Toys and toy assembly processes

Abstract

The invention relates to a toy comprising: a skeleton consisting of: a first body, a second body, and a sprue between the first and second bodies; and a casing assembly consisting of: a first casing configured to receive the first body; and a second casing configured to be joined to the first casing. The joining of the first and second casings severs the sprue.

Description

[0001] TOY AND TOY ASSEMBLY PROCESS CROSS-REFERENCE TO RELATED APPLICATION

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 593,306, filed on October 26, 2023, and titled TOY AND TOY ASSEMBLY PROCESS, which is incorporated herein by reference in its entirety.

[0003] TECHNICAL FIELD

[0004] This disclosure relates to a manufacturing process for a toy.

[0005] BACKGROUND

[0006] Persons of all ages enjoy playing with toys.

[0007] SUMMARY

[0008] In one aspect, a method includes: placing a skeleton in a first enclosure portion with a sprue of the skeleton positioned over a first interior wall of a first enclosure portion; positioning a second enclosure portion relative to the first enclosure portion such that the sprue of the skeleton is between the first interior wall and a second interior wall that is part of the second enclosure portion; and pressing the first enclosure portion and the second enclosure portion together to sever the sprue.

[0009] Implementations may include one or more of the following features.

[0010] The first enclosure portion may include a first alignment structure, and placing the skeleton in the first enclosure portion with a sprue of the skeleton positioned over the first interior wall may include placing a portion of the skeleton on the first alignment structure. Placing a portion of the skeleton on the first alignment structure may include placing a locating opening in the skeleton on a locating post of the first alignment structure. The second enclosure portion may include a second alignment structure configured to interact with the first alignment structure, and positioning the second enclosure portion relative to the first enclosure portion may include placing the second alignment structure in contact with the first alignment structure. Placing the second alignment structure in contact with the first alignment structure may include inserting a connection post of the second alignment structure into a recess in a locating post of the first alignment structure. Pressing the first enclosure portion and the second enclosure portion together may cause the first interior wall and the second interior wall to exert force on the sprue to sever the sprue.

[0011] In some implementations, after pressing the first enclosure portion and the second enclosure portion together to sever the sprue, an enclosure assembly that surrounds at least part of the skeleton is formed by sonic welding the first enclosure portion and the second enclosure portion.

[0012] In another aspect, a toy includes: a skeleton including: a first body portion, a second body portion, and a sprue between the first body portion and the second body portion; and an enclosure assembly including: a first enclosure portion configured to receive the first body portion; and a second enclosure portion configured to be joined to the first enclosure portion. Joining the first enclosure portion and the second enclosure portion severs the sprue.

[0013] Implementations may include one or more of the following features.

[0014] Each of the first enclosure portion and the second enclosure portion may include an interior wall, and the interior wall of the first enclosure portion may interact with the interior wall of the second enclosure portion to sever the sprue.

[0015] The skeleton may include a first polymer material, and the first enclosure portion and the second enclosure portion may include a second polymer material. The first plastic material may include Acrylonitrile Butadiene Styrene (ABS) plastic, and the second plastic material may include polyvinyl chloride (PVC). The first body portion may include a torso portion, and the second body portion mat include a limb portion.

[0016] In another aspect, a method includes: providing a first skirt portion, the first skirt portion including a locating post and interior walls; placing an opening in a body portion of a skeleton over the locating post to position the skeleton in the first skirt portion with a sprue of the skeleton being positioned over a first one of the interior walls; positioning a second skirt portion over the first skirt portion, the second skirt portion including an insertion post and interior walls; inserting the insertion post of the second skirt portion into an opening in the locating post of the first skirt portion while the skeleton is between the first skirt portion and the second skirt portion and the sprue is between the first one of the interior walls of the first skirt portion and one of the interior walls of the second skirt portion; and pressing the first skirt portion and the second skirt portion together to insert the insertion post into the opening and to sever the sprue.

[0017] Implementations may include one or more of the following features. The first skirt portion may be secured to the second skirt portion by sonic welding.

[0018] Placing the opening of the body portion of the skeleton over the locating post may position each of a plurality of sprues of the skeleton over one of the interior walls of the second portion.

[0019] In another aspect, a toy includes: a skirt body including: a first skirt portion including: a locating post, and first interior walls; a second skirt portion including: an insertion post configured for insertion into an opening in the locating post, and second interior walls; and a skeleton including: a body portion including a locating opening; a first sprue between the body portion and a first arm; a second sprue between the body portion and a second arm; a third sprue between the body portion and a leg assembly. Positioning the body portion in the first skirt portion with the locating post in the locating opening places the first sprue over a first one of the first interior walls, the second sprue over a second one of the first interior walls, and the third sprue over a third one of the first interior walls; and inserting the insertion post into the opening in the locating post aligns one of the second interior walls with one of the first interior walls to sever the first sprue, the second sprue, and the third sprue.

[0020] Implementations may include one or more of the following features.

[0021] The skeleton may include a first polymer material, and the skirt body may include a second polymer material. The first plastic material may include Acrylonitrile Butadiene Styrene (ABS) plastic, and the second plastic material may include polyvinyl chloride (PVC).

[0022] The techniques discussed herein may be implemented as a system, an apparatus, a device, or a method.

[0023] DRAWING DESCRIPTION

[0024] FIG. 1 shows an assembled toy figure.

[0025] FIG. 2 shows the toy figure of FIG. 1 in a partially assembled state.

[0026] FIG. 3 shows another toy figure in a disassembled state.

[0027] FIG. 4 shows the toy figure of FIG. 1 in a partially assembled state.

[0028] FIG. 5 shows the interior of two enclosure portions.

[0029] DETAILED DESCRIPTION

[0030] FIG. 1 shows an assembled toy figure 100. The toy figure 100 includes a head 110, a skeleton 120, and an enclosure assembly 380. The enclosure assembly 380 encloses part of the skeleton 120. The enclosure assembly 380 may be shaped and / or styled to appear as an article of clothing and / or as an accessory for attachment to the figure 100. For example, the enclosure assembly 380 may be shaped as a skirt, shirt, pants, shorts, jumpsuit, sweater, bathing suit, scarf, sword, bag, or shoe.

[0031] FIG. 2 shows the toy figure 100 in a partially assembled state, before the enclosure assembly 380 is attached to the skeleton 120. The head 110 is removable and is not part of the skeleton 120. The enclosure assembly 380, the skeleton 120, and the head 110 are made of a polymer material. For example, the enclosure assembly 380 may be made of Acrylonitrile Butadiene Styrene (ABS) plastic, the skeleton 120 may be made of polypropylene (PP), and the head 110 may be made of polyvinyl chloride (PVC).

[0032] The skeleton 120 includes a body portion 122, arms 124, and legs 126. The skeleton 120 is a single-piece object. For example, the skeleton 120 may be a single piece of injection molded plastic. The skeleton 120 has runners or sprues 129 between the arms 124 and the body portion 122. The runners 129 are thin and flexible enough to allow the arms 124 to articulate relative to the body portion 122 even though the skeleton 120 is a single-piece element.

[0033] As discussed below, as compared to prior and / or current toy skeletons for similar products, the skeleton 120 promotes more efficient and more precise manufacturing.

[0034] FIG. 3 is a photograph of the various parts of a toy figure, which is referred to as the toy figure 370. The toy figure 370 does not include a single-piece skeleton.

[0035] The toy figure 370 includes a torso support 371, arms 374, and a pelvis portion 375. The torso support 371 includes an opening 372 and a head connector 373. The torso support 371, the arms 374, and the pelvis portion 375 are positioned within the enclosure assembly 380. The enclosure assembly 380 includes a second enclosure portion 381 and a first enclosure portion 382.

[0036] To assemble the toy figure 370, the torso support 371 is positioned in a recess 383 of the first enclosure portion 382 with the opening 372 positioned over a post 384 and the head connector 373 extending upward from the first enclosure portion 382. Each arm 374 is positioned in a recess 385 of the second enclosure portion 381. The pelvis portion 375 is positioned in a recess 386 of the second enclosure portion 381. The first enclosure portion 382 is aligned with the second enclosure portion 381, with an opening 387 in the post 384 being aligned with a corresponding post 388 on the second enclosure portion 381 . The enclosure portions 381 and 382 are then pushed toward each other until the post 388 is inserted into the opening 387 and the perimeter of the enclosure portion 381 and the perimeter of the enclosure portion 382 touch. The torso support 371, the arms 374, and the pelvis portion 375 are captured inside the assembled enclosure assembly 380, with the head connector 373, arms 374, and legs extending out of the enclosure assembly 380. The enclosure portions 381 and 382 are glued and / or sonic welded together to finalize the formation of the enclosure assembly 380.

[0037] Thus, the assembly of the toy figure 370 involves manual placement of the arms 374, pelvis portion 375 (and legs), and the torso support 371 in the enclosure portion 381 and / or 382. The placement of these four separate objects in the enclosure assembly 380 adds time and complexity to the manufacturing process and also increases unintentional variations among toy figures.

[0038] On the other hand, and referring again to FIGS. 1 and 2, the skeleton 120 is a single piece that is placed in the enclosure portion 381 or the enclosure portion 382 all at once and without requiring placement of multiple separate components. Specifically, and referring also to FIG. 4, a locating opening 123 in the body portion 122 is placed over the post 384 with a neck connector 199 extending perpendicularly from the post 384. The neck connector 199 may be a mushroom connector. Placing the locating opening 123 over the post 384 aligns the skeleton 120 relative to the first enclosure portion 382 such that the arms 124 land in the recesses 385 and the pelvis and legs land in the recess 386. In this way, the skeleton 120 is positioned in the first enclosure portion 382 with a single placement. After the skeleton 120 is placed in the enclosure portion 382, the enclosure portion 381 is positioned over the enclosure portion 382 with the skeleton 120 between the enclosure portions 381 and 382. The enclosure portions 381 and 382 are attached to each other and then secured to each other by gluing and / or sonic welding, as discussed above.

[0039] FIG. 5 shows the interior of the enclosure portions 381 and 382. As discussed above, to attach the enclosure portion 381 to the enclosure portion 382, the enclosure portion 381 is positioned over the enclosure portion 382, the post 388 on the enclosure portion 381 inserted into the opening 387 on the enclosure portion 382, and the portions 381 and 382 are pushed together. The enclosure portion 381 also includes interior walls 394, 395, and 396. The enclosure portion 382 includes interior walls 391, 392, and 393.

[0040] When the skeleton 120 is positioned in the portion 382 (FIG. 4), each of the interior walls 392 and 393 is directly under an arm runner 129 (FIG. 1) that connects one of the arms 124 to the body portion 122. When the enclosure portion 381 is positioned over the enclosure portion 382, the interior wall 396 and the interior wall 394 of the enclosure portion 381 are aligned with the respective interior wall 393 and 392 of the enclosure portion 382. An arm runner 129 is between the interior walls 396 and 393 and another arm runner 129 is between the interior walls

[0041] 394 and 392.

[0042] When the enclosure portions 381 and 382 are pressed together, the interior walls sever the arm runners to thereby separate the arms 124 from the body portion 122. An interior wall

[0043] 395 on the enclosure portion 381 and an interior wall 391 on the enclosure portion 382 function in a similar manner to sever the runner between the body portion 122 and the legs 126. The severing allows the arms 124 and legs 126 to move freely relative to the enclosure assembly 380 without coming out of the enclosure assembly 380. For example, the arms 124 may rotate relative to the enclosure assembly 380.

[0044] The single-piece construction of the skeleton 120 simplifies the assembly process by using fewer steps as compared to the legacy approach. For example, the single-piece construction of the skeleton 120 allows positioning in the enclosure portion 382 with a single placement and without further adjustment of the skeleton 120. Moreover, because the skeleton 120 is a single-piece, the relative placement of the arms 124 and the legs 126 is more reliable and repeatable than in the toy figure 370. In this way, the single-piece design of the toy figure 100 results in fewer unintentional variations and manufacturing defects. Finally, the runners of the skeleton 120 are configured such that the attachment or assembly process for the enclosure assembly 380 also severs the arms 124 and the legs 126 from the body portion 122, allowing the arms 124 and the legs 126 to move relative to the enclosure assembly 380 and without requiring the user or the manufacturer to perform additional steps to mobilize the arms 124 and legs 126.

[0045] These and other implementations are within the scope of the claims. For example, although the enclosure assembly 380 encloses a part of the skeleton 120, the enclosure portions 381 and / or 382 may include openings that do not interfere with the interior walls. For example, the enclosure portions 381 and / or 382 may include decorative openings that form a polka-dot pattern or other design.

[0046] In another example, the skeleton 120 may take any form that includes at least two body portions that are connected by a sprue between the two body portions. The skeleton 120 may have a form other than shown in FIG. 4. For example, the skeleton 120 may lack the arms 124 or the legs 126. Moreover, the skeleton 120 may have a form that is other than human or humanoid. For example, the skeleton 120 may resemble an animal, a machine, a vehicle, an insect, or a marine creature.

Claims

WHAT IS CLAIMED IS:

1. A method comprising: placing a skeleton in a first enclosure portion with a sprue of the skeleton positioned over a first interior wall of a first enclosure portion; positioning a second enclosure portion relative to the first enclosure portion such that the sprue of the skeleton is between the first interior wall and a second interior wall that is part of the second enclosure portion; and pressing the first enclosure portion and the second enclosure portion together to sever the sprue.

2. The method of claim 1, wherein the first enclosure portion comprises a first alignment structure, and wherein placing the skeleton in the first enclosure portion with a sprue of the skeleton positioned over the first interior wall comprises placing a portion of the skeleton on the first alignment structure.

3. The method of claim 2, wherein placing a portion of the skeleton on the first alignment structure comprises placing a locating opening in the skeleton on a locating post of the first alignment structure.

4. The method of claim 2, wherein the second enclosure portion comprises a second alignment structure configured to interact with the first alignment structure, and wherein positioning the second enclosure portion relative to the first enclosure portion comprises placing the second alignment structure in contact with the first alignment structure.

5. The method of claim 3, wherein placing the second alignment structure in contact with the first alignment structure comprises inserting a connection post of the second alignment structure into a recess in a locating post of the first alignment structure.

6. The method of claim 1, wherein pressing the first enclosure portion and the second enclosure portion together causes the first interior wall and the second interior wall to exert force on the sprue to sever the sprue.

7. The method of claim 1, further comprising, after pressing the first enclosure portion and the second enclosure portion together to sever the sprue: forming an enclosure assembly that surrounds at least part of the skeleton by sonic welding the first enclosure portion and the second enclosure portion.

8. A toy comprising: a skeleton comprising: a first body portion, a second body portion, and a sprue between the first body portion and the second body portion; and an enclosure assembly comprising: a first enclosure portion configured to receive the first body portion; and a second enclosure portion configured to be joined to the first enclosure portion, wherein joining the first enclosure portion and the second enclosure portion severs the sprue.

9. The toy of claim 8, wherein each of the first enclosure portion and the second enclosure portion comprises an interior wall, and the interior wall of the first enclosure portion interact with the interior wall of the second enclosure portion to sever the sprue.

10. The toy of claim 8, wherein the skeleton comprises a first polymer material, and the first enclosure portion and the second enclosure portion comprise a second polymer material.

11. The toy of claim 10, wherein the first plastic material comprises Acrylonitrile Butadiene Styrene (ABS) plastic, and the second plastic material comprises polyvinyl chloride (PVC).

12. The toy of claim 8, wherein the first body portion comprises a torso portion, and the second body portion comprises a limb portion.

13. A method comprising: providing a first skirt portion, the first skirt portion comprising a locating post and interior walls; placing an opening in a body portion of a skeleton over the locating post to position the skeleton in the first skirt portion with a sprue of the skeleton being positioned over a first one of the interior walls; positioning a second skirt portion over the first skirt portion, the second skirt portion comprising an insertion post and interior walls; inserting the insertion post of the second skirt portion into an opening in the locating post of the first skirt portion while the skeleton is between the first skirt portion and the second skirt portion and the sprue is between the first one of the interior walls of the first skirt portion and one of the interior walls of the second skirt portion; and pressing the first skirt portion and the second skirt portion together to insert the insertion post into the opening and to sever the sprue.

14. The method of claim 13, further comprising securing the first skirt portion to the second skirt portion by sonic welding.

15. The method of claim 13, wherein placing the opening of the body portion of the skeleton over the locating post positions each of a plurality of sprues of the skeleton over one of the interior walls of the second portion.

16. A toy comprising: a skirt body comprising: a first skirt portion comprising: a locating post, and first interior walls; a second skirt portion comprising: an insertion post configured for insertion into an opening in the locating post, and second interior walls; and a skeleton comprising: a body portion comprising a locating opening; a first sprue between the body portion and a first arm; a second sprue between the body portion and a second arm;a third sprue between the body portion and a leg assembly, wherein positioning the body portion in the first skirt portion with the locating post in the locating opening places the first sprue over a first one of the first interior walls, the second sprue over a second one of the first interior walls, and the third sprue over a third one of the first interior walls; and inserting the insertion post into the opening in the locating post aligns one of the second interior walls with one of the first interior walls to sever the first sprue, the second sprue, and the third sprue.

17. The toy of claim 16, wherein the skeleton comprises a first polymer material, and the skirt body comprises a second polymer material.

18. The toy of claim 17, wherein the first plastic material comprises Acrylonitrile Butadiene Styrene (ABS) plastic, and the second plastic material comprises polyvinyl chloride (PVC).

Images