Abstract:
The present disclosure is directed to an electronic water toy and techniques to protect electrical components of the toy from water. The toy may include a plurality of waterproof electronics modules, a non waterproof outer housing, and a plurality of insulated wires. Each waterproof electronics module may include an electrical component, and a waterproof compartment to house the electrical component and to protect the electrical component from water. The non waterproof outer housing may physically interconnect the plurality of waterproof electronics modules. The waterproof compartment may include counterbore through holes to permit wires through the waterproof compartment and a counterbore leak test port to permit pressure testing of the waterproof compartment.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to electronic toys, and more specifically to electronic water toys and techniques to protect electrical components from water. 
       BACKGROUND OF THE INVENTION 
       [0002]    Electronic water toys are required to be waterproof to preventing water from entering the toy and short circuiting electrical components. One technique for waterproofing electronic toys is to waterproof the outer housing of the toy. In such a technique, a gasket is typically placed between an upper housing component and lower housing component. Screws or other fastening mechanisms cause the upper housing component to exert force upon the lower housing component. Such force compresses and deforms the gasket thus causing the gasket to seal the interface or seam between the two housing components. 
         [0003]    With the above described technique, however, the quality of the seal is highly reliant upon the upper and lower housing components having very closely matched surfaces and contours in order to exert the compression force evenly on the gasket. Due to the length and number of seams, manufacturing outer housing components with closely matched surfaces and contours proves to be costly. 
       BRIEF SUMMARY OF THE INVENTION 
       [0004]    The present disclosure is directed to electronic water toys and techniques to protect electrical components of such electronic water toys from water or other liquids. 
         [0005]    According to one aspect, an electronic water toy is provided. The electronic water toy may include a plurality of waterproof electronics modules, a non waterproof outer housing, and a plurality of insulated wires. Each waterproof electronics module may include an electrical component, and a waterproof compartment to house the electrical component and to protect the electrical component from water. The non waterproof outer housing may physically interconnect the plurality of waterproof electronics modules, and the plurality of insulated wires may pass through the waterproof compartments and electrically interconnect the electrical components housed in the waterproof compartments. 
         [0006]    According to another aspect, each waterproof compartment may include a leak test port in an outer wall of the waterproof compartment to permit leak testing of the waterproof compartment. The leak test port may include a hole and a counterbore. The leak test port may be plugged after testing to prevent water from entering the waterproof compartment during use of the water toy. Furthermore, the leak test port may be plugged with a fastener (e.g., a screw) and sealant (e.g., glue). The fastener may be inserted into the hole of the leak test port. The sealant may be deposited over the screw such that the sealant at least partially fills the counterbore. 
         [0007]    According to another aspect, each waterproof compartment may include one or more through holes and corresponding counterbores in a wall of the waterproof compartment. Each through hole may have an insulated wire of the plurality of insulated wires that passes therethrough to electrically connect to electrical components in the waterproof compartment. A sealant may at least partially fill the corresponding counterbore of the through hole and prevent water from entering the waterproof compartment via the through hole. 
         [0008]    Per yet another aspect, the waterproof modules may include one or more waterproof controller modules, one or more waterproof output modules such as waterproof speaker module and/or a waterproof light module, one or more waterproof input modules such as a waterproof button module, and/or one or more waterproof power modules such as a waterproof battery module. The waterproof controller module may include a processor such as a microprocessor, microcontroller, programmable array, and/or other logic component. The waterproof controller module may process electrical signals received from other waterproof modules via at least one insulated wire. The waterproof controller module may also provide electrical control signals to other waterproof modules via at least one insulated wire to control operation of such waterproof modules. 
         [0009]    The waterproof speaker module may includes a waterproof speaker. The waterproof speaker may produce sound in response to electrical signals received via at least one insulated wire of the plurality of insulated wires. 
         [0010]    The waterproof light module may include a light emitting device such as a light emitting diode (LED). The light emitting device may emit light in response to electrical signals received via at least one insulated wire of the plurality of insulated wires. 
         [0011]    The waterproof input module may include an input device such as a pressure switch or button. The input device may receive input and provide electrical signals that are indicative of the received input to another waterproof module via at least one insulated wire of the plurality of insulated wires. 
         [0012]    The waterproof power module may include a power source such as a battery. The power source may provide electrical power to another waterproof module via at least one insulated wire of the plurality of insulated wires. 
     
    
     
       BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
         [0013]    Embodiments are described herein by way of example and not by way of limitation in the accompanying figures. For simplicity and clarity of illustration, elements illustrated in the figures are not necessarily drawn to scale. For example, the dimensions of some elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference labels have been repeated among the figures to indicate corresponding or analogous elements in the figures. 
           [0014]      FIG. 1  shows an embodiment of an electronic water toy that includes waterproof electronics modules. 
           [0015]      FIG. 2  shows a block diagram depicting one manner by which waterproof electronics modules may be electrically connected. 
           [0016]      FIG. 3  shows an embodiment a waterproof input module. 
           [0017]      FIG. 4  shows an embodiment a waterproof speaker module. 
           [0018]      FIG. 5  shows an embodiment of a waterproof controller/power module. 
           [0019]      FIG. 6  shows an embodiment of a waterproof light module. 
           [0020]      FIG. 7A  shows an embodiment of wire through holes and an embodiment of a leak test port. 
           [0021]      FIG. 7B  shows an embodiment of a plugged leak test port. 
           [0022]      FIG. 8A  shows an interface between housing components prior to being ultrasonic welded to one another. 
           [0023]      FIG. 8B  shows an interface between housing components after being ultrasonic welded to one another. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0024]    References in the specification to “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, a particular feature, structure, or characteristic described in connection with an embodiment generally may be incorporated into or otherwise implemented by other embodiments regardless of whether explicitly described. 
         [0025]    Referring now to  FIG. 1 , there is depicted an embodiment of an electronic water toy  100  that may be suitable for play in a bath tub, wading pool, and/or other water environments. As shown, the water toy  100  may include an outer housing  110  having one or more outer housing components that define an outer shape of the water toy  100 . For example, the outer housing  110  may include outer housing components that define arms  112 ,  114 , legs,  116 ,  118 , body  120 , and head  122 . 
         [0026]    Despite the fact the water toy  100  includes electrical components; the outer housing  110  in one embodiment is not waterproof. Due to the size and number of moving components comprising the outer housing, manufacturing the outer housing  110  to be waterproof would be costly. Thus, in one embodiment, electrical components of the water toy  100  are housed in several smaller waterproof modules that are distributed throughout the outer housing  110 . Accordingly, the outer housing  110  in one embodiment does not protect electronic components from water. Instead, the outer housing  110  defines an outer shape of the water toy  110 , mechanically interacts with the waterproof electrical components, and mechanically interconnects the waterproof electrical components. 
         [0027]    As shown in  FIG. 2 , the water toy  100  may include a system  200  of waterproof electronics modules. In particular, the water toy  100  may include waterproof controller modules  210 , waterproof power modules  212 , waterproof input modules  220 ,  222 ,  224 ,  226 ,  228 , waterproof output modules  230 ,  232 , and/or waterproof hybrid modules that provide the functionality of one or more of the basic waterproof electronics modules. For example, the water toy  200  may include a waterproof hybrid module  240  which integrates the functions of a controller module  210  and a power module  212  into a single waterproof module. 
         [0028]    As shown, the system  200  may further include insulated wires  250  that electrically couple electronic components of one waterproof electronics module to another waterproof electronics module. In one embodiment, the components are electrically connected in a hub and spoke manner in which the hybrid processor/power module  240  is the hub and the insulated wires  250  are spokes connecting the hybrid processor/power module  240  to each of the other waterproof electronic components  220 ,  222 ,  224 ,  226 ,  228 ,  230 ,  232 . However, depending upon the communication needs of the electrical components, the insulated wires  250  may implement other interconnection topologies such as mesh, ring, etc. in order to provide appropriate electrical interfaces between the various electrical components of the waterproof electronics modules. 
         [0029]      FIG. 2  further illustrates the distributed nature of the waterproof electronics modules. For example, a processor/battery module  240  and a speaker module  230  may be positioned in a head portion  122  of the outer housing  110 . A right arm button module  220 , a left arm button module  222 , a right leg button module  224 , and a left leg button module  226  may be respectively positioned in a right arm portion  112 , a left arm portion  114 , a right leg portion  116 , and a left leg portion  118  of the outer housing  110 . Moreover, a light module  232  and a power button module  228  may be positioned in a body portion  120  of the outer housing  110 . 
         [0030]    Referring now to  FIG. 3 , further details of a button module embodiment  300  of a waterproof input module are shown. In particular, the button module  300  shown in  FIG. 3  may be suitable for implementing the input modules  220 ,  222 ,  224 ,  226 ,  228  of  FIG. 2 . As shown, the button module  300  includes a lower cabinet member  310 , an upper cabinet member  320 , a button  330 , and a printed circuit board  340  comprising one or more electrical component(s)  342 . 
         [0031]    In one embodiment, the button  330  performs a dual function. First, the button  330  is configured to transfer force applied to an upper surface  332  of the button  330  to a pressure switch, capacitive switch, or some other sensor component of the electrical components  342 . As a result of such transfer of force, the electrical components  342  may detect input (e.g., a user pressing the button) and may generate electrical signals that are indicative of the received input. In one embodiment, one or more insulated wires  250  carry such electrical signals to the controller module  240  for processing. 
         [0032]    The button  330  also serves as a gasket to help seal the interface or seam between the lower cabinet member  310  and the upper cabinet member  320 . To such an end, a lower surface of the button  330  includes a lower annular rib  334 , and an upper surface of the lower cabinet member  310  includes an annular groove  312  to receive the lower annular rib  334 . Similarly, an upper surface of the button  330  includes an upper annular rib  336 , and a lower surface of the upper cabinet member  320  includes an annular groove  322  to receive the upper annular rib  336 . Furthermore, the button  330  includes an annular lip  338  that extends radially beyond the location of the lower and upper annular ribs  334 ,  336 . The lower cabinet member  310  includes an annular seat  314 , and the upper cabinet member  320  includes an annular seat  324 . The annular seats  314 ,  324  are configured to compress and deform the annular lip  338  when the ribs  334 ,  336  are respectively received by the grooves  312 ,  322  and the upper cabinet member  320  is affixed to the lower cabinet member  310 . 
         [0033]    In one embodiment, the lower and upper cabinet members  310 ,  320  are affixed to one another through an ultrasonic welding process. To this end, a lower surface of the upper cabinet member  322  includes an annular rib  326 . Furthermore, an upper surface of the lower cabinet member  310  includes another annular groove  316  positioned radially outward from the other annular groove  312  and configured to receive the annular rib  326  of the upper cabinet member. The engagement of the annular rib  326  and the annular groove  316  prior to welding is shown in greater detail in  FIG. 8A . As shown, a gap  360  exists between the surface of the rib  326  and the surface of the groove  316 . However, as shown in  FIG. 8B , the ultrasonic welding processes deforms the rib  326  such that afterwards the gap  360  is eliminated, and the upper cabinet member  320  is fused to the lower cabinet member  310 . Thus, when assembled, the lower cabinet member  310 , upper cabinet member  320 , and button  330  define a waterproof compartment  350  to house and protect the electrical components  340   
         [0034]    As shown in greater detail in  FIG. 7A , the button module  300  may further comprise one or more though holes  370  in one or more walls of the waterproof compartment  350 . The through holes  370  permit the passage of insulated wires  250  through the walls of the waterproof compartment  350  to the electrical components  342 , and thus permit electrically coupling the electrical components  342  to electrical components external to the waterproof compartment  350 . 
         [0035]    As shown, each through hole  370  has a corresponding counterbore  372 . To prevent leaks, a sealant  374  such as glue is used to partially fill, fill, or overfill the counterbore  372  thus providing a waterproof seal between the insulated wire  250  passing through the hole  370  and the waterproof compartment  350 . In one embodiment, the diameter of the each through hole  370  is just large enough to accommodate the wire  250  passing through it. The corresponding counterbore  372  however has a greater diameter than its corresponding through hole  370 . The larger diameter of the counterbore  372  generally improves the efficacy of the seal between the wire  250  and the compartment  350  because it increases the surface area over which the sealant may affix. 
         [0036]    Moreover, the button module  300  may include a leak test port  380  through which a capillary tube  383  may pass in order to pressure test the button module  300  for leaks after assembly. Similar to the through holes  370 , the leak test port  380  may include a hole  382  and a counterbore  384  having a larger diameter than the hole  382 . As shown in  FIG. 7B , the capillary tube  383  may be removed from the leak test port  380  after leak testing. A plug  386  such as a fastener or screw may be inserted into the hole  382  of the leak test port  380  to plug the hole and maintain the waterproof nature of the compartment  350 . Moreover, sealant  388  such as glue may partially fill, fill, or overfill the counterbore  384 . The counterbore  384  generally improves the efficacy of the seal between the plug  386  and the compartment  350  because counterbore  384  increases the surface area over which the sealant may affix. 
         [0037]    The waterproof electronics modules may be pre assembled and sealants permitted to cure prior to final test and assembly. After curing, the external end of the capillary tube  383  may be attached to a pressure management device. The pressure management device may pump gas into the waterproof compartment  350 . The pressure management device may then monitor the internal pressure of the waterproof compartment  350 . If the waterproof compartment  350  is properly sealed, then there should be little change in the internal pressure. If the module passes the pressure test, then the leak test port  380  may be plugged with a fastener  386  and sealant  388  as described above. 
         [0038]    Referring now to  FIG. 4 , further details of a speaker module embodiment  400  of a waterproof output module are shown. In particular, the speaker module  400  shown in  FIG. 4  may be suitable for implementing the output module  230  of  FIG. 2 . As shown, the speaker module  400  includes a lower cabinet member  410 , an upper cabinet member  420 , a waterproof speaker  430  comprising one or more electrical component(s)  432 , a lower gasket  440 , and an upper gasket  450 . In general, the waterproof speaker  430  produces sound in response to electrical signals received via one or more insulated wires  250 . 
         [0039]    The lower gasket  440  helps seal the interface or seam between the lower cabinet member  410  and the speaker  430 . To such an end, an upper surface of the lower cabinet member  410  includes an annular edge  412  configured to engage the lower gasket  440 , and a lower surface of the speaker  430  includes an annular groove  432  to configured to receive lower gasket  440 . The annular edge  412  and the annular groove  432  are configured to compress and deform the lower gasket  440  in order to seal the interface between the lower cabinet member  410  and the speaker  430  when the upper cabinet member  420  is affixed to the lower cabinet member  410 . 
         [0040]    Similarly, the upper gasket  450  helps seal the interface or seam between the upper cabinet member  420  and the speaker  430 . To such an end, an upper surface of the speaker  430  includes an annular edge  434  configured to engage the upper gasket  450 , and a lower surface of the upper cabinet member  420  includes an annular groove  422  configured to receive the upper gasket  450 . The annular edge  434  and the annular groove  422  are configured to compress and deform the upper gasket  450  in order to seal the interface between the upper cabinet member  420  and the speaker  430  when the upper cabinet member  420  is affixed to the lower cabinet member  410 . 
         [0041]    As shown, the upper cabinet member  420  may further include an aperture  424  in an upper surface which exposes the upper surface of the speaker  434  to the external environment. The aperture  424  may improve sound quality of the speaker  434  by not placing an additional dampening surface between the speaker  434  and the listener. 
         [0042]    As the speaker  430  is a frequency response unit and produces tiny axial movement of cone paper, the cabinet members  410 ,  420  in one embodiment are fastened together via screws and not joined via ultrasonic welding process. To such end, the cabinet members  410 ,  420  include one or more flange members  460  have holes  462  to permit affixing the cabinet member  410 ,  420  to one another via screws and/or other types of fasteners. When assembled, the cabinet members  410 ,  420  and speaker  430  form a waterproof compartment  350  primarily between the lower surface of the speaker  430  and the upper surface of the lower cabinet member  410 . 
         [0043]    In a manner similar to the button module  300 , the lower cabinet member  410  may include one or more through holes  370 , a leak test port  380 , and a capillary tube  383  as shown in  FIG. 7A . Insulated wires  250  may pass through the through holes  370  and attach to speaker terminals on the lower side of the speaker  430 . Sealant  374  may fill counterbores  372  to prevent leaks via the through holes  370 . Moreover, sealant  388  and a fastener  386  may plug the leak test port  380  after testing as shown in  FIG. 7B . 
         [0044]    Referring now to  FIG. 5 , further details of a hybrid controller/power module embodiment  500  are shown. In particular, the controller/power module  500  shown in  FIG. 5  may be suitable for implementing the controller module  210  and the power module  212  of  FIG. 2 . As shown, the controller/power module  500  includes a lower cabinet member  510 , an upper cabinet member  520 , a battery cabinet member  530 , a printed circuit board  540  comprising electrical component(s)  542 , and a two way gasket  550 . 
         [0045]    In general, the hybrid controller/power module  500  provides the functionality of a controller module and a power module. As a power module, the module  500  may include a power source such as a battery. The power source may provide electrical power to other waterproof modules via the insulated wires  250 . 
         [0046]    As a controller module, the module  500  may include electrical components  542  such as a processor, microprocessor, microcontroller, programmable array, and/or other logic components. Such electrical components may receive electrical signals via the insulated wires  250 , and process electrical signals received from other waterproof modules. The electrical components may also provide electrical control signals to other waterproof modules via insulated wires  250  to control operation of such waterproof modules. 
         [0047]    The battery cabinet member  530  includes wells  532  configured to receive a portable power source such as batteries. The battery cabinet member  530  further includes an annular flange  534  toward an upper end of the battery cabinet member  530 . The two way gasket  550  includes an annular groove  552  in an inner surface that is configured to receive the annular flange  534 . Moreover, the lower cabinet member  510  includes an annular ledge  512  that is configured to receive the a lower surface of the two way gasket  550  after the flange  534  has been placed in the groove  552 . The lower cabinet member  510 , the battery cabinet member  530  and two gasket  550  are configured to form a waterproof compartment  350  when the gasket covered flange  534  rests upon the ledge  512 . 
         [0048]    As shown, the upper cabinet member  520  provides a hinged door that may be actuated to obtain access to the wells  532  of the battery cabinet member  530 . Moreover, a lower surface of the upper cabinet member  520  includes an annular ridge  522  that is configured to engage an upper surface of the two way gasket  550 . Furthermore, the upper cabinet member  520  includes holes  524  positioned outside the perimeter of the annular ridge  522 . The lower cabinet member  510  includes threaded holes  514  which correspond to the holes  524  of the upper cabinet member  520 . When the hinged door is closed, fasteners such as screws may be threaded through the holes  514 ,  524  and tightened. Such tightening causes the annular ridge  522  to compress and deform the two way gasket  550  and to form a waterproof seal between upper cabinet member  520  and the battery cabinet member  530 . As such, once assembled, the controller/power module  500  has two waterproof compartments  350 . One above the battery cabinet member  530  to house the power source and one below the battery cabinet member  530  to house the controller. 
         [0049]    In a manner similar to the button module  300 , the lower cabinet member  510  may include one or more through holes  370 , a leak test port  380 , and a capillary tube  383  as shown in  FIG. 7A . Insulated wires  250  may pass through the through holes  370  and attach to the printed circuit board  540 . Sealant  374  may fill counterbores  372  to prevent leaks via the through holes  370 . Moreover, sealant  388  and a fastener  386  may plug the leak test port  380  after testing as shown in  FIG. 7B . 
         [0050]    Referring now to  FIG. 6 , further details of a light module embodiment  600  of an waterproof output module are shown. In particular, the light module  600  shown in  FIG. 6  may be suitable for implementing the output module  232  of  FIG. 2 . As shown, the light module  600  includes a lower cabinet member  610 , an upper cabinet member  620 , a printed circuit board  630  comprising one or more electrical component(s)  632  such as a light emitting diode (LED) or other light emitting device. In general, the light emitting device may emit light in response to electrical signals received via the insulated wires  250 . 
         [0051]    The upper cabinet member  620  in one embodiment is formed from a translucent material to permit an external viewer such as a toddler to perceive light from the LED  632 . Moreover, the upper cabinet member  620  may include one or more flanges  624  which permit fastening the light module  600  to another object such as the outer housing  110  of the water toy  100 . 
         [0052]    In one embodiment, the lower and upper cabinet members  610 ,  620  are affixed to one another through an ultrasonic welding process. To this end, an upper end of the lower cabinet member  610  includes an annular rib  612 . Furthermore, a lower surface of the upper cabinet member  620  includes an annular groove  622  configured to receive the annular rib  612  of the lower cabinet member  610 . As described above in regard to  FIGS. 8A ,  8 B, the ultrasonic welding process elements a gap between surfaces of the rib  612  and groove  622  and results in the cabinet members  610 ,  612  being fused together to form a waterproof cabinet  350 . 
         [0053]    In a manner similar to the button module  300 , the lower cabinet member  610  may include one or more through holes  370 , a leak test port  380 , and a capillary tube  383  as shown in  FIG. 7A . Insulated wires  250  may pass through the through holes  370  and attach to the printed circuit board  630 . Sealant  374  may fill counterbores  372  to prevent leaks via the through holes  370 . Moreover, sealant  388  and a fastener  386  may plug the leak test port  380  after testing as shown in  FIG. 7B . 
         [0054]    Many modifications and variations of the disclosed embodiments are possible in light of the above teachings. Thus, it is to be understood that, within the scope of the appended claims, aspects of the disclosed embodiments may be practiced in a manner other than as described above.