Abstract:
The present invention is directed to a posable toy figure having realistic articulation, the ability to hold a pose and be repeatedly posed at multiple joints in the legs, head and/or neck, and longevity with resistance to failure. The toy figure includes a posable internal skeletal structure having a main body and at least one appendage. The appendage is attached to said main body using a flexible joint that allows the appendage to be posed into a variety of configurations. The flexible joint further allows the posable figure to be fixed in a particular configuration. The skeletal structure is covered with an outer overmolded material having sufficient flexibility to allow the figure to be posed in a variety of configurations. Finishing details may also be provided.

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
       [0001]    This is a non-provisional patent application claiming benefit of priority of U.S. Provisional Patent Application No. 60/900,482, filed on Feb. 9, 2007 in the name of Amy Pennington for “Posable Figure Having a Rigid Internal Structure.” 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    A. Field of the Invention 
         [0003]    The present invention relates to posable toy figures, and more particularly to a posable toy figure having a realistic skinned surface covering a skeletal structure including a plurality of armatures design to simulate real movement and poses in the toy figure, such that the exterior of the figure appears as a realistic and lifelike representation of the figure without any visible mechanical parts. 
         [0004]    B. Description of Prior Art 
         [0005]    Toys and devices designed to look and move realistically have long been known in the prior art. Many of these devices are designed to realistically and convincingly emulate the appearance and movements of babies or animals. For example, U.S. Pat. No. 1,189,585, which issued to Kruse on Jul. 4, 1916 for “Dummy Model for Reproducing All Movements of the Human or Animal Body” discloses a jointed doll having a frame composed of wound wire coils except at the joints to allow flexion. 
         [0006]    In many of these devices, particular attention is paid to the movable elements in the devices, and, in particular, the joint systems used to simulate lifelike motion. Several different types of joints are disclosed in U.S. Pat. No. 3,284,947, which issued to Dahl on Nov. 15, 1966 for “Adjustable Doll Having Degassed Malleable Core”—including bendable wire elements wherein the metallic material has been degassed and sealed, another with a degrees-of-freedom-limiting and constraining means, another with a spine-simulating skeletal structure, and another having a framework including bended metal portions. U.S. Pat. Nos. 3,325,939; 3,624,691; 4,932,919; and 5,017,173 also disclose various means for allowing dolls and posable figures to flex only at certain joints. 
         [0007]    It is also known to include an internal skeletal structure to more realistically capture the realistic appearance of the object being modeled, and to simulate the actual joint system of the animal itself For example, U.S. Pat. No. 6,800,016, which issued to Wittenberg et al. on Oct. 5, 2004 for “Flexible Dolls and Posable Action Figures” specifically refers to a posable figure having an inner skeleton. 
       BRIEF SUMMARY OF THE INVENTION 
       [0008]    It is a primary object of the present invention to provide a posable figure comprising an internal skeletal structure including armatures to simulate realistic movement and poses covered by a flexible and realistic material designed to simulate the skin or external structure of the figure. 
         [0009]    It is an object of the present invention to provide an improved interior armature for an over molded posable figure. 
         [0010]    A further objective is to provide a realistic life-like posable overmolded figure that will maintain a pose until further manipulated. 
         [0011]    An additional purpose is to enhance the playability of this inanimate figure by providing an improved posable overmolded figure with life-like articulation in the legs and neck at multiple points and a durable internal armature. 
         [0012]    Still another object of the present invention is to provide a posable figure in which the degree of movement at the joints is restricted such that a natural motion is achieved such that the limbs cannot hyper-extend beyond a normal range. 
         [0013]    But another object of the present invention is to provide an armature designed to simulate real movements in the corresponding real parts of an animal or human. 
         [0014]    A further purpose is to provide an improved posable over molded figure that will not fail over time or through prolonged use. 
         [0015]    Still another purpose of the present invention is to provide a posable interior armature that can be manufactured economically. 
         [0016]    A yet further objective is to provide an improved posable armature with a flexible outer skin that will not tear through the respective limbs. 
         [0017]    Still another objective of the present invention is to provide a fabricated injection-molded skeleton with limbs, such as a horse leg with joint members. 
         [0018]    An object is to provide a posable interior armature with the least amount of weight. 
         [0019]    An object is to provide a posable interior armature that has evenly distributed weight so that it can stand solidly on its own. 
         [0020]    A further object is to provide an armature with an internal body cavity that will embrace the over molded material so that the over molded material can attach itself to the skeleton providing a better bond between the skeletal member and the outer covering of molded plastic which completes the figure. 
         [0021]    Another object is to provide a body design that provides a mechanism through the embedded holes that will allow the over molded material to retain its shape and resiliency and not separate from the inner skeleton, thus, sagging and distorting the original shape of the posable figure. 
         [0022]    Still another object of the present invention is to provide a posable figure wherein the pins on the legs of the armature allow the over molded material to retain its shape and resiliency and not separate from the inner skeleton, thus, sagging and distorting the original shape of the posable figure. 
         [0023]    A yet further object is to have even PVC flow around the internal armature so that there is a consistent thickness of the PVC wall surrounding the internal armature. 
         [0024]    But another object of the present invention is to provide recessed longitudinal channels on the internal body cavity designed to help direct the flow of PVC during the over mold process. 
         [0025]    To accomplish these and other objects, the invention provides an improved posable figure having realistic articulation, the ability to hold a pose and be repeatedly posed at multiple joints in the legs, head and/or neck, and longevity with resistance to failure. 
         [0026]    The internal body is a thin-walled, molded unit that provides the required shape and strength with the least amount of weight. The design of the internal body cavity provides a low center of gravity to help improve stability for the figure when standing. The longitudinal ribs improve the strength and stiffness of the armature. In addition, the recessed longitudinal channels of the internal body cavity are designed to help direct the flow of PVC during the over mold process so that there is an even distribution of PVC during the over mold process insuring that the external PVC wall has an even thickness. The holes in the internal body cavity create the internal posts and sockets that help to hold the two halves of the body together and they provide areas where the over molded material can attach itself to the skeleton. The body cavity contains holes to provide a better bond between the skeletal member and the outer covering of molded plastic which completes the figure. The internal posts prevent the internal body cavity from becoming distorted due to the high temperature and pressure created by the over molding process. Without the internal posts, the internal body armature would collapse causing the internal cavity to fill with the over molding material. This result would also increase the weight of the over molded figure. 
         [0027]    The ratchet joint and stops reduce the forces that cause resistance to the leg movement, forces that result from the PVC outer skin being too thick. The pin above the ratchet joint clicks into the two or three holes (molded in details) which lock the joint in various poses and hold the poses against the resistance of the outer skin. In addition, the molded in two holes limit the range of motion, preventing the joint from breaking when it is pushed past the bendable point. The protruding bar located above the ratchet is designed to hit the end of the corresponding slot before the pin that holds the posable position takes any of the over-bending force exerted on the index pin. Thus, this feature prevents the joint from breaking when it is manipulated past its bendable point. When the joint is rotated the protruding bar comes into contact with the corresponding slot so that it cannot bend further. 
         [0028]    The molded leg elements bend only at the appropriate joints. The leg armature is designed so that the joints are very tight. The joints fit together with very little gap or clearance between the components which prevents the over molded material from getting into the joints. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0029]      FIG. 1  is an exploded perspective view of the posable figure of the present invention; 
           [0030]      FIG. 2  is a left side isometric view of the posable figure of  FIG. 1 ; 
           [0031]      FIG. 3  is a front isometric view of the posable figure of  FIG. 1 ; 
           [0032]      FIG. 4  is a rear isometric view of the posable figure of  FIG. 1 ; 
           [0033]      FIG. 5  is a top plan view of the posable figure of  FIG. 1 ; 
           [0034]      FIG. 6  is a left side perspective view of the posable figure of  FIG. 1 ; 
           [0035]      FIG. 7A  is a left side isometric view of the upper leg portion of the posable figure of  FIG. 1 ; 
           [0036]      FIG. 7B  is a right side isometric view of the upper leg portion of the posable figure of  FIG. 1 ; 
           [0037]      FIG. 7C  is a front isometric view of the upper leg portion of the posable figure of  FIG. 1 ; 
           [0038]      FIG. 7D  is a rear isometric view of the upper leg portion of the posable figure of  FIG. 1 ; 
           [0039]      FIG. 7E  is a left side perspective view of the upper leg portion of the posable figure of  FIG. 1 ; 
           [0040]      FIG. 8A  is a left side isometric view of the middle leg portion of the posable figure of  FIG. 1 ; 
           [0041]      FIG. 8B  is a right side isometric view of the middle leg portion of the posable figure of  FIG. 1 ; 
           [0042]      FIG. 8C  is a front side isometric view of the middle leg portion of the posable figure of  FIG. 1 ; 
           [0043]      FIG. 8D  is a rear side isometric view of the middle leg portion of the posable figure of  FIG. 1 ; 
           [0044]      FIG. 8E  is a left side perspective view of the middle leg portion of the posable figure of  FIG. 1 ; 
           [0045]      FIG. 9A  is a left side isometric view of the lower leg portion of the posable figure of  FIG. 1 ; 
           [0046]      FIG. 9B  is a right side isometric view of the lower leg portion of the posable figure of  FIG. 1 ; 
           [0047]      FIG. 9C  is a front isometric view of the lower leg portion of the posable figure of  FIG. 1 ; 
           [0048]      FIG. 9D  is a rear isometric view of the lower leg portion of the posable figure of  FIG. 1 ; 
           [0049]      FIGS. 10A through 10C  are various perspective views of the upper neck component of the posable figure of  FIG. 1 ; 
           [0050]      FIGS. 11A  is a top plan view of the middle neck component of the posable figure of  FIG. 1 ; 
           [0051]      FIGS. 11B through 11D  are various perspective views of the middle neck component of the posable figure of  FIG. 1 ; 
           [0052]      FIGS. 12A  is a top plan view of the lower neck component of the posable figure of  FIG. 1 ; 
           [0053]      FIGS. 12B through 12C  are various perspective views of the lower neck component of the posable figure of  FIG. 1 ; 
           [0054]      FIGS. 13A  is a left side isometric view of one of the head components of the posable figure of  FIG. 1 ; 
           [0055]      FIGS. 13B  is a right side isometric view of one of the head components of the posable figure of  FIG. 1 ; 
           [0056]      FIGS. 13C  is a top plan view of one of the head components of the posable figure of  FIG. 1 ; 
           [0057]      FIGS. 13D  is a perspective view of one of the head components of the posable figure of  FIG. 1 ; 
           [0058]      FIGS. 14A  is a left side isometric view of one of the body components of the posable figure of  FIG. 1 ; 
           [0059]      FIGS. 14B  is a right side isometric view of one of the body components of the posable figure of  FIG. 1 ; 
           [0060]      FIGS. 14C  is a top plan view of one of the body components of the posable figure of  FIG. 1 ; 
           [0061]      FIGS. 14D  is a perspective view of one of the body components of the posable figure of  FIG. 1 ; and 
           [0062]      FIGS. 14E and 14F  are perspective views of one of the body components of the posable figure of  FIG. 1  showing the channels for the overmolded material. 
       
    
    
     DETAILED DESCRIPTION OF INVENTION 
       [0063]    Referring to the drawings and, in particular, to  FIG. 1  thereof, the posable toy figure of the present invention is provided and is referred to generally by reference numeral  10 . The posable  FIG. 10  comprises an internal skeletal structure  100  which, in turn, comprises a main body interconnected with one or more appendages  104  of the type generally consistent with posable toys and figures, such as arms, legs, heads, tails, etc. For the purposes of this specification, particular reference will be made to the posable horse figures illustrated in the various Figures. It should, however, be appreciated that the various systems and methods disclosed herein may be easily applied to any number of other designs and shapes, such as humans (adults and infants), animals of all types, monsters, and even inanimate objects having one or more movable parts. 
         [0064]    In the preferred embodiment, the main body is manufactured in two complementary parts  106  which are then securely attached to each other. This embodiment was primarily chosen for manufacturing purposes and for the ease of attaching the appendages  104  thereto, but it could be easily manufactured as one or more than two separate parts  106 . 
         [0065]    The exterior surface  108  of the posable toy  FIG. 10  comprises a resilient outer overmolded material  110 . The overmolded material  110  serves several functions, including protection for the internal skeletal structure  110  and to assist in the posing of the various appendages  104 . However, the primary purpose of the overmolded material  110  is to simulate the “skin” of the object being modeled. In the preferred embodiment, the overmolded material  110  comprises a rubberized material that can easily withstand repeated deformation without losing any elasticity, so as to allow the various appendages  104  to be moved and positioned repeatedly without any loss of elasticity to the material  110 . Furthermore, the overmolded material  110  should capable of being dyed various colors so as to simulate the “skin” tone of the creature or object being modeled, and preferably be able to accept paint or dye so that additional ornamental designs, such as spots, tattoos, etc. can be applied thereto. 
         [0066]    In the preferred embodiment, the shape and configuration of the internal skeletal structure  100  is based on the actual skeletal structure of the object being modeled. Using the example of the horse illustrated in the Figures, the skeletal structure  100  is essentially an simplified version of the skeletal structure of an actual horse. 
         [0067]    In the preferred embodiment, one or more of the appendages comprise a plurality of armatures  112  interconnected with each other and with the main body  102 . For example, each of the horses legs illustrated in the Figures is three separate armatures  112  which cooperate to reproduce realistic movement to each of the legs both relative to each other and to the main body  102 . 
         [0068]    Once again using the example of the horse, two of the appendages  104  comprise front legs  114  and two of the appendages  106  comprise hind legs  116 . Each of these legs  114 ,  116  comprise three separate molded parts: the upper leg  118 , the mid leg  120  and the lower leg  122 . Of course, the shape of each of these components will differ depending upon whether the component is situated in the front right leg or the rear left leg, for example. 
         [0069]    Each of the appendages  104  and the main body  102  include attachment means  124  for attaching the appendage  104  to the main body  102 . Furthermore, for those appendages  104  that include multiple armatures  112 , attachment means  124  are also provided for attaching adjacent armatures to each other. While various attachment means  124  are contemplated, it has been found that the preferred means for providing realistic movement to the appendages  104  as well as allowing a user to fix an appendage  104  in a specific pose comprises a ratchet and post system of the type illustrated in  FIGS. 7A through 7D . For example, the upper leg  118  has a ratchet post  128  that attaches to a corresponding ratchet hole  130  on the body armature  132  and is secured by a screw  134  or other similar such means that is inserted into the hole on the outside of the leg  118  on the body armature  132 . A screw boss  134 A may also be provided at the center of each joint to limit the amount of tension force that the screw  134  used to assemble the two parts together will apply to the joint. 
         [0070]    At least one pin  136  on the upper leg  118  fits into a corresponding molded cavity detail  138  on the body armature  132  and has three joint locking positions  140  which limit the rotational range of motion of the upper leg  118  relative to the main body  102 . Of course, more or less joint locking positions  140  may be provided so as to allow for a greater or smaller range of motion, or for various different angles. It has been found that two such pins  136  serve to add to the strength of the assembled armatures  112 , and prevent breaking if over-bent. 
         [0071]    The range of rotational motion of the upper leg  118  is further limited by a protruding bar  142  located above the ratchet  144 . When rotated or posed to the fullest degree, the protruding bar  142 , which fits inside a corresponding channel  146 , hits the end of the recessed channel  146  and takes the pressure off of the pin  136 , thus preventing the joint from breaking. This feature is present at all the joint sites and helps to prevent the joint from breaking when it is manipulated past the bendable point. 
         [0072]    The upper leg  118  also includes two spacing pins  148  which help to center the leg armature  112  in the mold used during the overmold process. 
         [0073]    The mid leg  120  attaches to the upper leg  118  by means of a ratchet post  128  located on the upper leg  118  which fits into a receiving ratchet hole  130  in the mid leg  120 . The two parts are secured by a screw  134  that is inserted into the mid leg  120 . The pin  136  attached to the ratchet post  128  moves inside of the molded cavity detail  138  of the ratchet hole  130  such that there are two locking positions  149 . The mid leg  120  includes four spacing pins  148  that help to center the leg armature in the mold used during the overmold process. The lower leg  122  attaches to the mid leg  120  with a ratchet post  128  located on the mid leg  120  which fits into a receiving ratchet hole  130  in the lower leg  122 . The two parts are secured by a screw  134  that is inserted into the lower leg  122 . The pin  136  attached to the ratchet post  128  moves inside of the molded cavity detail  138  of the ratchet hole  130  such that there are two locking positions  140 . 
         [0074]    The various armatures  112  of the front legs  114  and hind legs  116  are illustrated in  FIGS. 7A through 9D . 
         [0075]    In the preferred embodiment, a head  150  and neck  152  are also provided as armatures  112  to the posable toy  FIG. 10 . As with the legs  114 ,  116 , in the preferred embodiment the head  150  and neck  152  are provided as internal skeletal structures  100  which are then covered by the resilient outer overmolded material  110 . The skeletal structure  100  of the head  150  can best be compared to a skull  154 , which, in the preferred embodiment is manufactured as two separate skull sides  156  which are then attached together. Also in the preferred embodiment, the neck  152  comprises one or more neck components  156  which cooperate to allow the neck  152  to bend and the head  150  to turn. The head  150  and neck  152  are constructed by attaching the two skull sides  156  together with the upper neck component  160 . In the preferred embodiment, the upper neck component  160  includes a protrusion  162  which fits between and is retained by the skull sides  156  when the latter are assembled. The interior of the skull sides  156  include internal posts  164  and sockets  166  that help to hold the two halves  156  together when assembled. These interior posts  164  and sockets  166  of the skull  154  also act as stiffeners like trusses that counteract the pressure of the over molding process. 
         [0076]    In the preferred embodiment, the skull sides  156  are glued and ultrasonically sealed together. The main body parts  106  may also be attached by such means. Also in the preferred embodiment, tongue and groove joints  167  are provided around the perimeter of the main body parts  106  and skull parts  156  where the two come together. The purpose for such joint  167  is to set off the high injection pressures that are used during the over-molding process. The tongue and groove joint  167  adds strength to the joint and helps to prevent distortion to the body  102  and head  150  that would otherwise result from the high injection forces of the over-molding process. It also helps to prevent the over-molded material  110  from being forced through the joint and into the internal cavity of the body  102  or head  150  during the molding process, the result of which would add unwanted weight to the toy  FIG. 10  and increase the cost due to the additional use of the overmolded material  110 . 
         [0077]    In the example of the horse, the neck  152  comprises three separate components  156 —the upper neck component  160 , the middle neck component  168  and the lower neck component  170 . It should be appreciated that multiple middle neck components  168  may be provided to lengthen the neck  152  (such as for a giraffe or for an elephant&#39;s trunk), or the middle neck component  168  may be removed entirely to shorten the neck  152 . In the horse example, the three components  158  of the neck  152  are assembled by placing two cylindrical pivot pins  172  into the adjacent components  158  or between the neck component  158  and the main body  102 . The neck  152  can pivot left and right at both points where the pivot pins  172  intersect the adjacent parts. A particular pose can be held in place as a result of the ratchet areas  174  at either end of the neck component  158 . 
         [0078]    The neck  152  is attached to the main body  102  by means of a protrusion  162  which is accepted by and retained within an upper opening  176  in the main body parts  106  when assembled. In the construction process, the two main body parts  106  are attached together with the upper opening  176  snapping over the inserted protrusion  162  of the neck assembly  152 . The interior of the body cavity  178  of each main body part  106  has posts  164  and sockets  166  that help hold the two halves  106  of the body  102  together. As with the skull  154 , these interior posts  164  and sockets  166  also act as stiffeners like trusses that counteract the pressure of the over molding process and provide areas where the overmolded skin  110  can attach itself to the skeletal structure  100 . 
         [0079]    In the preferred embodiment, the internal skeletal structure  100  is composed of a molded plastic or similar material. However, other materials may be used, such as a hardened rubber or a light metal such as aluminum. 
         [0080]    Once the entire internal skeletal structure  100  has been assembled, it is placed in an injection mold tool so that the outer overmolded material  110  can be molded around the structure  100 . As discussed, the structure  100  includes various spacing pins  148  disposed thereon which are used to accurately locate the armature in the mold. The pins  148  on the legs  114 ,  116  are used to center the skeletal structure  100  in the mold. However, they are constructed so that they are not apparent in the finished figure. After the skeletal structure  100  is in place, the mold is closed and the outer overmolded material  110  is injected into the mold. The covering mold has a cavity which covers the entire skeletal structure  100 ; therefore a single injection of material covers the whole posable toy  FIG. 10 . A flexible material is used for the outer overmolded material  110  so that it can facilitate articulation. In the preferred embodiment, this flexible material is PVC or the like. 
         [0081]    Finishing components  180  such as hair, hands, feet, etc. may be attached to the posable toy  FIG. 10  either before or after the overmolded material  110  has been applied. For example, to finish a horse, molded hoof like parts  182  are inserted into the bottom of the horse&#39;s feet  184 . These parts  182  also serve the purpose of covering the holes left by the pins of the mold. Synthetic hair  186  is then manually inserted and glued into the slots in the neck  152  and body  102  of the horse. A cut is made in the horse&#39;s mouth so that the mouth can open. Lastly, the horse is painted using a flexible paint. 
         [0082]    Having thus described the invention with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications can be made therein without departing from the spirit and scope of the present invention as defined by the appended claims.