Toy filling method and system

Abstract

A method for filling a heatable toy 100 comprises inserting a filling pipe (302, figure 3b) into the heatable toy through an aperture 108 located at an upper end of the heatable toy. Passing a heatabl

Description

The present invention relates to toy filling method and system, particularly to heatable toy filling method and system. Background Stuffed toys or plush toys are typically toy dolls with an outer fabric sewn from a textile and stuffed with a flexible material. A subtype stuffed toys are heatable soft toys, which comprise an outer fabric sewn from textile and filled with a first low density material such as polyester fiberfill and a second material suitable to be heated such as millet. Typically, the head of a heatable toy is filled with the first material and the main body is filled with the second material. If the toy comprises arms and legs, or other appendages, these would likely also be filled with the first material. The first material comprises a low density material which is stuffed though aperture in the head of the toy either completely manually or partially manually utilising a blow machine with a funnel. The second material mostly comprises a granular texture and is manually filled into the body using a scoop and a funnel placed through the same aperture in the head of the toy. Once the toy is filled, the aperture in the head of the toy is then machine closed or stitched. This process requires that the heatable toys to be predominantly manually filled and closed. This can be timely and costly. In addition, using this method can result in the granular material getting caught up in the polyfill in the head of the toy as opposed to settling in the body of the toy as intended. It is an aim of the invention to provide a system and method that mitigates one or more of the above-mentioned problems. Statements of invention According to a first aspect of the invention there is provided a method for filling a heatable toy comprising; inserting a filling pipe into the heatable toy through an aperture located at an upper end of the heatable toy, passing a heatable material through the filling pipe and into an internal cavity of the heatable toy, removing the filling pipe from the heatable toy, closing the aperture, wherein the filling pipe comprises part of an automated filling machine and performs the above automatically. The method may further comprise the heatable material being directed to the lower end of the heatable toy by a device located at the aperture. The method may comprise holding the aperture open for the filling pipe manually. The method may further comprise the aperture being held open for the filling pipe by a device. The method may further comprise inserting the device into the aperture before filling and removing the device before closing the aperture. The method may further comprise closing the aperture by a thread pre-stitched across the aperture and having one end attached to the device. The automated machine may comprise an auger filler. Alternatively, the automated machine may comprise a gravity fed filling machine, an air assisted filling machine. The automated machine may be any suitable type of automated machine or semiautomated machine. According to another aspect of the invention there is provided a heatable toy to be filled with a heatable material comprising; an aperture located at an upper end of the heatable toy for receiving a filling pipe, an internal cavity for receiving a heatable material, and a device located at the aperture. The device located at the aperture may comprise a chute for directing the heatable material to a lower end of the heatable toy. The chute may pass through the aperture and be removable from the aperture. The chute may comprise a rigid material such that the chute holds the aperture open. The chute may comprise cardboard or plastic. There may be a thread stitched across the aperture and connected to the chute. The chute may be attached to the aperture. One end of the chute may be attached to the aperture and a second end of the chute may be located within the lower end of the heatable toy. The chute may comprise a flexible material. The chute may comprise the same material as the heatable toy to be filled. The flexibly chute acts as a valve and prevents the heatable material held within the internal cavity exiting the internal cavity. There may be a second device located at the aperture and comprising a rigid material such that the aperture is held open by the second device. The second device may comprise a removable chute. The removable chute may extend through the chute attached to the aperture. According to another aspect of the invention there is provided a heatable toy to be filled with a heatable material comprising; an aperture located at an upper end of the heatable toy for receiving a filling pipe, an internal cavity for receiving a heatable material, and a chute having a first end attached to the aperture. The chute comprises a second end which is movable from outside of the aperture to inside the internal cavity. The second end can receive the heatable material from a filling pipe of an automated / semiautomated machine, or it can receive heatable material manually by a funnel or other means. Once the toy is filled, the second end of the chute is pushed into the internal cavity before the aperture is closed. The chute prevents grain in the internal cavity from getting close to the threat that closes the aperture reducing the chances of the heatable material exiting the closed aperture. This is beneficial as less stiches can be used to close the aperture. According to another aspect of the invention, there is provided a method for filling a toy comprising; inserting a filling pipe into the heatable toy through an aperture located at an upper end of the heatable toy, passing a heatable material through the filling pipe and into an internal cavity of the heatable toy, removing the filling pipe from the heatable toy, closing the aperture, wherein the filling pipe comprises part of an automated filling machine and performs the above automatically. Detailed description Practicable embodiments of the invention are described in further detail below with reference to the accompanying drawings, of which: Figure 1 shows a partial cut out back view of a heatable toy filled in accordance with the present invention. Figure 2 shows a partial side view of the heatable toy 100. Figures 3a to 3f shows stages of a method for filling a heatable toy in accordance with the present invention. Figure 1 shows an example of a heatable toy 100. In this example, the heatable toy 100 comprises an outer layer 101, a head 102, a main body 103, two legs 104, and two arms 105. The outer layer 101 may also be referred to as a skin. The outer layer 101 may comprise a textile in a desired shape. The outer layer 101 may comprise the shape of a bear or other animal. The outer layer 101 comprises at least one internal cavity. The outer layer 101 may comprise a plurality of internal cavities. In this example the outer layer 101 comprises the shape of a bear with a single internal cavity. The heatable toy 100 comprises an upper end 106 and a lower end 107. In this example the upper end comprises the head 102, and the lower end comprises the main body 103. The heatable toy 100 may further comprise one or a plurality of appendages to the main body and / or head. In the example shown in Figure 1, the heatable toy comprises a plurality of appendages. The heatable toy 100 appendages comprise two arms 105 and two legs 104. In other examples, the heatable toy may comprise any number of appendages such as a tail, ears, etc. The heatable toy 100 is filled with at least one heatable material. The at least one heatable material comprises a granular material. The at least one heated material may comprise millet. The heatable toy may be filled with a second material. The second material may comprise a synthetic flexible material. The second material may comprise polyester fiberfill. The heatable toy 100 may be filled a plurality of materials. The heatable toy may be filled with a first material, a second material and a third material. The third material may comprise a scented material. The heatable toy may be filled with lavender. The heatable toy 100 is filled with the heatable material. The internal cavity created by the outer layer may be filled by the heatable material. In this example, the upper end 106 of the heatable toy is filled with the second material and the lower end of the heatable toy is filled with the heatable material. The lower end may be filled with a mixture of the heatable material and the third material. The appendages may be filled with either the first material or the second material, or a mixture of the second and third materials. In this example, the head 102, arms 105 and legs 104 are filled with the second material and the main body 103 is filled with the heatable material. The heatable toy 100 comprises an aperture 108 into the internal cavity. In this example the aperture 108 is located in the head 102. The aperture may extend from one end of the head 102 to a second end of the head 102 where the head 102 meets the main body 103. The aperture may extend only partially The aperture 108 may extend substantially vertically from where the head 102 meets the main body 103 to the top of the head 102. The aperture may extend partially along the head 102. In an example of the invention, the aperture 108 may comprise a chute 109. The chute 109 shown in Figure 1 is within the internal cavity. The chute 109 surrounds the aperture 108 such that any material entering the aperture 108 is guided into the internal cavity by the chute 109. The aperture 108 opens into the chute 109. The periphery of the aperture 108 is connected to a first end of the chute 109. The second end of the chute 109 may extend within the internal cavity as shown in figure 1, alternatively, the second end of the chute may be pulled out of the internal cavity. The chute 109 may comprise part of the outer layer 101. The chute 109 may be internal. The chute may comprise the outer layer 101 folded within the internal cavity of the heatable toy. The edges of the aperture 108 may transition into the chute 109. The chute 108 may extend from the entry of the aperture 108 towards the lower end 107. The aperture 108 may comprise a thread 110. The thread 110 may be attached across the aperture 108. The thread 110 is attached across the aperture and untied at one end such that the aperture 108 can be opened by loosening the stitched thread 110, and closed by pulling the untied end of the thread 110. The thread 110 may comprise at least 3 stitches per inch of the aperture 108. The thread 110 may comprise 10 stitches per inch of the aperture 108. Figure 2 shows a partial side view of the heatable toy 100. Figure 2 shows the head 102 with the chute 109 at the back of the head 102. The chute 109 is outside of the aperture 108. The chute 109 is movable from within the internal cavity of the heatable toy 100 to outside the skin 101 and vice versa. In this example, the chute 109 comprises a material different to that of the skin 101. The chute 109 may comprise a flexible material such that it can be movable from within the internal cavity of the heatable toy 100 to outside the skin 101 and vice versa. The chute 109 may comprise a pocket material. The chute 109 may comprise cotton. The chute 109 may comprise polyester. The chute 109 may comprise a mixture of cotton and polyester. The chute 109 may vary in length. The chute 109 may be of a length that when it is within the external cavity it extends from the aperture 108 to the where the head 102 is connected to the main body 103. The chute 109 may be of a length that when it is within the external cavity it extends further into the main body 103. In another example, the aperture 108 may comprise a device. The device may comprise a substantially circular shape. The device may be located at the edges of the aperture 108. The device may be sufficiently rigid to keep the aperture open. The device may be releasably connected to the aperture 108. The device may In any example of the invention the aperture 108 may comprise a thread 110 as previously described. Method of filling The outer layer or skin comes pre-prepared. The pre-prepared outer layer comprise a textile stitched or otherwise bonded into a desired shape with at least one empty cavity. The pre-prepared upper end of the skin may comprise an aperture. Alternatively, an aperture is made in the upper end of the skin. The upper end of the skin may comprise a head. The upper end of the skin may comprise an appendage to a main body. A thread is attached across the aperture at the upper end of the pre-prepared skin. Alternatively, the thread may come pre-stitched to the aperture. The thread is stitched across the aperture but untied at one end such that the aperture can be opened by loosening the stitched thread, and closed by pulling the untied end of the thread. The thread may comprise at least 3 stitches per inch of the aperture. The thread may comprise 10 stitches per inch of the aperture. The skin is firstly filled with the first material. The appendages to the main body are filled with the first material. The skin is filled through the aperture. In this example shown in Figure 1 the skin comprises a main body 103, a head 102, two arms 105 and two legs 104. The head, arms, and legs of the skin are filled with the first material. An automated filled comprising a blower and a nozzle may be used to fille the head, arms, and legs of the skin with the first material. The nozzle may be inserted into the aperture and directed into the arms, legs, and head, the blower then forces the first material into the cavity of the skin and fills the cavity where the nozzle is directed. Alternatively to the automated machine, the head, arms, and legs of the skin may be filled with the first material by hand. Once the cavity of the appendages of the skin are filled with a first material, the skin is then filled with a second material. Figures 3a to 3f shows stages method for filling a heatable toy in accordance with the present invention. Particularly, Figures 3a to 3f show the stages of the method for filling the heatable toy with a heatable material. In this example, the main body 103 of the toy 100 is filled with a heatable material. The heatable material comprises a granular texture. To automate the filling of the heatable material into the toy 100, a machine comprising a filling pipe is used. The machine comprising a filling pipe may comprise an auger filling machine. The filling machine may comprises a hopper into which the heatable material is loaded into, and the filling pipe is located below the hopper. There is a mechanism which controls entry of the heatable material from the hopper into the filling pipe. Figure 3a shows the skin 101 partially filled with the second material. The aperture 108 located at the upper end 106 of the skin 101 is open and the thread 110 is loosely stitched around the aperture 108. A device 301 may be located at the aperture. The device may be 301 may be located around the aperture 108. The device 301 may extend within the internal cavity of the toy 100. In this example, the device may comprise a chute keeping the aperture 108 open such that a filling pipe can enter and exit the aperture 108 without the skin 101 needing to be manually repositioned. The chute may not be attached to the toy 100. The chute is positioned such that the chute extends within the toy 100 and outside the aperture 108. The chute is positioned such that the majority of the length of the chute is located inside the cavity of the skin 100. The chute may be substantially cylindrical. The chute may comprise a hollow cylinder. The chute is sufficiently rigid to keep the aperture open. In another example, the device may comprise a chute comprising a flexible material and an additional device which holds the aperture 108 open. The chute may be attached to the aperture 108. The chute may comprise part of the skin 101. The entire of the chute may be located within the internal cavity of the toy. Alternatively, the chute may be pulled out of the internal cavity. When the chute comprises a flexible material and is located outside the internal cavity, the end of the chute not attached to the aperture 108 may be held open. The chute may be held open by the same device which holds the aperture open. The chute may comprise the chute 109 described in figure 1 and figure 2. The additional device may comprise any means which holds the aperture 108 open such that a filling pipe can enter and exit the aperture 108 without the skin 101 needing to be manually repositioned. The additional device may not be attached to the aperture 108. Alternatively, the additional device may be releasably attached to the aperture 108. The additional device may comprise a two clips releasably attached to opposite ends of the aperture 108. In another example, the device may comprise two chutes. There may be a first chute attached to the aperture 108 and a second removable chute positioned within the aperture 100. The first chute may comprise a flexible material and the second chute may comprise a rigid material. The second chute may extend within the first chute. The first chute may comprise chute 109 described in figures 1 and 2. In any of the above examples, any of the chutes may extend from the entry of the aperture 108 to the lower end 107 of the skin 101. In another example, there may not be a device holding the aperture 108 open and a filling pipe may be manually placed within the aperture 108. In this example, the chute 109 described in figures 1 and 2 is present. Figure 3b shows a filling pipe 302 entering the toy 100 via the device 301 located at the aperture 108. The toy 100 may be positioned on a movable platform. The toy 100 may be positioned on a conveyor belt. The toy 100 such that it is positioned below the filling pipe 302. The filling pipe 302 is in an up position when the toy 100 is being positioned beneath the filling pipe 302. When the toy 100 is positioned below the filling pipe 302 the filling pipe 302 moves downwards toward the toy 100. If the aperture 108 or the chute is not held open by a device, it may be manually placed over the filling pipe 302. The filling pipe 302 enters the aperture 108. The filling pipe 302 enters the aperture 108 which is held open by the device 301. Figure 3c shows the filling pipe 302 passing through the device 301. In this example the filling pipe 302 passed entirely through the device 301. In this example the device 301 comprises a chute and the filling pipe 302 passes through the entirety of the chute such that it enters the lower end 107 of the toy 100. Alternatively, the filling pipe 302 may pass only partially into the device 301. When the filling pipe 302 is within the lower end 107 the heatable material is released through the filling pipe 302 and into the internal cavity. The heatable material empties into the skin 102. The heatable material empties through the filling pipe and into the lower end 107 of the toy 100. Figure 3d shows the filling pipe 302 retreating back through the device 301. Once the heatable material begins to empty into the heatable toy, the filling pipe 302 begins to move upwards. The filling pipe 302 begins to retreat back through the device 301. The filling pipe 301 injects the heatable material into the body 103 as it is withdrawing out of the aperture 108. In this example, the device 301 comprises a chute and when the filling pipe 302 retreats back through the chute, the heatable material is directed into the lower end 107 of the toy by the chute. The chute ensures the heatable material deposits into the lower end 107. Figure 3e shows the filling pipe 302 exiting the heatable toy 100. The filling pipe 302 stop distributing the heatable material. The filling pipe 302 may distribute the heatable material for a fixed period of time. The filling pipe 302 may stop distributing the heatable material when it reaches a certain height. The filling pipe 302 pulls all the way out of the aperture 108. The filling pipe 302 moves upwards to it’s up position. The filling pipe 302 moves to its highest position ready to fill the next product. The method described in figures 3b to 3e may be repeated. The method described in figures 3b to 3e may be repeated a plurality of times. The method described in figures 3b to 3e may be repeated as the heatable toy is moved down a production line to the next filling pipe 302. Figure 3f shows the skin 101 filled with the second material. The aperture 108 located at the upper end 106 of the skin 101 is closed and the thread 110 is stitched around the aperture 108. When a chute is present, this is placed within the internal cavity before the aperture 108 is closed. When the filling pipe is removed the closing thread is pulled tight and knotted to close the aperture. The closing thread may be pulled tight and knotted manually. Where a removable device 301 is present, the closing thread may be attached to the device such that when the device is removed the thread is pulled tight and closes the aperture.

Claims

1. A method for filling a heatable toy comprising:inserting a filling pipe into the heatable toy through an aperture located at an upper end of the heatable toy;passing a heatable material through the filling pipe and into an internal cavity of the heatable toy;removing the filling pipe from the heatable toy;closing the aperture;wherein the filling pipe comprises part of an automated filling machine and performs the above automatically.

2. The method of claim 1, further comprising the heatable material being directed to the lower end of the heatable toy by a device located at the aperture.

3. The method of claim 1 or 2, further comprising the aperture being held open for the filling pipe by a device located at the aperture.

4. The method of claims 2 or 3, further comprising inserting the device into the aperture before filling and removing the device before closing the aperture.

5. The method of claim 4, further comprising closing the aperture by a thread pre-stitched across the aperture and having one end attached to the device.

6. The method of claim 2, further comprising holding the aperture open for the filling pipe manually.

7. The method of any preceding claim, wherein the automated machine comprising an auger filler.

8. A heatable toy to be filled with a heatable material comprising:an aperture located at an upper end of the heatable toy for receiving a filling pipe;an internal cavity for receiving a heatable material;and a device located at the aperture.

9. The heatable toy of claim 8, wherein the device comprises a chute for directing the heatable material to a lower end of the heatable toy.10.The heatable toy of claim 9, wherein the chute passes through the aperture and is removable from the aperture.11 .The heatable toy of claim 10, wherein the chute comprises a rigid material such that the chute holds the aperture open.12.The heatable toy of claim 11, wherein the chute comprises cardboard or plastic.13.The heatable toy of claims 9 to 12, further comprising a thread stitched across the aperture and connected to the chute.

14. The heatable toy of claim 9, wherein the chute is attached to the aperture.

15. The heatable toy of claim 14, wherein one end of the chute is attached to the aperture and a second end of the chute is located within the lower end of the heatable toy.16.The heatable toy of claims 14 to 15, wherein the chute comprises a flexible material.17.The heatable toy of claim 16, wherein the chute comprises the same material as the heatable toy to be filled.18.The heatable toy of claims 14 to 17, further comprising a second device located at the aperture and comprising a rigid material such that the aperture is held open by the second device.19.The heatable toy of claim 18, wherein the second device comprises a removable chute.5 20.The heatable toy of claim 19, wherein the removable chute extends throughthe chute attached to the aperture.21 .A heatable toy to be filled by the method of claim 1 comprising:io an aperture located at an upper end of the heatable toy for receiving a fillingpipe;an internal cavity for receiving heatable material;a thread located across the aperture for closing the aperture.AMENDMENTS TO THE CLAIMS HAVE BEEN FILED AS FOLLOWS:16Claims1. A method for filling a heatable toy comprising:inserting a filling pipe into the heatable toy through an aperture located at5 an upper end of the heatable toy;passing a heatable material through the filling pipe and into an internalcavity of the heatable toy;removing the filling pipe from the heatable toy;closing the aperture;io wherein the filling pipe comprises part of an automated filling machine and fills the heatable toy automatically;the aperture being held open for the filling pipe by a device located at the aperture.

152. The method of claim 1, further comprising the heatable material being directed to the lower end of the heatable toy by a device located at theLD aperture.CM20CM 3. The method of claims 1 or 2, further comprising inserting the device into theaperture before filling and removing the device before closing the aperture.

4. The method of claim 3, further comprising closing the aperture by a thread pre-stitched across the aperture and having one end attached to the device.

305. The method of any preceding claim, wherein the automated machine comprising an auger filler.

356. A heatable toy to be filled with a heatable material comprising:an aperture located at an upper end of the heatable toy for receiving a filling pipe;an internal cavity for receiving a heatable material;40 a thread located across the aperture for closing the aperture;and a device located at the aperture.

7. The heatable toy of claim 6, wherein the device comprises a chute for directing the heatable material to a lower end of the heatable toy.5 8. The heatable toy of claim 7, wherein the chute passes through the apertureand is removable from the aperture.

9. The heatable toy of claim 8, wherein the chute comprises a rigid material such that the chute holds the aperture open.io10.The heatable toy of claim 9, wherein the chute comprises cardboard or plastic.1511 .The heatable toy of claims 7 to 10, wherein the thread located across the aperture is connected to the chute.IDCM20 12. The heatable toy of claim 7, wherein the chute is attached to the aperture.CM 13. The heatable toy of claim 12, wherein one end of the chute is attached tot— the aperture and a second end of the chute is located within the lower end25 of the heatable toy.14.The heatable toy of claims 12 to 13, wherein the chute comprises a flexible material.15.The heatable toy of claim 14, wherein the chute comprises the same material as the heatable toy to be filled.16.The heatable toy of claims 12 to 15, further comprising a second device located at the aperture and comprising a rigid material such that the aperture is held open by the second device.17.The heatable toy of claim 16, wherein the second device comprises a removable chute.18.The heatable toy of claim 17, wherein the removable chute extends through the chute attached to the aperture.LDCM

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