Plug-in module for motorized toy vehicle

A power module which when plugged into an open compartment in the body of a motorless toy vehicle acts to motorize the vehicle, the compartment being disposed above a coupling gear which is operatively linked to a wheel or other means to propel the vehicle. Pivotally supported within the case of the module is a DC motor and a gear assembly having attached thereto a control lever. A battery supply housed in the case is connected to the motor through a normally open switch that closes to power the motor when the control lever which normally is in a neutral mode, is shifted either to a forward mode in which the assembly is then inclined to drive the vehicle in the forward direction, or to a reverse mode in which the assembly is then oppositely inclined to drive the vehicle in the reverse direction. The assembly includes a worm gear on the motor shaft and a pair of drive pinions engaging the worm gear on either side thereof whereby the pinions are caused to rotate concurrently in opposite directions. In the neutral mode, neither pinion engages the coupling gear and the vehicle is then free wheeling. In the forward mode, the coupling gear is engaged by only one drive pinion to cause forward motion of the vehicle, and in the reverse mode, the coupling gear is engaged only by the other drive pinion to cause reverse motion of the vehicle.

BACKGROUND OF INVENTION 
1. Field of Invention 
This invention relates generally to motorized toy vehicles provided with a 
battery-powered DC motor, and more particularly to a self-sufficient power 
module which encases the motor and a battery supply therefor, the module 
being pluggable into an open compartment in the body of any one of a 
family of motorless toy vehicles, the module then acting to motorize the 
vehicle to drive it in either the forward or reverse mode whereby the same 
power module is usable to propel all vehicles in the family. 
2. Status of Prior Art 
The term "vehicle" as used herein encompasses all forms of transportation, 
such as an automobile or truck whose wheels propel the vehicle, a boat 
having a propeller, or a helicopter having a propeller. 
The typical motorized toy vehicle includes a miniature DC motor connected 
through a polarity-reversing switch to a battery supply. In the case of an 
automobile or truck, the motor is operatively geared to at least one wheel 
axle, so that when the motor is switched on, the vehicle is propelled in a 
direction that depends on the polarity of the applied voltage. In the case 
of a toy boat, the motor is operatively coupled to paddle wheels or a 
propeller, depending on the nature of the boat. 
In play, children usually seek as best they can to initiate an observed 
adult activity. Play, therefore, represents a learning experience that 
prepares the child for the adult world. Thus, a child who plays with a toy 
combat weapon prefers a toy whose appearance resembles that of an actual 
weapon, and a child who plays with toy cars or trucks is happiest with 
those that behave and look like vehicles of the type he has seen driven by 
adults. 
Also, children enjoy playing with an assortment or family of different 
vehicles such as cars, trucks, trailers, buses, tractors and other 
vehicles normally encountered on the road, for each vehicle has a 
specialized function and therefore calls for a play activity appropriate 
to this function. But should one wish to provide a child with a group of 
different motorized toy vehicles each having its own motor and battery 
supply, the overall cost of this group of toys will necessarily be high; 
for the motor, the battery supply and the gear train to link the motor to 
a wheel axle represent a substantial portion of the manufacturing cost of 
the vehicle. 
In our copending patent application, above-identified, there is disclosed a 
power module which when plugged into an open compartment in the body of a 
motorless toy vehicle and switched on, then acts to drive the vehicle in a 
selected direction. 
In our prior arrangement, the compartment is disposed above a coupling gear 
mounted on a wheel axle of the vehicle. The case of the module simulates 
the appearance of a multi-cylinder engine and houses DC motor and a 
battery supply therefor, the motor being operatively coupled to a single 
drive pinion whose teeth project below the base of the case to engage the 
coupling gear whereby when the motor is energized, the wheel axle is 
caused to turn to propel the vehicle. The upper end of the case which 
projects above the body has a rocker pivoted thereon which simulates an 
air scoop for the engine and functions as the actuator for a 
polarity-reversing switch connecting the battery supply to the motor. 
When the rocker is inclined down toward the front, the resultant switching 
action causes forward motion of the vehicle, the vehicle moving in the 
reverse direction when the rocker is inclined down toward the rear. When 
the rocker is in its neutral position, the battery supply is disconnected 
from the DC motor, hence the car is then stationary. However, since in the 
neutral position, the pinion of the module is still in mesh with the 
coupling gear of the vehicle, the wheel axle on which this gear is mounted 
is not free to turn and the car is not then free wheeling. 
Children, when playing with motorized vehicles will, in order to vary their 
play activity, seek to propel the vehicle by hand, so that instead of 
switching on the motor, the player gives the vehicle a strong push. This 
alternative play action is possible if the vehicle, when the motor is 
turned off, is free wheeling. But in a motorized vehicle of the type 
disclosed in our copending application, the drive pinion of the pluggedin 
power module is always in engagement with the coupling gear of the vehicle 
and the vehicle is never free wheeling; hence should the child attempt to 
propel the vehicle by hand, he may, in doing so, damage the gear works and 
render the vehicle inoperative. 
SUMMARY OF INVENTION 
In view of the foregoing, the main object of this invention is to provide a 
power module which when plugged into an open compartment in the body of a 
motorless toy vehicle, such as a truck, an automobile or a boat, then acts 
to motorize the vehicle to drive it either in the forward or reverse 
direction, or acts to render the vehicle free wheeling so that the player, 
if he elects to do so, may propel the vehicle by hand without inflicting 
any damage to the vehicle. 
Thus, with a plug-in module in accordance with the invention, three modes 
of play activity are possible when the power module is plugged in; namely 
motorized forward drive, motorized reverse drive, or free wheeling. 
A significant feature of the invention is that the appearance of the 
plug-in power module, to the extent that it is exposed to the 
viewer,suggests that of a standard multi-cylinder internal combustion 
engine, the upper section of the module which is provided with a control 
lever projecting above the body of the toy vehicle and being visible to 
the player; as a consequence of which the player enjoys the experience of 
installing this familiar engine in a toy vehicle and of controlling its 
operation. 
More specifically, an object of the invention is to provide a power module 
of the above type which can be plugged into an open compartment in a 
family of diverse toy vehicles each having an open motor compartment so 
that the same power module functions to drive any selected vehicle in the 
family. 
An important economic advantage of the invention is that the manufacturing 
cost of each vehicle in the family thereof is relatively low, for none of 
the vehicles includes a DC motor, a battery supply therefor, and a gear 
train to operatively couple the motor to a wheel axle or other means to 
propel the vehicle; for these elements are all housed in a single module 
usable with any vehicle in the family. 
Briefly stated, these objects are attained in a power module which when 
plugged into an open compartment in the body of a motorless toy vehicle 
acts to motorize the vehicle, the compartment being disposed above a 
coupling gear which is operatively linked to a wheel or other means to 
drive the vehicle. Pivotally supported within the case of the module is a 
DC motor and a gear assembly having attached thereto a control lever. A 
battery supply housed in the case is connected to the motor through a 
normally-open switch that closes to operate the motor when the control 
lever which normally is in a neutral mode is shifted either to a forward 
mode in which the assembly is then inclined to drive the vehicle in the 
forward direction, or to a reverse mode in which the assembly is then 
oppositely inclined to drive the vehicle in the reverse direction. 
The assembly includes a worm gear on either side thereof whereby the 
pinions are caused to rotate concurrently in opposite directions. In the 
neutral mode, neither pinion engages the coupling gear and the vehicle is 
then free wheeling. In the forward mode, the coupling gear is engaged by 
only one drive pinion to cause forward motion of the vehicle, and in the 
reverse mode, the coupling gear is engaged only by the other drive pinion 
to cause reverse motion of the vehicle.

DESCRIPTION OF INVENTION 
Basic Structure of First Embodiment 
Referring now to FIG. 1, there is shown a preferred embodiment of a 
motorless toy pick-up truck 10 having front and rear wheel sets 11 and 12. 
Provided at the front of the vehicle body where normally an engine is 
housed, is an open compartment 13 adapted to receive a plug-in module 14. 
Also included is a hinged hood 15 having a rectangular opening 15A to 
accommodate the upper section of the module from which extends a control 
lever 16. 
Thus, to install the power module, one must first raise hood 15, then plug 
power module 14 into compartment 13 and close the hood thereover, at which 
point the power module is in its operative state. The power module, as 
best seen in FIG. 2, is configured to resemble a multi-cylinder internal 
combustion engine. 
Pivotally supported within the power module is a battery-powered DC motor 
and gear assembly that includes a pair of drive pinions P.sub.1 and 
P.sub.2 whose teeth are exposed, as shown in FIG. 3, through an opening 17 
in the base of the module case. Below the open compartment is the front 
wheel axle of truck 10 on which is mounted a coupling gear. 
The arrangement is such, as will later be explained in greater detail, that 
when control lever 16 of power module 14 occupies its neutral mode N, the 
battery supply housed in the module case is then disconnected from the 
motor and the drive pinions P.sub.1 and P.sub.2 are then disengaged from 
the vehicle coupling gear so that in this mode, the vehicle is free 
wheeling. 
But when control lever 16 is shifted to incline the motor and gear assembly 
to operate in the forward mode F, this action closes a switch connecting 
the power supply to the motor which causes drive pinions P.sub.1 and 
P.sub.2 to rotate concurrently in opposite directions, only pinion P.sub.1 
then engaging the coupling gear to drive the vehicle in the forward 
direction. And when control lever 16 is shifted to oppositely incline the 
assembly to operate in the reverse mode R, this action again closes a 
supply switch to operate the motor, but this time only pinion P.sub.2 
engages the coupling gear to drive the vehicle in the reverse direction. 
Thus, the toy vehicle, when the power module is plugged therein, is capable 
of operating selectively in the neutral free wheeling mode, or in a 
motorized forward or reverse mode. 
Power Module (first version) 
As shown in FIGS. 4 and 5, power module 14 is provided with a molded 
plastic case having a box-like lower section 18L which is joined to an 
upper section 18U to create a form resembling that of a multi-cylinder 
internal combustion engine having an array of four cylinders on one side 
and a like array on the other side. 
Fitting over the open top of upper section 18U of the case through which 
extends control lever 16 is a cover 19 whose form is such as to simulate 
an air scoop for the engine. Cover 19 has a slot 19S therein to 
accommodate lever 16 which projects thereabove. 
Pivotally supported within the case by a pivot pin P is a motor and gear 
assembly 20 within whose frame 21 is supported a miniature DC motor 22 on 
whose shaft is mounted a worm gear 23. The opposite sides of gear 23 are 
engaged to drive pinions P.sub.1 and P.sub.2 so that when the motor is 
energized to turn worm gear 23, the drive pinions are then caused to 
rotate in opposite directions. Thus, pinion P.sub.1, as shown in FIG. 5, 
rotates in the counterclockwise direction as pinion P.sub.2 turns 
clockwise. 
Lower section 18L of the module case is partitioned by parallel walls 24 
and 25, as shown in FIG. 4, to define a center compartment for 
accommodating the motor and gear assembly, and side compartments to 
accommodate the batteries 26 of a battery supply for the motor. Lower 
section 18L is provided with a HINGED LID 27 to provide access to the 
battery compartments, the lid having contacts on its inner surface which 
engage the battery terminals. 
Battery supply 26, as shown schematically in FIG. 5, is connected to motor 
22, either through a switch S.sub.1 or a switch S.sub.2. Switch S.sub.1 is 
formed by a movable contact mounted on the left side of assembly frame 21 
and a fixed contact engaged by this movable contact when pivoted assembly 
20 is inclined by lever 16 to its forward mode (F) position. Switch 
S.sub.2 is formed by a movable contact mounted on the right side of the 
assembly frame 21 and a fixed contact engaged by this movable contact when 
the pivoted assembly 20 is oppositely inclined by lever 16 to its reverse 
mode (R) position. Hence, the motor is connected to the battery supply in 
both the forward and reverse mode, but not in the neutral mode when both 
switches are open. 
When the module is plugged into the open compartment of a vehicle, it is 
then in operative relation to a coupling gear 28 mounted on a front or 
rear wheel axle 29. In practice, coupling gear 28 may be a conventional 
toothed gear, but in lieu thereof it may take the form of a wheel having 
an O-ring tire to provide friction drive. 
In the neutral mode position N, as shown in FIG. 5, control lever 16 and 
assembly 21 to which it is attached are vertically oriented. In this 
neutral position, pinions P.sub.1 and P.sub.2 are symmetrically disposed 
on either side of the axis of coupling gear 18 and are spaced from the 
coupling gear so that in neutral mode N, the vehicle is free wheeling, and 
the power module motor is turned off. 
When pivoted assembly 21 is inclined rearwardly by control lever 16 and is 
in the F mode, then motor 22 is energized and rotating drive pinion 
P.sub.1 is brought into engagement with coupling gear 28 to drive the 
vehicle in the forward direction. Shifting control lever 16 to the R mode 
again causes motor 22 to be energized, but this time it is pinion P.sub.2 
which is brought into engagement with coupling gear 28; and because pinion 
P.sub.2 rotates in a direction which is the reverse of that of pinion 
P.sub.1, the vehicle is then driven in the reverse direction. 
The Powered Vehicle 
FIG. 6 shows the power module installed in the compartment of truck 10, the 
module motor and gear assembly being switched by lever 16 to operate in 
the forward mode F. 
In this mode, pinion P.sub.2 is in engagement with coupling gear 28 on 
front wheel axle 29. In order to provide four wheel drive, coupling gear 
28 is provided at one side with a ring gear 30 that is engaged by a bevel 
gear 31 on the front end of a horizontal power transmission shaft 32 
having a bevel gear 33 at its rear end. Rear bevel gear 33 engages 
COUPLING GEAR 34 on the rear axle 35 of the vehicle. 
Should the vehicle when being propelled by the power module be prevented 
from moving because of an obstacle in its path or because the player 
grasps the vehicle to prevent it from moving, this action will prevent 
rotation of the coupling gear in the vehicle. As a result, the rotating 
pinion of the module then engaging the arrested coupling gear will be 
forced to disengage therefrom to decouple the power module and thereby 
prevent damage thereto. This is made possible because the pinion is 
included in the pivotally-supported gear assembly and is therefore free to 
swing away from the arrested coupling gear. 
In practice, instead of four wheel drive, the vehicle may be made to 
operate with rear wheel drive, in which case coupling gear 28 is freely 
mounted on the front wheel axis 29, so that it acts as an idler gear to 
transmit the drive to the rear wheels. 
The power module lends itself to use in any motorless vehicle provided with 
an open compartment which is positioned above a coupling gear mounted on a 
wheel axle. In practice, one may provide a player with a group or family 
of different toy vehicles such as buses, trucks, tractors and a variety of 
other toy vehicles, and a common plug-in power module to power any of 
these vehicles. In this way, the child is afforded a broad range of play 
possibilities to maintain his interest. 
A vehicle included in the group may incorporate hoists and other 
motor-driven expedients which can be selectively coupled to the drive 
pinion of the module so that the player can pick up loads or carry out 
other play activities. And the vehicle may take the form of a toy boat 
whose propeller is coupled to the drive pinion of the plug-in module. 
Also, the power module may be used to power toys which simulate crane 
trailers, coal conveyors, hydraulic lifts and other types of industrial or 
farm equipment. 
Referring now to FIG. 7, another version of a power module 36 in accordance 
with the invention is shown. In terms of its internal mechanism and 
function, power module 36 is essentially the same as the power module 
shown in the preceding figures and it includes an operating lever 37. This 
lever is shiftable by an operator from the neutral or free-wheeling mode 
to either a forward mode in which the coupling wheel 38 on the axle of the 
vehicle driven by the module (see FIG. 8) is engaged by one pinion of the 
pivoted DC motor and gear assembly, or to a forward mode in which the 
other pinion engages the coupling wheel. 
The main difference is that in the second version of the power module, the 
two batteries for powering the motor, instead of being housed at positions 
on either side of the motor and gear assembly as in the first version, are 
housed in an extension 39 projecting rearwardly from case 40 which houses 
this assembly. In all other respects, the first and second versions of the 
power modules have the same internal mechanism and work in the same 
manner. 
FIG. 8 shows a motorless vehicle to accommodate the power module shown in 
FIG. 7 and to be driven thereby. This vehicle includes a box-like chassis 
41 from which the front wheels 42 and rear wheels 43 are supported. 
Coupling gear 38 is mounted on the front wheel axle and its teeth are 
exposed at the bottom of the compartment defined by the chassis, the 
dimensions of which are appropriate to the power module 36. 
Body 44 of the vehicle is hinged to the rear wall of chassis 41, so that 
when this body is swung open, as shown in FIG. 8, it gives access to the 
chassis compartment in which the power module is to be installed. Body 44 
is provided with an opening 44A through which is projected the upper 
section of the installed module and lever 37. When, as shown in FIG. 9, 
body 44 is swung down over the installed power module, the engine-like 
upper section of the power module is then exposed, giving the impression 
of a high-powered vehicle. 
Power Boat 
Referring now to FIGS. 10 and 11, there is shown a toy boat 45 having an 
open cockpit 46 providing an open compartment to accommodate a power 
module of the type shown in FIG. 7. Mounted for rotation on the floor of 
the compartment is a coupling gear 47 which is operatively linked to a 
propeller 48 extending behind the stern of the boat to propel the boat in 
water. 
Hence, in this instance when the module is installed, the operator of the 
boat can shift the lever to the forward mode to propel the boat in the 
forward direction, or to the reverse mode to propel the boat in the 
reverse direction. 
Thus, the same power module may be plugged into a toy automobile, a toy 
boat or any other land, sea or air toy vehicle adapted to accommodate the 
powermodule and including a coupling gear which is engaged by either 
pinion of the power module, which coupling gear is linked to whatever 
drive or other operating means are possessed by the vehicle to be powered 
by the module. 
While there have been shown and described preferred embodiments of a 
plug-in module for motorized toy vehicle in accordance with the invention, 
it will be appreciated that many changes and modifications may be made 
therein without, however, departing from the essential spirit thereof. 
Thus, in lieu of a power module in which the motive force is supplied by a 
DC motor that is battery-operated, one may provide a wind-up coiled spring 
motor, thereby dispensing with the need for batteries and electrical 
switch contacts, and making possible a more compact, lighter and less 
expensive module. The key for winding the spring motor could be a separate 
piece or locked to the motor. Thus, the air scoop on top of the module 
could be made to function as a turnable wind-up key. 
As with power modules which use DC motors, a power module of the spring 
motor type could be plugged into any one of a family of vehicles. Thus, 
the module could be plugged into a toy airplane fabricated primarily of 
light weight styrofoam, the module when plugged in acting to drive a 
propeller to provide a toy flying machine.