Abstract:
A system for molding a jointed linkage support system with joints that allow movement and bending in many directions and degrees of freedom. A chain-like linkage system made up of a series of joints is molded in a single step from materials having different melting temperatures in a series of alternating communicating mold cavities. The jointed linkage support system emerges from the mold fully assembled. An electrical switch may be provided within one of the joints between sleeves and rods whereby movement of the rod relative to the sleeve actuates the switch.

Description:
FIELD OF THE INVENTION  
       [0001]    This is a divisional of allowed U.S. patent application Ser. No. 09/665,031, filed Sep. 19, 2000, and hereby incorporated by reference. 
     
    
     
         [0002]    This invention relates to jointed linkage support systems and more particularly, but not exclusively, to support systems for toys having lifelike joints.  
         BACKGROUND AND SUMMARY OF THE INVENTION  
         [0003]    There are many uses for a jointed linkage support system of the described type. The system may serve, for example, as a toy for making original geometric forms, or as a support for an object on display. However, a principal use of particular interest to the inventors is as a skeleton for a toy such as a doll, an animal, or the like. Toy animals and figures with movable necks, arms, legs, and spines may be made in many forms including skeletal figures, action figures, fashion dolls and stuffed animals covered in plush, simulated fur or vinyl.  
           [0004]    For any of these and many other uses, the present jointed linkage support system may take on many different forms. For example, one might use the human body as a model representative of structures which may be built according to the invention. As a generality, the neck, shoulder, and hip joints may rotate and move through a cone of 360° with the apex of the cone having an angle of up to nearly 90° taken with respect to the central axis of the cone. The present invention will satisfy these requirements. Of course, other degrees of motion about the joints are also achievable in the invention.  
           [0005]    On the other hand, knees, elbows, spines, and other body parts may bend in different ways. For example, the lower arm and leg may twist and rotate over a somewhat limited distance, but neither bends backward. The elbow and knee only bend back and forth so that the range of movement of the lower arm and leg is quite different from the range of movement of the upper arm and leg. The ankle has a limited rotational and back-and-forth movement. The same is true of the arm and wrist. Toes and fingers have movement which is apparent to anyone who flexes them. These types of motion can also be achieved with the present invention.  
           [0006]    The new inventive linkage system of the present invention is preferably used to create an internal skeleton support system for a stuffed plush/vinyl toy and used to replace the malleable metal-wire insert traditionally used in stuffed toys often called “bendable”. The traditional “bendable” toy has used flexible wire inserts to give the toy a limited ability to bend in a somewhat random fashion. The present jointed linkage support system has a chain-like form, which is bendable in ways simulating actual body movements. This jointed linkage support system also overcomes the following problems common to metal-wire inserts:  
           [0007]    Durability: The insert molding links that comprise the chain-like form of the new inventive linkage system provide many more play cycles than metal wire because the linkage system is not subject to metal wire fatigue. As a result of a number of play cycles in wire-supported bendable toys, the wire breaks. That breakage may, in turn, lead to cosmetic defects and create safety problems in the form of sharp, protruding broken wire tips.  
           [0008]    Safety: It has been difficult to solve the potential safety problems created by the sharp points formed on the ends of wire materials used as inserts for toy figures and the like. The inventive jointed linkage support system uses molded parts which eliminate the sharp-point hazard present with metal-wire inserts. In fact, the linkage parts may be made with curved or rounded ends that add to the margin of safety over wire inserts.  
           [0009]    Shape of Support System: Since this inventive linkage support system is produced by an injection molding process, it can provide a range of design and a degree of flexibility and strength not available in prior art systems.  
           [0010]    Real-feel Feature: The insert-molding linkage parts have a rigidity that corresponds to the skeletons of real-life humans or animals, giving the feeling of real bones inside the soft stuffing materials, plush fabrics, vinyl skins, and the like. The prior art metal-wire inserts do not offer this unique real-feel feature. Likewise, the new inventive system may be used to form a display stand with legs and feet which may be raised or lowered, spread around or squeezed between obstacles. Hence, the invention offers a broad range of uses.  
           [0011]    Accordingly, it is apparent that a preferred jointed linkage support system should provide for many alternative degrees of freedom. This need for flexibility of design creates a series of challenges. If the jointed linkage is created from an assembly of such as turning on lights, activating synthesized or recorded speech, or other sounds and the like.  
           [0012]    Accordingly, an object of the invention is to provide a jointed linkage support system having the foregoing features. A general object of the invention is to provide a general-purpose system having many different uses. A particular object of the invention is to provide a jointed linkage system which may be used as a skeleton for toys.  
           [0013]    Another object is to provide a method of making a joint having a controlled degree of freedom of movement.  
           [0014]    Yet another object is to provide a molded jointed linkage support system which is already assembled as it emerges from the mold.  
           [0015]    Still another object is to provide a molded jointed linkage support system having an integrally formed switch.  
           [0016]    In keeping with an aspect of the invention, these and other objects are accomplished by providing a molded product made of plastics having different melting temperatures. Using a ball and socket joint, by way of example, the ball part is first formed in any desired fashion such as molding in a separate mold plate. Preferably, the ball is made of a plastic material which has a first melting temperature. An injection mold plate is then provided with communicating cavities in the socket contours. The previously formed ball parts are placed in the corresponding socket cavities of the second mold plate so that the balls effectively become part of the second mold plate, with the balls projecting into the cavities corresponding to the sockets. The mold plate cavities corresponding to the sockets are charged with a plastic having a melting temperature which is lower than the melting temperature of the plastic forming the balls, referred to below as “low temperature plastic”. Thus, after the plastic in the socket cavities solidifies, sockets are molded around the balls. The lower melting point of the plastic material enables sockets to solidify around the balls without fusing to the balls or causing any distortion of the balls.  
           [0017]    If a jointed linkage support system is to be formed in accordance with the invention, a series of communicating mold cavities may be configured to provide a series of jointed linkages that provide different degrees of freedom of movement. Hence, unique jointed linkage support systems may be provided which are already assembled as they emerge from the mold. In the preferred usage, the communicating cavities are configured to provide jointed linkages having the geometry of a skeleton corresponding to the geometry of a skeleton of a human or animal which the toy, stuffed and covered with plush or vinyl, simulates.  
           [0018]    In an embodiment of the invention a jointed linkage support system is provided which includes a motion actuated switch. The switch may be integrally formed with the jointed linkage support system, and the switch opened and closed by relative movement between various components of the jointed linkage support system.  
           [0019]    The principles of the invention and a preferred embodiment thereof may be best understood from the following specification taken with the attached drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]    [0020]FIG. 1 is a plan view, partially in cross-section, showing a ball and socket joint with dot-dashed lines illustrating the freedom of motion for the ball and socket joint;  
         [0021]    [0021]FIG. 2 is a cross-section of a two-plate injection mold for making a ball and socket jointed linkage support system;  
         [0022]    [0022]FIG. 2A is a perspective view of a lower jointed linkage arm support system made in the cavity of FIG. 2 for use in a skeleton of a toy;  
         [0023]    [0023]FIG. 3 is a perspective view showing a mold plate having one side of a mold primarily made in the form of communicating cavities having at least two contours and with empty cavities;  
         [0024]    [0024]FIG. 4 is a schematic showing how insert joint parts (a rod with balls on its opposite ends) are ready to be placed in the corresponding mold cavities;  
         [0025]    [0025]FIG. 5 shows all of the first or ball insert parts situated in the corresponding mold cavities, so that the insert ball parts become a part of the socket mold itself;  
         [0026]    [0026]FIG. 6 is a front elevation view showing the jointed linkage support system as it appears in the form of a skeleton with all joints interconnected after it is removed from the mold;  
         [0027]    [0027]FIG. 6A shows a separate jointed linkage support system;  
         [0028]    [0028]FIG. 7 is a front elevation view having an outline of a stuffed plush/vinyl toy with the molded jointed linkage support system inside the outline of the toy; and  
         [0029]    [0029]FIG. 8 is a partial side elevation view of the toy of FIG. 7 to show a molded tail linked to the jointed linkage support system inside the outline of the toy.  
         [0030]    [0030]FIG. 9 is a perspective view of a sleeve and an annular contact element according to an embodiment of the invention comprising a joint switch;  
         [0031]    [0031]FIG. 10 is a cross section of the sleeve of FIG. 9 with the annular contact mounted within the sleeve;  
         [0032]    [0032]FIG. 11 is a cross section of a cooperating second part of a joint switch;  
         [0033]    [0033]FIG. 12 is a cross section of an assembled joint switch shown in an orientation when the switch is open;  
         [0034]    [0034]FIG. 13 is a cross section of an assembled joint switch shown in an orientation when the switch is closed;  
         [0035]    [0035]FIG. 14 is a perspective view of a mold plate similar to that of FIG. 3 but including a cavity for receiving a pre-molded switch assembly;  
         [0036]    [0036]FIG. 15 is a schematic showing insert joint parts (a rod with balls on opposite ends) and a pre-molded switch assembly ready to be placed in the corresponding mold cavities;  
         [0037]    [0037]FIG. 16 shows all of the ball insert parts and the pre-molded switch assembly situated in the corresponding mold cavities so that the insert ball parts and the pre-molded switch assembly become a part of the socket mold itself;  
         [0038]    [0038]FIG. 17 is a front elevation showing the jointed linkage support system as it appears in the form of a skeleton including the pre-molded switch assembly after it has been removed from the mold; and  
         [0039]    [0039]FIG. 18 is a front elevation showing the outline of a stuffed plush/vinyl toy with the molded jointed linkage support system inside the outline of the toy. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0040]    [0040]FIG. 1 shows the principles of a single flexible joint  20  having three parts, a pair of ball parts  22  and  22 A in sockets  32  and  34  at opposite ends of a socket part  24 . The ball parts each comprise a rod  26  with a ball  28 ,  30  on each end. The socket part  24  has cavities  32 ,  34  on each end. A ball of first ball part  22  is in socket  32  while a ball  28  of second ball part  22 A is in socket  34 .  
         [0041]    The ball parts  22  and  22 A are made from a first plastic having a relatively high melting temperature of from about 150° C. to 265° C. (and preferably about 175° C. to 265° C.). The socket parts  24  comprise a sleeve made from a second plastic having a lower melting temperature than the high melting temperature of the ball part  22  of from about 110° C. to 175° C. (and preferably about 130° C. to 175° C.). This way, the socket parts  24  may be molded with their sockets  32  and  34  encircling and retaining balls  28  and  30 .  
         [0042]    As the socket plastic cools, it shrinks to create a grip on the ball which provides enough resistance to hold the ball and socket in any selected position after a movement thereof, but the resistance is not enough to prevent manipulation of the joint.  
         [0043]    Also, the socket part  24  and rod  26  are configured so that the ball part  22 A may swivel without having the sleeve of one socket part engage, interfere with, and limit the movement of the sleeve of an adjoining socket part. The movement of the ball part  22 A, as it pivots with respect to the axis of the ball and socket member, is indicated by dot-dashed lines on the left side of FIG. 1. In a preferred embodiment, the ball joint part  22 A may swing 360° around and within an imaginary conical surface having an apex angle of about 60° taken with respect to an axis  35  of the imaginary cone.  
         [0044]    The method of making the joint of FIG. 1 is illustrated in FIG. 2. Two mold plates  36 ,  38  have a cavity between them which is made in a conventional manner. Previously, the two ball parts  40 ,  42  were each made in a separate mold. The ball parts are made of a first plastic of a relatively high temperature melting point. Then, the ball parts are inserted in the corresponding cavities of mold plates  36 ,  38  and the mold is closed. Another plastic having a melting point which is lower than the melting point of the first plastic is injected into the cavity via gates  44 ,  46 . The low melting plastic flows into the cavity and around the balls of parts  40 ,  42  to form socket parts  48 ,  50 . Since the ball parts melt at a temperature higher than the temperature of the molten socket plastic, there is no adverse heat-caused effect on the contours of the ball parts. The result is that the ball parts  40 ,  42  are captured in the socket parts  48 ,  50  without any distortion or fusion of the low temperature plastic with the high temperature plastic.  
         [0045]    Every thermoplastic material has shrinkage after a molding process. As a result of the shrinkage of the low temperature plastic, a friction is generated between the ball and the socket because there is a reduced diameter of the socket relative to the diameter of the ball in order to create a tight fit. With this friction between ball and socket, the joint is more likely to remain stationary after a manipulation of the joint, which tends to hold the toy in the position which the child playing with it selects.  
         [0046]    After the socket plastic cools sufficiently, the mold plates  36 ,  38  open and ejector pin  52  frees the molded part from the mold. FIG. 2A shows the finished part as an example of a jointed linkage support system that is useful as the lower arm bone  54  of a doll. The arm bone includes the ball parts  40 ,  42  captured in the socket parts  48 ,  50 . The outer end of the second socket part  50  is molded in the form of a hand  56 . Of course, the molded part may be cast in any suitable shape. The part shown in FIG. 2A may be completed in any suitable manner, as by encasing it in a stuffed plush/vinyl toy, as described below.  
         [0047]    [0047]FIG. 3 shows a mold cavity  60  for making a jointed linkage support system of the invention which may be used, for example, as a skeleton in a stuffed plush/vinyl toy in the form of an animal or doll. In greater detail, mold plate  38  has a surface  58  with a cavity in the form of a full skeleton including: a head  60 ; a neck  62 ; two arms  64 ,  66 ; a spine  68 ; two legs  70 ,  72 ; and a tail  74 . As can be seen, each of the parts  62 - 74  has a number of joints formed in a communicating series of cavities. There are two cavities which alternate with each other in the jointed linkage support system. One cavity  23  has contours for receiving ball parts  22 ,  22 A. The other cavity  25  has contours for receiving the socket part  24 .  
         [0048]    A sliding block  76  has pins  78 - 82  which fit into holes  84 - 88  in the mold plate  38  in order to produce molded snap couplers which eliminate screws and other fasteners often found on the surface of plush/vinyl toys. Inserts  79 ,  81  will make openings in feet  83 ,  85 .  
         [0049]    [0049]FIG. 4 is a composite and schematic illustration of the first of two steps for making a jointed linkage support system. The first step is to place one of the previously made, high temperature ball parts, such as  90 , in each of the corresponding cavities, such as  92 , in surface  58  of the mold plate  38 . Hence, the balls  100 ,  102  become part of the internal contour of cavity  96 . FIG. 5 shows a ball part insert in each of the other ball cavities on surface  58  of the mold.  
         [0050]    After the mold is closed with the ball parts in place, the second step in the molding process is to inject the low temperature plastic into the sleeve or socket mold cavities, such as  96 , thereby forming a low temperature socket part in each end of the sleeve cavity. The molten low temperature plastic flows into the cavity and around each ball. For example, a socket sleeve formed at  96  (FIG. 5) contains balls  100 ,  102 , thus forming two ball and socket joints at opposite ends of the sleeve molded in cavity  96 . After the plastic cools, the jointed linkage support system will emerge from the mold already assembled.  
         [0051]    The finished molded, jointed linkage support system may also include other parts which are useful for manufacturing a finished product in the form of a doll or animal. For example, part  104  will support a head of the doll or animal. Part  106  will support the shoulders. Part  108  plays the role of the pelvic bone.  
         [0052]    Any other suitable forms may also be produced in the cavity of the mold. For example, shoe support socket parts  110 ,  112  are formed in the foot positions. Devices  79 ,  81  will create openings as shown in the shoe support parts  110 ,  112  so that a snap coupler molded in cavity  84 , for example, may be connected to a suitable independent part, such as a hand, glove, claw or the covering of a plush/vinyl toy, depending upon the desired appearance of a doll or animal. A part  116  is here shown as a blade in order to indicate that various parts may be made with any suitable contours.  
         [0053]    For devices other than a doll or animal skeleton, similar unique parts may be included in the cavity. For example, if a part molded in cavity  120  is to become part of the tail of an animal toy, a special coupler  121  may be the last part of the jointed linkage support system. Depending upon the nature of the end product animal, the tai molded in cavity  120  may be molded as a separate part which is later added to the finished skeleton jointed linkage support system by any suitable means, such as being snapped or bonded into place on the “pelvic bone”  108 .  
         [0054]    Various options are shown which may or may not be provided depending upon the final form of any product that may be made from the jointed linkage support system of FIG. 6. For example, couplers  122 - 126  may be snapped into holes in parts  116 ,  110 ,  112  to attach hands, shoes or feet, or to attach the skeleton inside the plush/vinyl toy. Part  114  shows, by way of example, another form of coupler. Still other suitable couplers or devices may be molded at suitable places on the jointed linkage support system.  
         [0055]    [0055]FIG. 6 shows the finished jointed linkage support system  119  as it is removed from the mold. FIG. 6A shows a single jointed linkage which was molded in cavity  120  (FIGS. 4, 5). Each of these is formed by the corresponding communicating series of individual cavities shown in FIGS.  2 - 6 .  
         [0056]    [0056]FIG. 7 shows a completed stuffed toy having a body  130  with a shell  131  made of any suitable material such as plush, fabric, vinyl and the like and stuffing  133  filling the space between shell  131  and linkage support system  119 . The body  130  may be made in any conventional or convenient manner, such as by shells simulating animals, rag doll bodies, simulated skin, etc. Various stuffing materials may be used, such as polyester fiber, cotton, foam, plastic chips, plastic beads, gel, liquid in capsules and the like. The stuffing material does not interfere with the functioning of this system in light of all the linkage components being formed and joined together during the molding process that forms the skeleton. The feet  132  of the body  130  may be snapped to the skeleton foot  112  by way of coupler  126 . In a similar manner, snap couplers may appear at any other suitable place on the skeleton. This use of snap couplers anchors the skeleton inside the doll or animal body without requiring connectors, such as screws, on the outside surface of the toy.  
         [0057]    [0057]FIG. 8 is a partial side view of the toy of FIG. 7 to show the molded tail linked to the rest of the skeleton system. Here, the separately molded tail  120  has a couple  136  which slips into a hole  138  in the “pelvic bone”  108 . The coupling  136 ,  138  may be secured by snapping, friction, cement, heat bonding, or the like. The point is that essentially the same support system may be assembled in different ways to make a number of different toys.  
         [0058]    A child playing with the toy may bend the legs, arms, spine, neck, etc., to have the finished doll or animal assume many different poses or postures. The heat shrink friction between the ball and socket joints holds the pose or posture until the child next bends the legs, etc.  
         [0059]    There are several combinations of thermoplastic compositions which illustrate how the first joint part and second joint part can be formed. The most important point is the melting temperatures of the materials. The second thermoplastic needs to have a melting point that is sufficiently less than the melting point of the first thermoplastic to make the joint with the desired friction and without a distortion or fusion of the first plastic responsive to the heat of the second plastic. Examples of suitable plastics with the necessary temperature characteristics are given below:  
                                                                             Injection       Combination   Thermoplastic   Melting Temp   Temp                                1   1 st     Acetal Copolymer   175° C.   204° C.           2 nd     Polyethylene High   130° C.   150° C.               Density       2   1 st     Acetal Copolymer   175° C.   204° C.           2 nd     Polyvinyl Chloride    75° C.   175° C.       3   1 st     Polyamide Type 6/6   265° C.   300° C.           2 nd     Acetal Copolymer   175° C.   204° C.       4   1 st     Polyamide Type 6/6   265° C.   300° C.           2 nd     Acrylonitrile Butadiene   110° C.   230° C.               Styrene       5   1 st     Polycarbonate   150° C.   295° C.           2 nd     Polyethylene High   130° C.   150° C.               Density                  
 
         [0060]    In an alternate embodiment of the invention, one or more joints in a jointed linkage support system similar to that shown in FIG. 6 may include an integrally formed electrical switch actuated by relative movement of the components of the joint. FIGS.  9 - 13  disclose such a switch. A sleeve  222  is formed having similar external dimensions as the socket part  24  described above, but having an internal bore  225  extending axially through the sleeve  222 . Under cut regions  226 ,  228  are formed within the sleeve at each end to form sockets for receiving ball portions. A contact ring  250  made from a conductive material such as copper is fitted within the internal bore  225  adjacent the undercut region  226 . An electrical lead preferably formed of insulated wire is soldered to contact ring  250  at solder joint  254 . The electrical lead  256  is threaded through a small exit bore  256  formed in sleeve  222  to communicate with external circuitry. FIG. 10 shows a cross section of sleeve  222  having the contact ring  250  positioned adjacent undercut region  226 .  
         [0061]    [0061]FIG. 11 shows a modified ball part  224  comprising a portion of the electrical switch. As with the previous embodiment, the modified ball part  224  includes a central rod portion  230  with balls  232 ,  234  formed at each end. In the switch embodiment, a bore  258  is formed axially through the length of the modified ball part. Counter-sunk bores  260 ,  262  are formed at each end. A conductive shaft  264  is inserted through the axial bore  258  and extends at least into the counter sunk regions  260 ,  262 . A spring  266  is friction fitted over a first end of conductive shaft  258  within counter sunk region  262  and extends out beyond the end of modified ball part  224 . A contact head  268  is mounted at the distal end of spring  266 . At the opposite end of the shaft  264  an electrical lead  272  is soldered to the shaft.  
         [0062]    A ball and socket joint  220  may be formed by inserting the ball  234  of modified ball part  224  into the socket formed by undercut region  226  at the end of sleeve  222 . Ball and socket joint  220  allows for angular motion of the ball  224  relative to the socket part  224  in substantially every direction. A second sleeve  236  similar to sleeve  222  but not having a conductive ring inside may be joined to the opposite end of modified ball part  224  by inserting ball  232  into an undercut socket formed at the end of sleeve  236 . This arrangement is shown in cross section in FIG. 12.  
         [0063]    When ball  232  is inserted within second sleeve  236 , electrical lead  270  may be threaded through a small exit bore  272  formed in the side wall of the second sleeve  236  to communicate with external electrical circuitry. At the opposite end of the ball part  224 , ball  234  is movably secured within the socket  226  at the end of sleeve  222 . Spring  266  extends from the end of ball part  224  such that contact element  268 , mounted at the distal end of the spring  266 , is positioned within the annular confines of contact ring  250 . Contact ring  250  and contact element  268  form the contact elements of an electrical switch across leads  252 ,  270 .  
         [0064]    [0064]FIG. 12 shows the socket part  222  and ball part  224  oriented in a substantially axially aligned position. As can be seen, contact element  268  is spaced apart from contact ring  250 . In this position the electrical switch is open. FIG. 13 shows the ball part  224  angularly displaced relative to the socket part  222 . As shown in FIG. 13 the contact element  268  is pivoted against the contact ring  250 , thereby closing a circuit across leads  252 ,  270 . Due to the flexibility of spring  266 , contact element  268  may be held in engagement with contact ring  250  over a wide range of displacement angles of ball part  224  relative to socket part  222 , while simultaneously allowing substantially unrestricted movement of the ball part  224  relative to the socket  222 . According to an embodiment of the invention the switch joint allows movement of the ball part  24  of up to 30° from the axis of socket part  222  in any direction.  
         [0065]    [0065]FIG. 13 also shows unmodified ball parts  280 ,  282  inserted into the sockets formed by the undercut regions of sleeves  222  and  236  at the ends of the sleeves opposite the switch components. The unmodified ball parts  280 ,  282  may be formed in an identical manner as described in the previous embodiment shown in FIGS.  1 - 8 . In other words, unmodified ball parts, in addition to having the same shape as the ball parts of the previous embodiment, are formed of a plastic having a relatively higher melting point around which adjacent, relatively lower melting point plastic socket parts may be over molded. The sleeves  222  and  236  are also formed of a relatively high melting point plastic so that the switch components will not be damaged during an overmolding process.  
         [0066]    The process for creating a jointed linkage support system, such as skeleton in a stuff plush/vinyl toy, incorporating an integrally formed electrical switch will now be described with regard to FIGS.  14 - 18 . FIG. 14 shows a mold plate  330  for forming the jointed linkage support system. Mold plate  330  is identical to the mold plate  30  of FIG. 3, but for the inclusion of a switch insert cavity  331 . Thus, in addition to the added switch insert cavity  331 , cavities formed in the surface  358  of mold plate  330  include a head  360 ; a neck  362 ; two arms  364 ,  366 ; a spine  368 ; two legs  370 ,  372 ; and a tail  374 . In the embodiment shown the switch insert cavity  331  is located in arm  366 .  
         [0067]    Turning to FIG. 15, the step of placing the previously made higher melting point ball parts  390  in each of the corresponding cavities  392  is shown. This step is the same as in the previous embodiment except that a pre-assembled switch assembly  393  is also inserted into the switch insert cavity  331 . An isolated trough  335  is formed in communication with the switch insert cavity  331  to protect the wire leads  252 ,  270  extending from the switch assembly. FIG. 16 shows all of the mold inserts in place prior to closing the mold.  
         [0068]    After the mold is closed with the ball parts and the switch assembly in place, low temperature plastic is injected into the sleeve or socket mold cavities, thereby forming low temperature socket parts between and partially surrounding the ball parts, including those extending from the pre-assembled switch assembly  331 . The finished molded, jointed linkage support system, including the integrally formed switch assembly  331  is shown in FIG. 17. FIG. 18 shows the Completed jointed linkage support system within the skin of a stuffed plush/vinyl toy figure. With the exception of the added switch assembly, the figures shown in FIGS. 17 and 18 are identical to those of FIGS. 6 and 7.  
         [0069]    When the joint switch just described is incorporated into the skeletal frame of a toy figure, an electrical signal which is passed when the switch closes may be used to activate a special feature or special effect. For example, the switch can be used to activate a speech function, or activate various sensors such as touch sensors, sound sensors, light sensors and others.  
         [0070]    There are many advantages resulting from the invention. Those who are skilled in the art will readily perceive various modifications that will fall within the scope and spirit of the invention. Therefore, the appended claims are to be construed to include all equivalent structures.