Pouch Assembly

Abstract

A balloon valve / pouch assembly including a balloon valve and a pouch is attached to the neck of the balloon. The pouch is configured to receive and hold a lighting device in place. The valve has a valve inlet and a valve outlet at an opposite end of the valve. The valve framework is defined by a sealing path and layers. The pouch has an opening through which the lighting device can be inserted and an opposite closed end of the pouch. The pouch framework is defined by a first sealing path and layers. The layers are heat sealed together along the substantially V-shaped first sealing path, with the open end of the V forming the pouch opening and the closed end of the V forming the closed end of the pouch. The pouch is attached to and heat sealed to the valve so that the valve inlet faces the pouch opening and the valve outlet faces the closed end of the pouch. A heat-resistant patch is provided to prevent heat sealing at certain locations within the pouch assembly, thereby maintaining the functionality of the valve and pouch.

Description

[Technical Field]

[0001] FIELD OF THE INVENTION The present invention relates to pouch assemblies for use with inflatable toys, arrays of pouch assemblies, inflatable toys having pouch assemblies, and methods relating thereto. [Background technology]

[0002] Inflatable toys can be made from flexible materials that can be inflated with a gas such as air or helium. Examples of inflatable toys include balloons, balls, and lilos.

[0003] It is known to provide lighting devices in inflatable toys by fitting lighting devices inside the inflatable toy. Examples of inflatable toys with lighting devices can be found in GB 2535830 and GB 2472785.

[0004] In the case of conventional inflatable toys with lighting devices, the lighting device is currently inserted into the inflatable toy and sealed (which makes the lighting device inaccessible to end users and facilitates compliance with toy safety regulations such as European Standard EN71). A problem with this manufacturing method is that once the inflatable toy with the lighting device is manufactured, the lighting device is inaccessible from the outside of the inflatable toy. Another problem with this manufacturing method is that custom / dedicated manufacturing equipment is required to insert and seal the lighting device into the inflatable toy, which increases manufacturing costs. Another problem with the prior art is that different manufacturing equipment is required to manufacture inflatable toys with different lighting devices, which increases manufacturing costs.

[0005] Another problem with conventional inflatable toys is that they lack compactness. This is because the lighting device and the means for inflating / deflating the inflatable toy are typically provided in separate openings in separate locations on the inflatable toy. This configuration also contributes to the poor balance of the inflatable toy. Generally, the switch for the lighting device in conventional inflatable toys is located outside the inflatable toy, which also contributes to the lack of compactness.

[0006] A further problem with conventional inflatable toys is that it is difficult to securely retain the lighting device within the inflatable toy, resulting in the lighting device being easily displaced due to the lack of precision in its retention.

[0007] Conventional inflatable toys also suffer from the problem that the lighting device and the means for retaining the lighting device within the inflatable toy add to the overall weight of the toy, making them impractical and therefore less desirable. For example, if the inflatable toy is a balloon inflated with a low-density gas (e.g., helium), the added weight of the lighting device and the means for retaining the lighting device makes it more difficult to keep the balloon afloat. A known solution to this problem is to increase the inflation volume of the entire balloon, so that when the balloon is inflated with the low-density gas, the increased inflation volume provides sufficient buoyancy to keep the balloon afloat. However, increasing the inflation volume of the balloon means that more gas is required, which increases costs.

[0008] It is an object of the present invention to at least partially overcome or mitigate one or more of the above and other problems. Summary of the Invention

[0009] A first aspect of the present invention is a pouch assembly for use with an inflatable toy, the pouch assembly including a pouch having an upper pouch layer and a lower pouch layer, the upper pouch layer and the lower pouch layer sealed together along a first sealing path, the pouch configured to receive a lighting device and hold the lighting device in place. the pouch has gripping means configured to hold the lighting device in place, the gripping means being provided as one or more protrusions, the one or more protrusions being defined by the first sealing path. The present invention provides a pouch assembly having a configuration.

[0010] The pouch assembly of the present invention allows for access to the pouch after the inflatable toy is manufactured, allowing a lighting device to be incorporated into the inflatable toy after the toy is manufactured. For example, the inflatable toy with the pouch assembly can be manufactured first, and then the lighting device can be inserted into the pouch and sealed thereto (i.e., two-step manufacturing of the inflatable toy with the lighting device). This means that the inflatable toy can be manufactured using standard manufacturing equipment rather than dedicated / custom equipment (because the lighting device can be inserted and sealed later), thereby reducing manufacturing costs. Furthermore, the pouch can be sealed so that the end user cannot access the lighting device held within the pouch, making it easier to comply with toy safety standards (e.g., European Standard EN71).

[0011] In use, i.e., when the inflatable toy with the assembly is inflated and the lighting device is held within the pouch, the pressure difference between the interior of the inflatable toy and the interior of the pouch causes any excess air to be expelled from the pouch, causing the pouch to effectively form a vacuum seal around the lighting device, thereby more securely holding the lighting device within the pouch.

[0012] Furthermore, the pouch of the present invention allows the lighting device to be attached to the inflatable toy more easily and conveniently than conventional inflatable toys, and the pouch securely holds the lighting device to the inflatable toy, reducing the risk of the lighting device slipping off.

[0013] To illustrate one advantage of the present invention, the assembly of the present invention forms a single unit that receives and holds a lighting device within an inflatable toy via the pouch. Thus, for example, if the inflatable toy is a balloon incorporating the assembly, and the balloon is inflated with a low-density gas (such as a flotation balloon), it can be manufactured with a smaller inflation volume (still buoyant enough to float when inflated and equipped with a lighting device) than conventional balloons (which require a relatively large inflation volume). Balloons incorporating the assembly of the present invention can be manufactured in a wider range of sizes than conventional balloons. Therefore, cost savings can be realized by manufacturing smaller balloons that require less gas to inflate.

[0014] The inflatable toy may be any suitable inflatable toy known to those skilled in the art. Examples of inflatable toys include, but are not limited to, balloons, balls, and lyro toys. Examples of balloons include, but are not limited to, simple shaped balloons or complex shaped balloons. Examples of simple shaped balloons include, but are not limited to, geometric shapes, such as, but not limited to, spheres, ellipses, ovoids, and polyhedrons. Examples of complex shaped balloons include, but are not limited to, imitation shapes, such as, but not limited to, imitation swords.

[0015] The inflatable toy may be made of a heat-sealable material. The inflatable toy may be composed of one or more of polyethylene, polypropylene, polyester, nylon, polyvinyl chloride, cellulose acetate, and cellophane. The inflatable toy may consist essentially of polyethylene. The inflatable toy may consist of low-density polyethylene. The inflatable toy may consist essentially of low-density polyethylene. Advantages of low-density polyethylene include that it is easily heat-sealable and is readily available and inexpensive. The inflatable toy may consist of one or more sheets. The inflatable toy may be composed of a plastic material, and the inflatable toy may be metallized.

[0016] The lighting device may be any suitable lighting device known to those skilled in the art. The lighting device may comprise a light-emitting lighting element, which may be a lamp or a light-emitting diode (LED), or may comprise a printed circuit board (PCB), which may be flexible.

[0017] The lighting device may include a battery configured to be in electronic communication with the lighting element by an electronic circuit.

[0018] The lighting device may be provided with a switch for turning the lighting device on and off, and this switch may be a button switch, and the switch may form part of an electronic circuit.

[0019] The lighting device may include a pull tab configured to prevent electrical connection between the battery and the lighting element. The use of the pull tab is advantageous for preventing drainage of battery power. The pull tab may be provided between electrical contacts of a circuit to prevent charge flow. The pull tab may be detachable from the electrical contacts to electrically connect the battery and the lighting element. In use, the pull tab may be accessible from outside the inflatable toy.

[0020] The lighting device may be an LED strip light (also known as an LED tape or ribbon light).

[0021] The lighting device may include a communication unit, examples of which include, but are not limited to, a Bluetooth device, a GPS device, and a Wi-Fi device.

[0022] The lighting device may comprise a processor operable to process information, for example the information may be a control signal received by a communication unit.

[0023] The lighting device may comprise output means, examples of which include, but are not limited to, audio output means and video output means.

[0024] The lighting device may be provided with tactile feedback means, examples of which include, but are not limited to, vibration means.

[0025] The pouch may be configured to receive and hold the lighting device therein, thereby hiding the physical components of the lighting device, thereby facilitating a smaller size and improving tamper resistance.

[0026] If the lighting device is a general lighting device, the pouch may be configured to receive and hold the switch of the lighting device therein, and the pouch may be configured to receive and hold the lighting element of the lighting device therein, and by retaining the switch and / or lighting element within the pouch, the lighting device is more securely held in place and less likely to become dislodged.

[0027] The pouch may be framed by the first sealing path, the top layer of the pouch, and the bottom layer of the pouch.

[0028] The pouch may include a gripping means configured to hold the lighting device in place, the gripping means being configured to hold a switch on the lighting device in place. The gripping means may be provided as one or more protrusions. The protrusions may be curved or straight. The gripping means may be provided as one or more protrusions formed by a first sealing passage. The gripping means may provide the effect of securely holding the lighting device within the pouch.

[0029] The pouch may have an opening through which the lighting device can be inserted, the opening being located at one end of the pouch, with the other opposite end of the pouch being closed.

[0030] The pouch assembly may be configured such that, in use, the pouch forms a vacuum seal around the lighting device held therein, and may be configured such that, in use, the pouch extends into the interior of the inflatable toy.

[0031] The assembly includes an inflation valve, which allows the assembly to be configured as an inflation valve and pouch assembly for use with an inflatable toy. In use, the inflation valve allows the inflatable toy including the assembly to be easily inflated and deflated. Furthermore, because the valve and pouch are provided as a single unit in this configuration, the inflatable toy including the assembly can be lighter, smaller, and more stable than prior art inflatable toys in which the means for holding a lighting device within the inflatable toy and the inflation valve are provided in separate openings in separate locations.

[0032] When the inflatable toy is a balloon, the inflation valve may be a balloon valve.

[0033] The valve has a valve inlet and a valve outlet, and the valve inlet may be at one end of the valve and the valve outlet may be at the other end of the valve. As will be apparent to those skilled in the art, in use, to inflate an inflatable toy having an assembly, air flows from the valve inlet through the valve outlet and into the inflatable toy; and to deflate the inflatable toy, air flows from the valve outlet through the valve inlet and out of the inflatable toy.

[0034] The valve may be a self-sealing valve so that, in use, when an inflatable toy having the assembly is inflated, the internal pressure of the inflatable toy seals the valve.

[0035] The valve may include an upper valve layer and a lower valve layer, and the upper valve layer and the lower valve layer may be sealed together along the second sealing path. The framework of the valve may be defined by the second sealing path, the upper valve layer, and the lower valve layer.

[0036] The pouch may be located adjacent to the valve or may be located at the valve. The valve inlet may be located proximal to the pouch opening and the valve outlet may be located proximal to the closed end of the pouch, such that the valve inlet and pouch inlet can be conveniently positioned (i.e., adjacent to each other) and easily accessed.

[0037] The first and / or second sealing paths can be formed by any suitable sealing process. The first and / or second sealing paths can be formed by heat sealing. Suitable heat sealing methods are known to those skilled in the art.

[0038] The assembly may be provided with one or more heat resistant patches. Advantageously, the heat resistant patches may prevent heat sealing (e.g., during the heat sealing process) from occurring in desired locations on the assembly. In this way, if heat sealing is used on the assembly, the specific shape and dimensions of the valve and / or patch may be controlled because the heat seal can be precisely localized.

[0039] The valve and / or pouch may be provided with one or more heat-resistant patches. The upper valve layer and / or lower valve layer may be provided with one or more heat-resistant patches. The upper pouch layer and / or lower pouch layer may be provided with one or more heat-resistant patches. The upper valve layer, lower valve layer, upper pouch layer, and lower pouch layer may each be provided with one or more heat-resistant patches. Each heat-resistant patch may be provided in any suitable shape for a particular application.

[0040] Each heat-resistant patch may be constructed of heat-resistant ink.

[0041] The assembly may be made of any suitable material known to those skilled in the art, and the assembly may be made of a heat sealable material.

[0042] The assembly can be comprised of one or more of polyethylene, polypropylene, polyester, nylon, polyvinyl chloride, cellulose acetate, and cellophane. The assembly can consist essentially of polyethylene, or it can consist of low-density polyethylene, which is easily heat-sealable and is readily available and low-cost.

[0043] The assembly can be formed from a single film.

[0044] The total thickness of the assembly may be 100 to 160 microns; if the total thickness is less than 100 microns, the product performance will be reduced, and if the total thickness is 160 microns or more, manufacturing will be difficult.

[0045] The thickness of each of the upper and / or lower valve layers, and the upper and / or lower pouch layers may be 25 to 40 microns; thicknesses less than 25 microns will result in reduced product performance, and thicknesses greater than 40 microns will make production difficult.

[0046] Another aspect of the present invention provides an array of pouch assemblies for use in an inflatable toy, the array comprising a plurality of interconnected pouch assemblies according to the first aspect of the present invention.

[0047] By providing a plurality of assemblies connected together, an array can be used to quickly and efficiently manufacture a plurality of inflatable toys, each having an assembly, resulting in a more efficient manufacture of inflatable toys.

[0048] The assemblies can be connected in parallel.

[0049] Each assembly may be separated from another assembly by an assembly cut line, and thus each assembly can be separated (i.e., singulated) by cutting along the assembly cut line.

[0050] Another aspect of the present invention provides an inflatable toy comprising a pouch assembly according to the first aspect of the present invention, the assembly being adapted to be attached to the neck of the inflatable toy.

[0051] The assembly may be attached to the neck of the inflatable toy using any suitable means. The assembly may be attached to the neck of the inflatable toy by sealing means (e.g. heat sealing).

[0052] The inflatable toy includes a lighting device that can be received and held in place in the pouch.

[0053] In use, the inflatable toy includes the assembly, holds the lighting device within the pouch, and the lighting device includes a pull tab, allowing the inflatable toy to be turned on and off externally via the pull tab, so that the lighting of the inflatable toy can be controlled externally without damaging the seals of the inflatable toy.

[0054] In yet another aspect, the present invention provides a method of manufacturing a pouch assembly for use in an inflatable toy, the pouch receiving and holding in place a lighting device, the method comprising the steps of: (a) providing an upper pouch layer and a lower pouch layer; and (b) sealing the upper and lower pouch layers together to form the pouch, wherein the pouch assembly comprises: 1. A pouch assembly for use with an inflatable toy, the pouch assembly comprising a pouch having an upper pouch layer and a lower pouch layer, the upper pouch layer and the lower pouch layer sealed together along a first sealing path, the pouch receiving a lighting device and holding the lighting device in place; The pouch may have gripping means configured to hold the lighting device in place, the gripping means being provided as one or more protrusions, the one or more protrusions being defined by the first sealing path.

[0055] By sealing the layers together to form the pouch, the pouch assembly can be manufactured efficiently in terms of physical requirements and / or cost.

[0056] In step (a), an upper valve layer and a lower valve layer can be further provided, and in step (b), the upper valve layer and the lower valve layer can be further sealed together to form a valve of the inflatable toy. Therefore, this method can be said to be a method of manufacturing an inflatable toy valve and pouch assembly for use in an inflatable toy.

[0057] In step (a), one or more heat-resistant patches may be applied to at least one of the pouch upper layer, pouch lower layer, valve upper layer (if present), and valve lower layer (if present). An advantage of the heat-resistant patch is that it can prevent heat sealing (e.g., during the heat sealing process) at a desired location in the assembly. In this way, if heat sealing is used in the assembly, the heat sealing can be precisely localized, thereby controlling the specific shape and dimensions of the valve and / or pouch. In step (a), one or more heat-resistant patches may be applied to each of the pouch upper layer, pouch lower layer, valve upper layer (if present), and valve lower layer (if present). The heat-resistant patch may be comprised of a heat-resistant ink.

[0058] In step (a), the pouch top layer, pouch bottom layer, valve top layer, if present, and valve bottom layer, if present, can be provided in a single film, thus allowing the assembly to be manufactured more advantageously than known methods using multiple separate films.

[0059] In step (a), the pouch upper layer may be connected to the pouch lower layer via a pouch fold line, and in step (a), the pouch lower layer may be connected to the valve upper layer via an intermediate cut line. In step (a), the valve upper layer may be connected to the valve lower layer by a valve fold line.

[0060] In the present invention, a "fold line" defines an area along which each layer can be folded, and a "cut line" defines an area along which each layer can be folded and separated by cutting.

[0061] In step (b), the sealing can be performed using any suitable sealing means. Preferably, in step (b), the sealing is heat sealing. Suitable heat sealing methods are known to those skilled in the art.

[0062] In step (b), the upper and lower pouch layers can be sealed together along the first sealing path to set the framework of the pouch.

[0063] In step (b), the valve upper layer and the valve lower layer can be sealed together along the second sealing path to set the framework of the valve.

[0064] In this method, after step (a) and before step (b), the intermediate cut line may be cut to separate the pouch lower layer from the valve upper layer. In this method, after step (a) and before step (b), folding along the valve fold line may be performed to place the valve upper layer on the valve lower layer. In this method, after step (a) and before step (b), folding along the pouch fold line may be performed to place the pouch upper layer on the pouch lower layer.

[0065] In this method, after the valve and pouch are formed (ie, in step (c)), the ends of the valve may be cut towards the fold line to open both ends of the valve.

[0066] In this method, after the valve and pouch are formed (i.e., in step (c)), the valve can be sealed to the pouch, i.e., the valve and pouch form an integral unit, so that the valve and pouch cannot be separated. Sealing can be done by heat sealing.

[0067] In this method, after step (b) or step (c) (i.e., in step (d)), the lighting device may be inserted into the pouch.

[0068] In this method, after step (b), step (c), or step (d) (i.e., in step (e)), the assembly may be placed in an inflatable toy material, the inflatable toy material may be cut to a predetermined shape as needed, and the assembly may be sealed to the inflatable toy material. In other words, this method is a method for manufacturing an inflatable toy.

[0069] In the method, after step (b), or step (c), or step (d), or step (e), the inflatable toy material may be sealed around the lighting device to securely hold the lighting device within the inflatable toy, thereby making the lighting device inaccessible and facilitating compliance with European standard EN71.

[0070] The inflatable toy material may be provided with marking lines to facilitate alignment of the inflatable toy material.

[0071] In the method, after step (b) or step (c), a retaining means may be used to hold the assembly and the inflatable toy material together, thereby facilitating alignment of the assembly and the inflatable toy material before and during sealing. An electrostatic attractive force may be applied to the retaining means, and an electrostatic attractive force may also be applied to the assembly and / or the inflatable toy material.

[0072] This method can be used to manufacture an array of assemblies, specifically by providing a pouch upper layer, a pouch lower layer, a valve upper layer (if present), and a valve lower layer (if present) in step (a), and sealing the pouch upper layer and pouch lower layer together to form each pouch in step (b), and sealing the valve upper layer (if present) and the valve lower layer (if present) together to form each valve.

[0073] Specifically, the assemblies may be connected in parallel.

[0074] Specifically, each assembly may be provided on a single film.

[0075] Specifically, the assemblies may be separated from one another by assembly cutting lines. By cutting the assembly cutting lines, the assemblies can be separated (i.e., individualized). Optional features of one aspect of the invention are equally applicable to other aspects of the invention. DETAILED DESCRIPTION OF THE INVENTION

[0076] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which it is believed that a better understanding of the invention will be provided.

[0077] FIG. 1 is a cross-sectional view of a balloon according to the present invention having a balloon valve and pouch assembly attached to the neck of the balloon. FIG. 2 shows the balloon of FIG. 1 with a lighting device held within the assembly. FIG. 3 is a diagram illustrating a portion of the film used to manufacture the balloon assembly of FIG. FIG. 4 is an exploded perspective view of the balloon of FIG. FIG. 5 is an exploded perspective view showing the balloon of FIG. 1 with a lighting device held within the assembly.

[0078] 1 to 5, balloon valve / pouch assembly 1 attached to the neck of a balloon includes balloon valve 2 and pouch 3. Pouch 3 is configured to receive lighting device 100 and hold it in place.

[0079] 2 and 5, lighting device 100 includes a battery (not shown), an electrical circuit (not shown), a button switch 101 for turning the device on or off, a light-emitting diode (LED) as lighting element 102 that emits light when the device is turned on, and a removable pull tab 103 that prevents electrical connection between the battery and lighting element 102. As will be appreciated by those skilled in the art, pull tab 103 is configured to be located between electrical contacts in the electrical circuit to prevent charge from flowing and prevent lighting device 102 from illuminating, and to allow charge to flow and light device 102 to illuminate when removed from the electrical contacts. The pull tab prevents accidental depletion of battery power.

[0080] Valve 2 has a valve inlet 2A and a valve outlet 2B. Valve inlet 2A is located at one end of valve 2, and valve outlet 2B is located at the opposite end of valve 2. Valve 2 comprises a valve upper layer 2C and a valve lower layer 2D. Layers 2C and 2D are heat sealed to each other along a second sealing path 4, which has a substantially rectangular portion 4A adjacent to a substantially funnel-shaped portion 4B. Funnel-shaped portion 4B extends toward valve inlet 2A, and rectangular portion 4A terminates toward valve outlet 2B. Valve 2 is self-sealing. The framework of valve 2 is defined by second sealing path 4 and layers 2C and 2D.

[0081] The pouch 3 has an opening 3A through which the lighting device 100 can be inserted (see FIGS. 2 and 5). The opening 3A is provided at one end of the pouch 3, and the pouch closed end 3B is closed. The pouch 3 has a pouch upper layer 3C and a pouch lower layer 3D. The layers 3C and 3D are heat sealed to each other along a substantially V-shaped first sealing path 5, with the open end of the V forming the pouch opening 3A and the other end of the V forming the pouch closed end 3B. The framework of the pouch 3 is defined by the first sealing path 5 and the layers 3C and 3D.

[0082] The pouch 3 is mounted on the valve 2 and heat-sealed to the valve 2, with the valve inlet 2A facing the pouch opening 3A and the valve outlet 2B facing the closed end 3B of the pouch. The pouch 3 has two gripping protrusions 3E, 3F that hold the lighting device 100 in place. The protrusions 3E, 3F are defined by a first sealing path 5; that is, the protrusions are radially inward, opposed, and project toward the closed end of the V-shape at an oblique angle relative to the longitudinal axis of the V-shape. The protrusions 3E, 3F contact and hold the button switch 101, thereby securely holding the lighting device 100 in place within the pouch 3. The LED lighting element 102 extends toward the closed end of the pouch between the protrusions 3E, 3F and is held within the first sealing path 5 (see FIGS. 2 and 5).

[0083] The balloon valve and pouch assembly 1 is provided with heat-resistant patches 6A, 6B. The heat-resistant patches 6A, 6B have a heat-resistant ink so that heat sealing does not occur (see, for example, FIG. 3). A substantially torch-shaped patch 6A is provided on the valve layers 2C, 2D. Specifically, on each layer 2C, 2D, the patch 6A begins at the funnel-shaped portion of the second sealing path 4 and terminates approximately halfway along the second sealing path 4. On each layer 3C, 3D, a patch 6B is provided toward the pouch opening 3A, and another patch 6B is provided between the gripping projections 3E, 3F toward the closed end 3B of the pouch.

[0084] Layers 2C, 2D, 3C, 3D of assembly 1 consist of a single low density polyethylene film 10 having a thickness of about 25 microns.

[0085] A method for manufacturing an array of balloon valve / pouch assemblies is described below.

[0086] The film 10 is provided with printed markings corresponding to the valve upper layer 2C, the valve lower layer 2D, the pouch upper layer 3C, the pouch lower layer 3D, the fold lines 7 connecting each pouch upper layer 3C to its corresponding pouch lower layer 3D, the intermediate cut lines 8 connecting each pouch lower layer 3D to its corresponding valve upper layer 2C, the valve fold lines 9 connecting each valve upper layer 3C to its corresponding valve lower layer 3D, and optional markers that visually indicate whether layers 2C, 2D, 3C, and 3D are properly aligned when folded into place (as described in detail below). That is, multiple printed markings corresponding to each balloon valve / pouch assembly are provided side by side on the film. The longitudinal axes of the printed markings corresponding to each balloon valve / pouch assembly are aligned parallel to one another. Figure 3 shows a portion of the film. For simplicity, only the markings for a single assembly 1 are shown in Figure 3. In other words, the film 10 extends along the "X" axis as shown in FIG. 3 and has a plurality of separate balloon valve / pouch assemblies 1 connected in parallel to one another.

[0087] The film 10 also has heat resistant patches 6A, 6B made of heat resistant ink that prevent the areas of the film having the patches 6A, 6B from heat sealing.

[0088] Film 10 is cut along each intermediate cut line 8, so that valve top layer 2C separates from pouch bottom layer 3D.

[0089] The film 10 is folded along the valve folding line 9 to provide the valve upper layer 2C on the valve lower layer 2D, so that the heat-resistant patch 6A of the valve upper layer 2C overlaps the heat-resistant patch 6A of the valve lower layer 2D.

[0090] The film 10 is folded along the pouch folding line 7, and the pouch upper layer 3C is positioned on the pouch lower layer 3D, so that the heat-resistant patch 6B overlaps the heat-resistant patch 6B provided on the pouch lower layer 3D.

[0091] The valve upper layer 2C is heat sealed to the valve lower layer 2D along the second sealing path 4 to form each valve 2. Thus, the framework of each valve 2 is defined by the layers 2C, 2D and the respective second sealing paths 4. Each valve 2 has a valve inlet 2A and a valve outlet 2B.

[0092] The upper pouch layer 3C is heat sealed to the lower pouch layer 3D along the first sealing path 5 to form each pouch 3. In this manner, the framework of each pouch 3 is set by the layers 3C, 3D and the respective first sealing paths 5. Each pouch 3 has a pouch opening 3A at one end through which the lighting device 100 can be inserted, and is closed at the opposite end 3B.

[0093] Once each valve 2 and pouch 3 are formed, the pouch 3 is placed on the valve 2 so that the pouch bottom layer 3D is positioned on the valve top layer 2C, i.e., the pouch opening 3A is adjacent to the valve inlet 2A and the pouch closed end 3B is adjacent to the valve outlet 3B. The valve 2 and pouch 3 are aligned using the appropriate markers described above.

[0094] Each valve 2 and pouch 3 are heat sealed at various connection locations.

[0095] Those skilled in the art will appreciate that the heat seal at the connection point must not interfere with the valve 2 and pouch 3 .

[0096] The end of the valve 2 facing the fold line 7 is cut off so that the valve 2 is open at both ends, with the cut off end forming the valve outlet 2B and the opposite end forming the valve inlet 2A.

[0097] Thus, an array of balloon valve / pouch assemblies 1 can be produced, each connected in parallel. As will be appreciated by those skilled in the art, the balloon valve / pouch assemblies 1 can be singulated using any suitable cutting means.

[0098] As will be appreciated by those skilled in the art, the order in which the folding, cutting and sealing steps are performed can be changed as needed.

[0099] A method for manufacturing a foil balloon having an assembly 1 according to the present invention will now be described.

[0100] The lighting device 100 having the button switch 101 and the LED lighting element 102 is inserted into the pouch opening, and the button switch 101 is held within the pouch by the gripping protrusions 3E and 3F. The LED lighting element 102 protrudes toward the closed end 3B of the pouch between the gripping protrusions 3E and 3F and is held within the sealing path by the first sealing path 5.

[0101] With the lighting device 100 received within the assembly 1, the assembly 1 is placed between two foil sheets of balloon material of approximately the same shape and size. The foil sheets are heat sealed along their periphery and then cut to form a balloon with a neck to which the assembly 1 is attached. The components of the lighting device 100 are not shown.

[0102] In some cases, an electrostatic attraction can be applied to the assembly 1 and / or the foil sheet of balloon material before sealing the assembly 1 and foil sheet together, which can hold the assembly 1 and foil sheet in place and prevent inadvertent separation.

[0103] The above-described embodiments are for illustrative purposes only. Various modifications are possible without departing from the scope of protection defined in the claims. In particular, although the above-described embodiments have been described with reference to balloons, those skilled in the art will appreciate that the present invention can also be applied to other inflatable toys.

Claims

1. A pouch assembly for use with an inflatable toy, the pouch assembly comprising a pouch having an upper pouch layer and a lower pouch layer, the upper pouch layer and the lower pouch layer being sealed together along a first sealing path, the pouch receiving a lighting device and holding the lighting device in place; the pouch having a gripping means configured to hold the lighting device in place; said gripping means being provided as one or more projections; The pouch assembly, wherein the one or more projections are defined by the first sealing passage.

2. 2. The assembly of claim 1, wherein said first seal path, said pouch upper layer and said pouch lower layer define a framework for said pouch.

3. 3. The assembly of claim 1 or 2, wherein the pouch has an opening through which a lighting device can be inserted.

4. 4. The assembly of claim 3, wherein said opening is located at one end of said pouch and said other end of said pouch is closed.

5. An assembly according to any one of claims 1 to 4, further comprising one or more heat resistant patches provided on said assembly.

6. The assembly of any one of claims 1 to 5, wherein the assembly is formed from a heat sealable material.

7. The assembly of any one of claims 1 to 6, wherein the assembly comprises a valve.

8. 8. The assembly of claim 7, wherein said valve has an upper layer and an underlayer, said upper layer and underlayer being sealed together along a second sealing path, said valve framework being defined by said second sealing path, said upper layer and said underlayer.

9. 9. An array of pouch assemblies comprising a plurality of assemblies according to any one of claims 1 to 8, said assemblies being connected to one another.

10. An inflatable toy having the pouch assembly according to any one of claims 1 to 8, wherein the pouch assembly is attached to a neck portion of the inflatable toy.

11. The inflatable toy of claim 10, wherein the inflatable toy comprises a lighting device.

12. 1. A method of manufacturing a pouch assembly having a pouch, the pouch receiving and holding a lighting device in place, comprising: (a) providing a pouch upper layer and a pouch lower layer; and (b) sealing the upper and lower pouch layers together to form a pouch. provided that the pouch assembly is a pouch assembly for use with an inflatable toy, the pouch assembly comprising a pouch having an upper pouch layer and a lower pouch layer, the upper pouch layer and the lower pouch layer being sealed together along a first sealing path, the pouch receiving a lighting device and holding the lighting device in a predetermined position; the pouch having a gripping means configured to hold the lighting device in place; said gripping means being provided as one or more projections; The one or more protrusions are defined by the first sealing path.

13. 13. The method of claim 12, further comprising providing an upper valve layer and an under-valve layer in step (a), and further sealing the upper valve layer and the under-valve layer together in step (b) to form a valve.

14. 14. The method of claim 13, wherein in step (a), at least one of the pouch upper layer, the pouch lower layer, the valve upper layer if present, and the valve lower layer if present, is provided with one or more heat resistant patches.

15. 15. The method of claim 13 or 14, wherein in step (a), the pouch upper layer, the pouch lower layer, the valve upper layer if present, and the valve lower layer if present are provided on a single membrane.

16. 16. The method of claim 12, wherein in step (b), the pouch upper layer and the pouch lower layer are sealed together along a first sealing path to form the pouch.

17. A method according to any one of claims 15 to 16 when according to claim 13, wherein in step (b), the valve upper layer and the valve lower layer are sealed together along a second sealing path to form the valve.

18. A method according to any of claims 15-16 when according to claim 13, wherein in step (a), the pouch upper layer is connected to the pouch lower layer by a pouch fold line, the pouch lower layer is connected to the valve upper layer by an intermediate cut line, and the valve upper layer is connected to the valve lower layer by a valve fold line.

19. After step (a) and before step (b), cutting the intermediate cut line to separate the pouch lower layer from the valve upper layer; The pouch is folded along the pouch fold line to provide the pouch upper layer on the pouch lower layer.

20. The method of claim 18.

20. The method of any one of claims 12 to 19, further comprising, after step (b), inserting a lighting device into the pouch and mounting the pouch assembly within an inflatable toy.

21. The method of any of claims 12 to 20, further comprising, after step (b), providing the pouch assembly within an inflatable toy material, cutting the inflatable toy material, and sealing the assembly to the inflatable toy material.

22. 22. The method of any one of claims 12 to 21, comprising the steps of: providing, in step (a), a pouch upper layer, a pouch lower layer, a valve upper layer, if present, and a valve lower layer, if present, each of the pouches; and, in step (b), sealing the pouch upper layer and the pouch lower layer together to form each pouch, and sealing the valve upper layer and the valve lower layer, if present, to form each valve.

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