U.S. patent application number 11/030865 was filed with the patent office on 2005-09-01 for doll.
Invention is credited to Glassberg, Debbie, Marine, Jon C., Wittenberg, Mark S..
Application Number | 20050191936 11/030865 |
Document ID | / |
Family ID | 34890957 |
Filed Date | 2005-09-01 |
United States Patent
Application |
20050191936 |
Kind Code |
A1 |
Marine, Jon C. ; et
al. |
September 1, 2005 |
Doll
Abstract
A toy doll is described having a first member and a second
member coupled to said first member. The said second member can
slidably and/or rotatably move relative to said first member, said
second member comprising an armature, an element coupled to said
armature, said element being more compliant than said armature, and
a molded form around at least said armature and element to simulate
a body part with a bendable joint. In another embodiment, the doll
includes a body member, where the body member has electronics
configured to selectively energize a light emitting source exposed
through said body member and a platform configured to enable
removable coupling of an accessory to said body member, where said
source illuminates at least portions of said accessory.
Inventors: |
Marine, Jon C.; (Fullerton,
CA) ; Wittenberg, Mark S.; (Rossmoor, CA) ;
Glassberg, Debbie; (Manhattan Beach, CA) |
Correspondence
Address: |
KOLISCH HARTWELL, P.C.
520 S.W. YAMHILL STREET
SUITE 200
PORTLAND
OR
97204
US
|
Family ID: |
34890957 |
Appl. No.: |
11/030865 |
Filed: |
January 5, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60534887 |
Jan 7, 2004 |
|
|
|
60557033 |
Mar 25, 2004 |
|
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Current U.S.
Class: |
446/376 |
Current CPC
Class: |
A63H 3/04 20130101; A63H
9/00 20130101 |
Class at
Publication: |
446/376 |
International
Class: |
A63H 003/46 |
Claims
1. A toy doll, comprising a first member; a second member coupled
to said first member, where said second member can slidably
rotatably move relative to said first member, said second member
comprising an armature, an element coupled to said armature, said
element being more compliant than said armature, and a molded form
around at least said armature and element to simulate a body part
with a bendable joint.
2. The doll of claim 1 wherein said first member is a plastic body
member.
3. The doll of claim 1 wherein said first member is a plastic torso
member.
4. The doll of claim 1 wherein said second member is a limb.
5. The doll of claim 4 wherein said limb is an arm.
6. The doll of claim 4 wherein said limb is an leg.
7. The doll of claim 1 wherein said relative movement includes
rotating movement.
8. The doll of claim 1 wherein said armature is plastic and insert
molded to said first member to form said coupling.
9. The doll of claim 1 wherein said element comprises twisted
wire.
10. The doll of claim 1 wherein said coupling is configured to form
an articulated shoulder joint.
11. The doll of claim 1 wherein said coupling is configured to form
an articulated hip joint.
12. A doll, comprising: a body member, the body member comprising:
electronics configured to selectively energize a light emitting
source exposed through said body member; a platform configured to
enable removable coupling of an accessory to said body member,
where said source illuminates at least portions of said
accessory.
13. The doll of claim 12 wherein said source is a light emitting
diode.
14. The doll of claim 12 wherein said platform includes a magnet
configured to be coupled to a magnet in said accessory.
15. The doll of claim 14 wherein said platform includes at least
two magnets configured to be coupled to at least two magnets in
said accessory.
16. The doll of claim 12 wherein said accessory is at least
partially translucent to transmit light from said source through
said accessory and create a visual glowing effect.
17. The doll of claim 12 wherein said accessory includes wings.
18. A toy doll, comprising an accessory; a first member, said first
member comprising: electronics configured to selectively energize a
light emitting source exposed through said body member; a platform
configured to enable removable coupling of said accessory to said
body member, where said source illuminates at least portions of
said accessory; a second member coupled to said first member, where
said second member can rotatably move relative to said first
member, said second member comprising an armature, an element
coupled to said armature, said element being more compliant than
said armature, and a molded form around at least said armature and
element to simulate a body part with a bendable joint.
19. The doll of claim 18 wherein said platform includes at least
two magnets configured to be coupled to at least two magnets in
said accessory.
20. The doll of claim 18 wherein said accessory is at least
partially translucent.
Description
[0001] The present application claims priority to provisional
application Ser. No. 60/534,887 filed Jan. 7, 2004 and provisional
application Ser. No. 60/557,033 filed Mar. 25, 2004, the entire
contents of each of which is incorporated by reference for all
purposes.
BACKGROUND
[0002] Examples of known bendable dolls are found in U.S. Pat. Nos.
593,592; 1,189,585; 3,325,939; 3,624,691; 3,955,309; 4,233,775; and
5,516,314; and in publications JP49-18956 A; JP50 037068 B2;
JP62-164092U; JP63-103685 A; EP1108454; GB2354456. Examples of
known dolls with magnetic attachments are found in U.S. Pat. Nos.
4,038,775, 4,118,888, 4,170,840, 4,176,492, 4,183,173, 4,186,515,
4,206,564, 5,277,643, 5,295,889, 5,380,233, 5,727,717, and
6,171,169. The disclosures the patents and publications listed in
this paragraph are incorporated herein by reference.
SUMMARY
[0003] The present disclosure relates generally to toy dolls with a
bendable armature, and in one example, to dolls in which the
armature includes a combination of bendable limbs and articulated
joints. In another example, it further relates to such dolls in
which a torso of the doll houses electronics, and provides an
attachment platform for accessories such as simulated wings. In
another example, electronics power an LED in the torso, and the
wings are attached to the torso by aligning magnets in the wings
with corresponding magnets in the torso. Still further, the wings
can be translucent to transmit light within the wings.
[0004] The advantages of the present disclosure will be understood
more readily after a consideration of the drawings and the Detailed
Description of Example Embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a drawing of a doll in accordance with the present
disclosure.
[0006] FIG. 2 is a drawing of an opposite side of the doll shown in
FIG. 1, showing the attachment of simulated wings to the back of
the doll.
[0007] FIGS. 3-4 are drawings of example sets of wings that may be
attached to the doll of FIGS. 1 and 2, for example.
[0008] FIG. 5 is a rear view of an alternative doll torso
configuration.
[0009] FIGS. 6A and 6B are drawings of the torso of the doll of
FIG. 5 coupled to the wings of FIG. 4.
[0010] FIG. 7 is a front elevation view of an armature that could
be used for an alternative embodiment of a doll.
[0011] FIG. 8 is a magnified view of a portion of the armature of
FIG. 7, showing details of the twisted wire structure of the
armature.
[0012] FIG. 9 is a front view of a head portion of an armature for
a posable figure, according to another embodiment of the
disclosure.
[0013] FIG. 10A is a front elevation view of a partially formed
posable figure, after one step of insert molding.
[0014] FIG. 10B is a rear elevation view of the partially formed
posable figure of FIG. 10A.
[0015] FIG. 11A is a magnified view of a portion of the partially
formed posable figure of FIGS. 10A and 10B, showing details of
upper arm connecting pegs.
[0016] FIG. 11B is a magnified view of a portion of the partially
formed posable figure of FIGS. 10A and 10B, showing details of
upper leg locating pegs.
[0017] FIG. 11C is a magnified view of a portion of the partially
formed posable figure of FIGS. 10A and 10B, showing details of
lower leg locating pegs.
[0018] FIG. 12 is a front and rear elevation view of a posable
figure after two steps of insert molding, according to an
embodiment of the disclosure.
[0019] FIG. 13 is a semi-transparent front elevation view of the
posable figure of FIG. 12, showing an armature and a molded body
enclosing the armature.
[0020] FIG. 14 is a semi-transparent side elevational view of the
posable figure of FIG. 13.
[0021] FIG. 15 is a detailed drawing of an alternative partially
formed arm insert of the doll of FIGS. 1 and 2.
[0022] FIG. 16 is a detailed drawing of an alternative arm using
the insert of FIG. 15.
[0023] FIGS. 17-18 are detailed drawings of an alternative leg
insert.
[0024] FIG. 19 is a detailed drawing of an alternative leg using
the insert of FIGS. 17-18.
[0025] FIG. 20 shows alternative embodiments of arms, legs, arm
inserts, and leg inserts.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
[0026] In the doll 1000 shown in FIG. 1, the legs 1010 and arms
1020 are formed of rigid plastic, and the shoulder and hip joints
1022 and 1024, respectively, are simulated through the use of pins
that interconnect the arms and legs to the torso. In one
embodiment, the shoulder joint is an insert-molded swivel and hinge
joint, of the type shown in FIG. 4 of U.S. Pat. No. 4,673,374, the
disclosures of which are incorporated herein by reference. Still
further, the arm-portion of the joint, identified as reference
character 34 in U.S. Pat. No. 4,673,374, is molded from a rigid
plastic, and is sized and shaped so as to define less than the
entire desired outer shape of the complete arm. This rigid element
is then encased in a soft, flesh-like material such as Kraton or
soft PVC. An example structure is shown below, wherein the
resulting shoulder joints may have two degrees of freedom. A
similar joint may be used at the hip, or a simpler mushroom joint
may be used.
[0027] In one embodiment, a pair of twisted wires is trapped within
the arm portion of the joint, and extends approximately to a wrist
portion of the arm.
[0028] It is believed that twisted wire may improve cyclic life for
the limb, allowing the doll to be manipulated further, and more
often, while maintaining acceptable durability. Furthermore, by
using twisted wire, this can be achieved with simple manufacturing
processes to generate the twisted wire either during the doll
assembly, or before the raw material is shipped to the plant. Also,
the use of twisted wire trapped within the arm can achieve other
synergistic effects. For example, in some cases with untwisted
wire, a different modulus of elasticity can be encountered
depending on the bend angle. As such, by using twisted wire, a more
uniform effect can be achieved, if desired. Not also that the
twisted wire can include three strands of wire twisted together, or
other multiples higher than 2.
[0029] A second rigid plastic member may be used to trap the ends
of the twisted wires, safely encasing those ends in protective
plastic. A further alternative includes legs with a similar
insert-molded joint and armature, as described below herein.
[0030] Due to the shape of the legs 1010, in which a narrow isthmus
1026 is defined at the knee of the leg, as shown in FIGS. 1 and 2,
bending action naturally occurs at or about the knee area, even if
only short rigid elements are molded on the wires embedded within
the legs. In this way, it is possible to reduce manufacturing and
part costs, yet maintain functionality desired by users. More
specifically, by reducing the cross-sectional area of the knee,
relative to the upper and lower leg portions 1028 and 1030,
respectively, it is possible to enable bending action to occur at
or about the knee area. However, in an alternative embodiment,
rigid elements can also be used in the legs, similar to the example
embodiment of the arms.
[0031] Accessories for the various embodiments described above
include removable wings, such as the wings 1300 of FIG. 3, however
various other accessories could be used, such as, for example:
capes, backpacks, equipment, or weapons. Magnets may be used to
attach the wings to the torso, such as magnets 1310 and 1312, by
including mating magnets, one in the torso, and another in the
wings. If desired, multiple mating pairs of magnets may be used,
such as shown in FIG. 3. Alternatively, only one pair need be used,
and additional structural support may be provided by mating posts
and holes, with the post formed in one of the torso or the wing,
and a corresponding hole formed in the other of the torso and wing.
Still other structure may be used, such as matting bends or other
surface contours between the torso and wing.
[0032] Note that, in one example, the magnets not only can be used
to maintain a connection between the doll and the accessory, but
also can be used to locate the accessory to the doll during
connection. In other words, the magnets can also be used to align
the accessory, such as the wings, to the doll, thereby allowing
easier attachment and detachment of accessories to a doll. This is
due in part to the self-centering action of magnets, caused by the
shape of the magnetic field. Further, since this easier
attachment/detachment may require less dexterity than other
attachment approaches, it can be easier for children playing with
the doll to attach and detach the accessories, without degrading or
breaking the parts.
[0033] Another aspect of the present doll is electronics contained
within the torso, and/or within other locations of the doll body.
An LED (such as LED 1314) may be powered by the electronics, and
may be aligned with the wings so that light from the LED shines
through the wings. Note that other LEDs can be added at various
portions of the body as an alternative, or in addition to, the LED
used to shine through the wings. By making the wings of translucent
or clear plastic, light may be transmitted throughout the wings,
creating a magical glow effect. For example, totally and/or
partially internally reflective surfaces may be used to direct
light through the wings, before being reflected outward to a
viewer. In this way, certain portions of the wings may appear
illuminated, even though the entire structure is translucent (or
transparent).
[0034] The detachable wings 1300 can be of various forms. The
figures show example wing configurations, however, others can also
be used. In one example, the wings are formed of translucent
material, such as polymeric material, to allow transmission of
light from a light source, such as an LED as described above.
Further, the wings can be fabricated with integrally molded
recesses for receiving and holding a magnet. In the example of FIG.
3, the wings have multiple sections, and may include sticker
decorations.
[0035] FIG. 4 shows an alternative pair of wings 1400 for mating to
doll 1500 of FIG. 5. In this example, the wings utilize magnets
1410 and 1412 for attachment to mating magnets in doll 1500 (such
as magnets 1510 and 1512 of FIG. 5). Further, hold 1414 is shown
that aligns with a protruding LED in doll 1500, such as LED 1514 of
FIG. 5. Wings 1400 further contain etched forms, such as stars 1420
and/or sections 1422. In one example, the etches areas reflect
internal light outward to a viewer from the LED, so that when
viewing the front of the doll, light in the wings can be seen, even
though the LED is in the doll's back. FIGS. 6A-B shows the wings
1400 attached to the doll 1500 from a rear and side perspective. In
particular, FIG. 6B shows a bend angle 1430 of wings 1400, which
enable a more contoured fit between the wings and the dolls back,
thereby providing a more life-like appearance.
[0036] Returning to FIG. 5, it also shows access panel 1516 (held
closed by screw 1518, which enables access to internal electronics
for powering the LED 1514, as well as the ability to change
batteries. Further, FIG. 5 shows button 1520, which activates LED
1514. In one example, a single actuation of button 1520 creates
flashing of the LED, whereas in other examples, the LED is lighted
continuously during depression of button 1520.
[0037] FIGS. 7-14 show an alternative embodiment of a posable
figure, in which no hinged or pivoted articulations are included.
However, the features described below, or selected groups of
features, can be incorporated in the limbs described above.
[0038] Referring to FIG. 7, an armature 10 for a posable figure is
shown. Although it is anticipated that armature 10 will eventually
be enclosed by and bonded to an outer covering, such as an
injection-molded body of a posable figure, FIG. 7 shows the inner
core of the armature in isolation for clarity. Armature 10 may
include a plurality of twisted strands of wire 12, best seen in
FIG. 8, which may be joined together to form an articulated
structure. As depicted in FIG. 8, strands 12 may be constructed
from three pliable metal wires twisted together, although other
suitable numbers of wires and/or materials may be used to construct
the inner armature.
[0039] As depicted in FIG. 7, armature 10 may include a lower
strand 14, a middle strand 16, and an upper strand 18. Lower strand
14 may extend from a first foot portion 20a to a second foot
portion 20b, and middle strand 16 may extend from a first hand
portion 22a to a second hand portion 22b. Upper strand 18 may
extend from an upper portion 24 of the lower strand, to a head
portion 26.
[0040] The strands of wire in the armature may be connected at
junctures 28 and 30 to form a unitary structure. As indicated,
juncture 28 may connect lower strand 14 to upper strand 18 at a
point at or near a lower end of the upper strand, so that the upper
strand may not extend appreciably below its intersection with the
lower strand at juncture 28. Juncture 30 may connect the middle
strand to the upper strand at a point between juncture 28 and head
portion 26. Junctures 28 and 30 may be formed, for example, by spot
welding, although other forms of adhesion such as gluing, crimping,
or the like may also be suitable for forming connections between
the strands of wire.
[0041] As depicted in FIG. 7, armature 10 may be formed into an
articulating structure that includes lower leg portions 32a and
32b, upper leg portions 34a and 34b, lower arm portions 36a and
36b, upper arm portions 38a and 38b, and a neck portion 40. For
simplicity, symmetric pairs of parts such as the leg and arm
portions, among numerous others, may hereinafter be referred to by
a single reference number. Thus, "lower leg portions 32" will be
understood to mean lower leg portions 32a and 32b, and so
forth.
[0042] The strands of wire may be chosen to have any diameter that
permits a desired amount of flexibility in the various regions of
the armature. For example, lower strand 14 and upper strand 18 may
be formed from twisted wires that are approximately 0.030-inches in
diameter, and middle strand 16 may be formed from a twisted wire
that is approximately 0.025-inches in diameter. However, it will be
appreciated that wires of other diameters may be equally suitable
or more suitable for various designs, depending on the overall size
of the posable figure and its intended use.
[0043] In the embodiment depicted in FIG. 7, a distal end of upper
strand 18 forms head portion 26 in the shape of a substantially
circular loop 42 that is spot welded to neck portion 40 at an upper
juncture 44. However, it should be appreciated that the head
portion may be suitably formed in various other ways. For example,
FIG. 9 shows an embodiment in which a head portion 126 is formed in
the shape of a curved hook or semi-loop 46.
[0044] In FIGS. 7-9, the various wire strands 14, 16, and 18 that
are included in armature 10 are shown before any injection molding
steps involving the toy figure have been performed. Such injection
molding may typically be performed in a two-step process. In the
first injection molding step, a plurality of structures may be
injection molded around the inner wire, to form a more rigid and
substantial inner skeleton. In the second injection molding step, a
flesh-like outer covering may be molded around the skeleton to form
a surrounding body, which may enclose both the inner wire armature
and portions of rigid structures that were added in the first step.
These two injection molding steps are described below in greater
detail.
[0045] FIGS. 10A and 10B show front and rear elevation views,
respectively, of a partially formed posable figure 110, after a
first injection molding step has been performed. After the first
injection molding step, partially formed figure 110 may include
wire armature 10 as described above, as well as a plurality of
support members. These support members may include surrounding
members 48, 50, and 52, end caps 54 and 56, and sprues 58, 60, and
62, among others. The support members may extend outward from the
strands of wire, adding structure and stability to armature 10. As
described below, some of the support members may also allow
partially formed figure 110 to be located accurately and
conveniently in a mold, prior to a second injection molding
step.
[0046] The support members may be constructed from any suitable
material, such as a resin material that may be conveniently molded
around wire armature 10 in molten form. The support member material
may, for example, be a relatively flexible polymer material such as
polypropylene, or it may be a more rigid polymer such as
polyethylene. The support member material may also be a
thermoplastic elastomer material such as polyvinylchloride (PVC),
or a styrene-based elastomer such as a Kraton material manufactured
by Kraton Polymers of Houston, Tex. In some embodiments, this
material may be chosen to bond and/or be otherwise compatible with
a material used for the outer covering of the toy figure.
[0047] Surrounding members 48, 50, and 52 each may be configured to
surround a portion of the wire of armature 10, and each may include
a plurality of locating pegs extending substantially radially
outward from the wire. For example, surrounding member 48 may
include upper arm pegs 64 and 66, surrounding member 50 may include
upper leg pegs 68 and 70, and surrounding member 52 may include
lower leg pegs 72, 74, and 76. The locating pegs may be
substantially cylindrical as depicted in FIGS. 10 and 11, or they
may have any other suitable shape. For example, the locating pegs
may be substantially conical or frustoconical. The locating pegs
may also have rounded ends.
[0048] FIG. 11 shows details of the structure of surrounding
members 48, 50, and 52, and their associated locating pegs. The
locating pegs may be configured to assist in locating partially
formed figure 110 in a mold, in preparation for a second injection
molding step. As indicated, upper arm pegs 64, upper leg pegs 68,
and lower leg pegs 72 may extend forward and away from the
armature, upper arm pegs 66 and upper leg pegs 70 may extend
backward and away from the armature, lower leg pegs 74 may extend
laterally and away from the armature, and lower leg pegs 76 may
extend medially and away from the armature.
[0049] Providing locating pegs of the type just described may help
to position partially formed figure 110 in a desired location
within a mold. For example, a particular locating peg may be
configured to substantially span a radius of the mold, thereby
holding a wire strand of the armature spaced away from the walls of
the mold. This may allow material to be injected into the mold to
form a continuous molded body, encasing and bonded to the armature,
with the wires of the armature spaced away from the surface of the
body.
[0050] As depicted in FIGS. 10A and 10B, end caps 54 and 56 may be
disposed to cover free ends of lower strand 14 and/or middle strand
16. In other words, the end caps may be disposed to cover foot
portions 20 and/or hand portions 22 of the inner wire armature. End
caps 54 and 56 may hold loose ends of the wires together, and may
reduce the chances that an end of one of the wires will break
through the body of the toy.
[0051] Sprues 58, 60, and 62, which may be substantially
cylindrical, may serve to further locate partially formed figure
110 in a mold during a second injection molding step. For example,
the sprues may be placed in corresponding cylindrical depressions
or recesses in the mold, to hold the armature in position while a
surrounding body is injection molded around partially formed figure
110.
[0052] As depicted in FIGS. 10A and 10B, sprues 58 and 60 may be
disposed near end caps 54, and attached to the end caps by
connecting shafts 78. In addition, sprues 60 may be attached to
surrounding members 80 by shafts 82, and surrounding members 80 may
be attached to each other by a connecting shaft 84. In this manner,
sprues 58 and 60, connecting shafts 78, 82 and 84, and surrounding
members 80 all form a substantially continuous structure for
locating the partially formed figure in a mold, and supporting it
there during a second injection molding step. Similarly, sprues 62
may be connected to end caps 56 by connecting shafts 86, and end
caps 56 may be connected to each other by a connecting shaft 88, as
indicated.
[0053] Aside from the aforementioned structures, a molded head
portion 90 may also be added during the first injection molding
step. Molded head portion 90 may include a rear section 92
extending in slight relief from the remainder of the molded head
portion. Rear section 92 may include a substantially rectangular
aperture 94, and two smaller circular apertures 96. Apertures 94
and/or 96 may be used for additional secure positioning of
partially formed figure 110 in a second mold, for instance using
shafts, pins, or the like to extend from the mold into the
apertures.
[0054] A chest portion 98 may also be added during the first
injection molding step. Furthermore, portions of the inner wires
may be covered with a relatively thin coating of material,
generally indicated at 100. The additional structure of chest
portion 98 and wire coating 100 may serve to selectively increase
the rigidity of portions of the toy figure, and to provide greater
stability to the partially formed figure prior to a second
injection molding step.
[0055] FIGS. 12-14 show a toy figure, generally indicated at 210,
after two steps of injection molding. As is best seen in FIGS.
13-14, toy figure 210 may include partially formed figure 110
(including armature 10), and also a surrounding and continuously
molded body 212. Body 212 may be constructed from any resilient,
flexible material, such a highly elastic thermoplastic material
such as a soft polyvinyl chloride (PVC) material having a Shore
hardness of approximately 65. The body material may be colored to
match the desired finished color of the posable figure, but the
body material is depicted as transparent in FIGS. 13-14, so that
partially formed figure 110 may be seen disposed within it.
[0056] Although in general, any suitable material may be used to
construct the body of the toy figure, in some embodiments the body
material may be chosen to bond to and/or be otherwise compatible
with the material used for the support members of the armature of
the toy figure. For example, the body material and the support
member material may both be constructed from styrene-based
elastomers such as a Kraton material, with either similar or
different Shore hardnesses. Such similar elastomers may tend to
bond particularly securely to each other during injection molding
of the body around the armature.
[0057] FIG. 12 shows front and rear views, respectively, of toy
figure 210 after a second step of injection molding but before
final finishing of the toy figure is complete. Sprues 58, 60, and
62 may still be attached externally to figure 210 after the second
molding step. Similarly, portions of connecting shafts 78, 82, 86,
and/or 88 may remain outside of body 212 after the second molding
step. The protruding sprues and/or shafts, if any, may be cut or
broken off of toy figure 210 as part of final finishing steps.
[0058] Further, FIG. 12 also shows electronic chip 230, which can
include analog or digital circuitry for powering electronic
actuators in the body, such as LED 236. Also, a battery (or
batteries) 238 is shown coupled to the electronic chip for
providing a power source. However, alternative power sources can be
used, such as an electromagnetic generator that is powered by
motion (e.g., motion caused by someone playing with the doll) of
the doll.
[0059] Electronic chip 230 is housed within the molded body of the
doll. In this particular example, chip 230 is located in torso
region 228. However, the chip, or its circuitry, could be located
in other regions (such as the legs), or distributed about various
regions of the body. Also, in this example, the light source (in
this case LED 236) is located at the surface of the body so that
light can be emitted out to the accessory (not shown) coupled via
magnets 232 and 234.
[0060] Electronic chip 230 is also coupled to a switch 240 for
actuating LED 236. In this case, a contact switch is utilized in
which the user depresses a button to activate LED 236. The LED is
activated while switch 240 is depressed, and the LED is deactivated
while switch 240 is not depressed. Note however that alternative
switches could be used. For example, a heat sensor could be used to
sense heat from the user's body contacting the doll. Other
alternative sensors could also be used that sense when the doll is
held, or contacted in a certain way by the user. Such sensor could
further be integrally molded in the doll, which may also provide
improved appearance of the doll body.
[0061] Continuing with FIG. 12, the rear view shows magnets 232 and
234 that can be used to locate and attach the wings (or other
accessories), described above. In this case, the magnets 232 and
234 are located within the body mold, such that the surface of the
back is smooth, with the magnets exposed. However, the magnets can
be internally integrally molded and covered with a smooth layer of
body material, if desired. This may provide an improved appearance
in some applications.
[0062] FIG. 13 shows a front view of toy figure 210 after some
final finishing steps, with the material of molded body 212
depicted as transparent so that armature 10 may be seen within the
figure. As depicted in FIG. 13, locating pegs 74 and 76 may extend
to lateral and medial surfaces 214 and 216 of the body,
respectively. Also as depicted in FIG. 13, various finishing steps
may be applied to the toy figure after the second injection molding
step. For example, sprues and/or connecting shafts that remain
external to molded body 212 may be removed, possibly leaving
portions of shafts 82 extending to surfaces of the body. Facial
features, generally indicated at 218, may be added by, for example,
etching and/or painting. Hair 220 may be attached to the figure by,
for example, heat sealing or gluing. In some embodiments, clothing
and/or other accessories may be added to the figure.
[0063] FIG. 14 shows a right side view of toy figure 210, with the
material of molded body 212 depicted as transparent as in FIG. 13.
As depicted in FIG. 14, locating pegs 64, 68, and 76 may extend to
an anterior surface 222 of the body, and locating pegs 66 and 70
may extend to a posterior surface 224 of the body. End portions of
the various locating pegs extending to surfaces of the body may be
sanded or otherwise smoothed as desired, as a final finishing
step.
[0064] FIG. 15 shows a detailed approximately 1:1 scale drawing of
an arm insert 300 which can be used in the doll described above.
The drawing shows the arm insert, which can be used for both the
left and right arms, after two molding steps, where the molding can
be insert molding as described herein.
[0065] Specifically, FIG. 15 shows arm insert 300 having a first
insert molded pivot at 310 and a pair of parallel disks 312 used to
form a shoulder joint captured by the doll torso. The following
molding steps can be used to form insert 300, although alternative
approaches may also be used. First, wire 314, which spans from
approximately hole 320 to hole 322 is placed in a mold and held or
located by the pins of the mold (not shown), where the pins form
holes 320 and 322 in insert 300. Wire 314 can be a twisted pair of
two or more wires, or a single wire. Then, the insert is partially
molded, forming the lower structure 324, and middle structure 326.
Included in lower structure 324 are locating pegs 330, which are
used to locate the piece after the first molding operation in later
molds. After forming the lower and middle structure 324 and 326, a
second molding operation is performed which forms upper structure
328 around middle structure 326, thereby forming rotary pivot 310.
Further, the second molding operation, which forms upper structure
328, also forms disks 332 and 334 (which are later captured by the
doll body to form a second pivot at the shoulder in addition to
pivot 310). Alternatively, these two molding operations could be
combined into a single molding operation.
[0066] After the second molding operation, the piece is placed in
another mold and located by pegs 330 to form either a right arm or
left arm as described in more detail below. By structuring insert
300 in this way, it is possible to have a single insert design that
can be used to form both the left and right arms, thereby saving
cost.
[0067] Lower structure 324 is shown with two locating pegs 330,
however only a single peg, or more than 2 pegs, could be used, if
desired. Further, lower structure 324 has a stepped outer form
which can improve the strength of the piece and thereby improve
durability, while still properly capturing wire 314. Likewise,
middle structure 326 is also formed in a step manner, for similar
reasons. Also, lower and middle structures 324 and 326 have
reinforced structure around holes 320 and 322, respectively to
compensate for the lack of material in the hole. Again, this
improves strength and durability of the finished arm, thereby
allowing repeated use by a doll user.
[0068] FIG. 15 includes a top and side views in conventional
drawing format. Further, an isometric view is also shown,
illustrating various features of the insert.
[0069] Referring now to FIG. 16, a right arm 400 is shown, which is
formed using insert 300. FIG. 16 includes an isometric view and
details of right arm 400.
[0070] As shown in FIG. 16, insert 300 is used in a third molding
operation to form the right arm 400 over insert 300. The view
illustrates the shape of the hand and arm, including joint 418 and
disks 412 later used to form a two degree of freedom rotary
shoulder joint. FIG. 16 also shows locating pins 430 which were
used to locate insert 300 in the mold forming the arm 400. After
this molding operation, pins 430 can be cut off, thereby leaving a
finished arm for assembly to the doll body.
[0071] Arm 400 is thus formed to provide improved durability and
desired flexibility, as well as a more realistic simulation of
human parts, while still enabling the desired degrees of freedom
and motion for effective play by the user. Therefore, the
combination of rotary shoulder joints with bendable elbow joints
thus provides an advantageous result.
[0072] While the above example shows a right arm, it is also
possible to form a left arm in a substantially similar way.
[0073] Referring now to FIGS. 17-19, detailed drawings of the left
leg insert (FIGS. 17-18) and finished right leg (700 of FIG. 19)
are shown, with FIG. 19 at approximately 1:1 scale. The legs are
formed in a manner similar to the arms discussed above with respect
to FIGS. 15-16. However, there are various differences.
[0074] First, as shown in FIGS. 17-19, the leg insert 600 includes
a single degree of freedom insert molded hip joint 610, which is
angled relative to the upper leg section 612. The hip joint 610 is
captured by the doll torso.
[0075] The following molding steps can be used to form insert 600,
although alterative approaches may also be used. First, wire 614,
which spans from approximately hole 620 to hole 622 is placed in a
mold and held or located by the pins of the mold (not shown), where
the pins form holes 620 and 620 in insert 600. Wire 614 can be
twisted pair of two or more wires, or a single wire. Then, the
insert is partially molded, forming the lower structure 624, and
the middle structures 626. Included in lower structure 624 are
locating pegs 630, which are used to locate the piece after the
first molding operation in later molds. After forming the lower and
middle structure 624 and 626, a second molding operation is
performed which forms upper structure 628, thereby forming rotary
pivot 610 (which is later captured by the doll body to form a pivot
at the hip). Alternatively, these two molding operations could be
combined in a single molding operation.
[0076] After the second molding operation, the piece is placed in
another mold and located by pegs 630 to form a left leg as
described in more detail below. While the different left and right
leg inserts are described, they could be reused as described above
with regard to FIGS. 17-19.
[0077] Lower structure 624 is shown with two locating pegs 630,
however only a single peg, or more than 2 pegs, could be used, if
desired. Further, lower structure 624 has a stepped outer form
which can improve the strength of the piece and thereby improve
durability, while still properly capturing wire 614. Likewise,
upper structure 628 is also formed in a step manner, for similar
reasons. Also, lower and upper structures 624 and 628 have
reinforced structure around holes 620 and 622, respectively to
compensate for the lack of material in the hole. Again, this
improves strength and durability of the finished leg, thereby
allowing repeated use by a doll user.
[0078] Referring now to FIG. 19, a left leg 700 is shown in an
approximately 1:1 scale drawing, which is formed using insert
600.
[0079] As shown in FIG. 19, insert 600 is used in a third molding
operation to form the left leg 700 over insert 600. The various
views illustrate the shape of the leg and foot, including joint 610
later used to form a single degree of freedom rotary hip joint.
FIG. 19 also shows locating pins 630 which were used to locate
insert 600 in the mold forming the leg 700. After this molding
operation, pins 630 can be cut off, thereby leaving a finished leg
for assembly to the doll body.
[0080] Leg 700 is thus formed to provide improved durability and
desired flexibility, as well as a more realistic simulation of
human parts, while still enabling the desired degrees of freedom
and motion for effective play by the user. Therefore, the
combination of rotary hip joints with bendable elbow knees thus
provides an advantageous result. Furthermore, the shape formed by
this third molding operation provides a thinned portion 720 to form
the knee. Thus, even though wire 614 spans an area much larger than
the knee joint, the knee bends about thin area 720 due to the shape
formed in this third molding operation. As such, less manufacturing
complexity can be used while still achieving repeatable bending at
a desired location. Again, a right leg may be formed in a similar
fashion.
[0081] Referring now to FIG. 20, several alternative embodiments
are described. The two right side drawings in FIG. 20 show
alternative arm and arm insert designs, in which section 326 is
modified to include small dimples 810 and 812 to inner and outer
parts of the upper arm section 326. In this way, it is possible to
provide improved location of the insert in the third molding
operation which forms the arm around the insert. In other words,
these dimples (or a single dimple, or more than 2 dimples) can help
prevent, or reduce, location errors of the skeleton in arm
mold.
[0082] Continuing with FIG. 20, the left side drawings show an
alternative leg insert and leg. First, a small dimple 814 is added
to section 628 of the leg insert at the upper inner thigh area of
the leg, again to prevent or reduce location errors of the leg
skeleton in leg mold, as described above with regard to dimples 810
and 812. While a single dimple 814 is used, more than one could
also be used.
[0083] Second, the barrel diameter in the location near dimple 814
has been reduced, and a support rib 816 has been added to increase
the strength of the leg section 628, thereby providing improved
durability.
[0084] It is believed that the disclosure set forth above
encompasses multiple distinct examples with independent utility.
While each of these examples has been disclosed in example form,
the specific embodiments thereof as disclosed and illustrated
herein are not to be considered in a limiting sense as numerous
variations are possible. The subject matter of the disclosure
includes all novel and non-obvious combinations and subcombinations
of the various elements, features, functions and/or properties
disclosed herein. Similarly, where any claim recites "a" or "a
first" element or the equivalent thereof, such claim should be
understood to include incorporation of one or more such elements,
neither requiring nor excluding two or more such elements.
[0085] Inventions embodied in various combinations and
subcombinations of features, functions, elements, and/or properties
may be claimed through presentation of claims in a related
application. Such new claims, whether they are directed to a
different invention or directed to the same invention, whether
different, broader, narrower or equal in scope to the original
claims, are also regarded as included within the subject matter of
the inventions of the present disclosure.
* * * * *