Toy Figure Hip Joint Assembly with Insert-Molded Articulation

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Solution Overview

Problem

Existing toy figures lack efficient articulation mechanisms that allow for versatile and stable movement of limbs, particularly in hip joints, which restricts the range of motion and realism in play.

Innovation Solution

The use of an elongate member with insert-molded articulation elements and sockets that permit pivotable and rotational movements, combined with frictional elements for stability, allows for improved articulation and movement of limbs, such as legs and arms, relative to the torso.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional joint assemblies are used in toy figures, then the structure is simple and easy to manufacture, but the range of motion and stability of limbs are limited

Engineering Contradiction:

Improverange of motionVSAvoidjoint assembly structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The joint assembly is divided into separate functional components: an elongate member with articulation elements for movement, and friction elements for stability. This segmentation allows each component to optimize its specific function while working together to provide both range of motion and stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The articulation elements are insert-molded onto the elongate member, creating a nested structure where one component is integrated within another. This nesting approach increases complexity only slightly while significantly improving the range of motion and stability.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If articulation elements are insert-molded onto the elongate member, then the stability and retention of joint positions are improved, but the manufacturing process becomes more complex

Engineering Contradiction:

ImprovestabilityVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The articulation elements and elongate member are combined into a single integrated component through insert-molding. This merging creates a stable, retention-prone joint structure while using a standard manufacturing technique that, while slightly more complex than simple molding, remains efficient for mass production.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If frictional elements are added to the joint assembly, then the stability and secure retention of joint positions are enhanced, but the device complexity increases

Engineering Contradiction:

Improvesecure retentionVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Frictional elements with specific coefficient of friction values are introduced to control the stability and retention characteristics. By adjusting the friction parameter, the joint assembly achieves secure retention without requiring complex mechanical locking mechanisms, thus limiting the increase in device complexity.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS9056258B2Toy figures

Publication Date: 2015.06.16 MATTEL INC

AI summary

Toy figures may include a torso, an elongate member extending from the torso, an articulation element, and a limb having a socket. The elongate member may include an end region. The articulation element may be molded substantially around the end region and may be received within the socket. The socket may be configured for pivotable movement about the articulation element. Some examples of toy figures may include a hip joint assembly.