piece comprising molded finger members 400, 402,
404. These finger members are each molded of a first thermoplastic
material, preferably ABS, generally in the shape of
naturally-positioned, relaxed fingers. Finger members 400, 402, and
404, each of which has a proximal end 400a, 402a and 404a, with a
respective bore 400b, 402b and 404b, extending transversely
therethrough for receiving a pivot pin 406 on which finger members
400, 402 and 404 are pivotally mounted on the pin, as shown in FIG.
14. The pivotally mounted finger members are centered on pivot pin
136 with clearance at each end of the pin (i.e., between finger
member 400 and pin head 408, and between finger member 404 and pin
fastener 410). As best seen in FIGS. 13 and 14, the proximal ends
of the finger members, 400a, 402a and 404a, have a combined width
that is less than the length of pivot pin 406. In this
configuration having the combination of finger members 400, 402 and
404 pivotally attached to pin 406 constitutes a first joint member
(pivotally mounted on pin 136 to be used) as an insert part for
injection molding of left hand 102. Additionally, a second insert
part for injection molding of left hand is provided by wrist joint
member 412 (preferably made of ABS) consisting of shaft 414
attached at one end to disk 416 and at the other end to a ring 418.
Ring 418 has a bore 420 therethrough and notches 422 to prevent
relative rotation of the ring with respect to bore liner 424 (made
of second thermoplastic material) which is molded to the ring in an
injection molding step. See also FIG. 16. Bore liner 424 increases
pivotal friction achieved when hand 102 is pivotally mounted on
pivot pin 90 of fourth arm segment 80 during assembly of left arm
14 to resist unintended movement of joint 14f. See FIGS. 1 and
2.
[0129] As depicted in FIG. 16, left hand 102 is completed in a
vertical injection molding step wherein the exposed ends of pivot
pin 406 (including head 408 and fastener 410) and wrist joint
member 412 are positioned opposite each other in insert mold 430
having a first cavity 432 sized and shaped to form the body 436 of
hand 102 including a thumb 438. Hand portion 436, the shape of
which is defined by the shape of the mold, forms around and
captures pin 406 (preferably encasing pin head 408 and fastener
410) to secure the fingers pivotally to hand 436 and also forms
around shaft 414 and disk 416 of wrist joint member 412. Second
cavity 434 defines the surface of bore liner 424 which is formed
simultaneously with hand portion 436 to complete left hand 102 in
the molding process. The injection mold 430 maintains the finger
members 400, 402 and 404 outside of communication with the cavity
of the injection mold so that the material used in forming hand
portion 162 does not fill the areas between the finger members. The
molding does, however, form flush with the exposed sides 400c and
406c of finger members 400 and 406, thereby capturing the ends of
pivot pin 406 along with pin head 408 and pin fastener 410.
[0130] Applicants' foregoing description of the present invention
is illustrative. Other modifications and variations will be
apparent to those of ordinary skill in the art in light of
applicants' specification, and such modifications and variations
are within the scope of their invention defined by the following
claims.
* * * * *