Crayon maker

An apparatus for making crayons is provided. The apparatus includes a base that houses a heating component, a melt pan disposed to absorb heat from the heating component, a mold, and a cover. The melt pan receives crayon material and contains it as the heating component increases the temperature, causing the crayon material to liquefy. The liquefied crayon material can then be drained by the user of the device, into a mold with crayon-shaped cavities. A cover prevents access to the melt pan and the mold during particular operating conditions of the apparatus.

FIELD OF THE INVENTION

This invention is directed generally to the category of toys and, more particularly, to an apparatus for making crayons.

BACKGROUND OF THE INVENTION

Crayons have long been used as a children's playtime staple. Their educational and developmental value are well-known. Due to their nature, however, crayons wear down to small pieces with use. Moreover, popular colors wear down more quickly than those used less frequently, resulting in a wide variety of crayon shapes and sizes, from what was once a uniformly-sized collection.

Unfortunately, the smaller pieces become difficult to use and store in their original container. As a result, they lose some of their play value, and tend to cause clutter. This results in waste, because crayons are typically sold as a collection, not individually, thus requiring the purchase of an entire collection to replace worn individual colors. Evidently, there exists a need for an apparatus that facilitates crayon recycling. Such a device, configured as an interactive toy, would fulfill this need, and provide a fun activity for children.

Moreover, it is generally accepted that interactive toys have a high play value for children, particularly when such toys give children the feeling of being grown up or doing something that adults do. The play value of an interactive toy is further enhanced, particularly in the eyes of parents, when the toy incorporates scientific or educational aspects such as environmental consciousness, recycling, and the observation of physical states of matter or color theory.

Of course, children's toys must be designed for safety, including protection from potential hazards such as heated components, and the like. In addition to safety, parents value other benefits, such as the reduction or elimination of messy play conditions, and increased economic value, reflected in low cost and the capability to recycle and reuse other toys, like crayons.

The invention described herein embodies such features and advantages, thus providing a fun, safe and educational toy for children, with considerable benefits for their parents.

BRIEF SUMMARY OF THE INVENTION

An apparatus for making crayons is provided. The apparatus incorporates a base that houses a heating element. The heating element increases the temperature of a melt pan, in order to melt crayon material placed thereon. The melt pan is hinged at one end such that it can rotate between a flat, melting position, and an inclined pouring position from which molten crayon material will flow.

From the inclined melt pan, the molten crayon material flows into a crayon mold. The mold may be divided into two or more easily separable pieces so that the finished crayons may be removed from the mold after they have cooled. The mold may also be removable from the base portion in its entirety. This allows the user to disassemble the mold in a more convenient location than if it were fixed to the base.

Also attached to the base is a hinged cover that a user may pivot between an open and a closed position. In its closed position, the cover enshrouds the components of the device that are heated, including the heating element, the mold, and the melting pan, to protect the user from contacting the heated components.

The apparatus further includes a timer-operated locking mechanism for securing the cover in its closed position. This is an important safety feature of the device, as it protects a user from exposure to the heated components of the toy, namely the melt pan and the mold. By turning a knob that sets the timer, a user winds a drive shaft attached to a coil spring, that, when released, rotates the drive shaft via a series of reduction gears. The drive shaft, in turn, rotates a cammed and slotted disc. The slot engages a lever that slides a locking bar into a receiving notch in the cover. The locking bar locks the cover in the closed position until the spring has rotated the disc such that the slot moves the lever to its non-locking position after a predetermined time, thus disengaging the locking bar from the receiving notch in the cover.

The cam on the disc engages and operates a switch that controls power to the heating element. When the timer is set, the disc cam closes the switch, thus energizing the heating element as the locking bar locks the cover. As the timer spring unwinds, the crayon material melts, and the cam portion of the disc reaches the point where it opens the switch, thus turning off the heat source. At this point, the user can incline the melt pan, causing the molten crayon material to flow into the mold, all while the timer continues to run. After a preset time, the disc slot pivots the locking lever to its unlocked position, thus moving the locking bar out of the cover receiving slot and allowing the cover to be opened. The user can, at this point, disengage the mold from the base and remove the cooled, newly formed crayons from the mold.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1illustrates an embodiment of the crayon making apparatus100including a base110and a cover112hingedly connected to the base. The right side panel114of the base110includes the operating controls of the device. Specifically, these include the tilting knob116and the timer control118. The tilting knob116rotates a melt pan120, hingedly attached to the base, between a flat position, as shown inFIG. 3, wherein crayon material is received and heated until it melts, and an inclined position from which the melted crayon material flows into a mold122, as shown inFIG. 4

FIGS. 3 and 5illustrate the heating components of the invention which heat crayon material placed upon the melt pan120, thus melting and liquefying it. The heating components include an enclosure130, a socket132and a heating bulb134, all of which may be disposed within the base110. In this embodiment, the bulb134is located beneath the melt pan120, and, as such, radiantly heats the melt pan120in order to melt crayon material placed thereon by a user. Of course, other types of heat sources may be used, without deviating from the inventive concept. For example, a resistance heating element may be conductively coupled to the melt pan120. In another example, the heat source may be a hot liquid source.

The crayon material may be used crayons or new crayons. The labels would be removed from the crayons prior to placement in the melt pan. In addition, the crayons may be broken prior to placement in the melt pan. For example, the crayon making apparatus may be sold as a kit which includes a bag136of broken or unbroken new crayons with or without labels or a box138of unbroken or broken new crayons with or without labels as shown in FIG.1. In addition, the crayon material may be pellets of crayon material for use with the crayon making apparatus. The pellets may be included with the crayon making apparatus or may be sold separately. The pellets may be packaged in pre-portioned bags. The portions may correspond to the amount of crayon material needed to make a predetermined number of crayons, such as, one crayon, two crayons, three crayons, or four or more crayons. Furthermore, the pellets may be colored or uncolored. If the pellets are uncolored, a coloring additive may be included with the crayon making apparatus or may be sold separately. In addition, the user can mix new or used crayon pieces with the pellets.

To prevent a user from contacting the melted crayon material, the melt pan120and the various heating components, including the enclosure130and the heating bulb134, the cover112of the invention enshrouds them during the operating conditions described below. In this embodiment, the cover112is made of a clear plastic material that enhances the play value of the invention by allowing a user to see the various operations of melting the crayon material and pouring the material into the mold. However, in other embodiments, the cover112may be made of an opaque, or semi-opaque material, without deviating from the scope of the invention. Additionally, the cover may include one or more vents140, as shown inFIG. 1, to facilitate cooling of the heated components.

As seen inFIGS. 3,5and6, the cover112is hingedly connected to the base110by a hinge pin150. The hinge pin150rests in a hinge block156of the cover112, and the ends158,160of the hinge pin150are received by the hinge pin sockets162,164of the base110. The hinge arrangement allows the cover112to rotate between a closed position, shown inFIG. 3, and an open position, shown in FIG.6. The open position facilitates access under particular operating conditions such as when a user is placing crayon material on the melt pan120, or removing newly molded crayons. The cover includes a locking slot166which, in conjunction with other components to be described below, facilitates the locking of the cover in the closed position under certain conditions. The cover112thus prevents a user from contacting heated components within the cover12. However, the hinge construction described in connection with this embodiment is not to be construed as limiting this invention to this particular hinge arrangement. In contrast, various types of hinges can be used to facilitate a cover that rotates between an open and a closed position, including, among others, a living hinge or a multi-pin hinge design. Moreover, a cover may be employed that is not hingedly connected to the base, and is completely removable from the base in its open position.

As discussed above, and shown inFIG. 1, one of the components heated during operation of the invention is the melt pan120. The melt pan120receives the crayon material placed thereon by a user, contains the material as it is melted, and facilitates pouring into a mold122. In this embodiment, the melt pan120is a shallow, metal vessel with three channels170,172,174, which receive the crayon material to be melted. It is to be noted that, in other embodiments, the mold can be manufactured of different materials and in different shapes without deviating from the scope of the invention. Moreover, the melt pan may include any number of melt channels, for example, one, two, four, five, six, or more, without deviating from the inventive scope. In this embodiment, the melting pan120is constructed of a heat-conducting metal, which facilitates efficient heat transfer from the heating bulb134.

As previously discussed, the melt pan120is hingedly connected to the base110so that the melt pan120can be rotated between a flat, melting position, shown inFIG. 3, and an inclined, pouring position as shown in FIG.4. Moreover, as shown inFIGS. 1 and 5, the melt pan120includes hinge pins176,178which are received in hinge pin openings provided in tabs180,182extending out of base110. The hinge pins176,178facilitate rotation of the melt pan120, as a user rotates the tilting knob116. Thus, a user deposits crayon material to be melted on the melt pan120, and closes the cover112. Upon activating the heating components and locking the cover112, the crayon material liquefies, and the user tilts the melt pan120to pour the liquid into the mold122.

The tilting knob116allows a user to control the operation of the melt pan120from outside the closed cover112. As shown inFIG. 5, the tilting knob116is fixed to the knob end190of a tilting axle192, such that when a user rotates the knob116, direct rotation of the tilting axle192occurs. Inside the base110, the tilting axle192rests on bearing columns194,196, that allow its free rotation. The link end198, of the tilting axle192, is fixed to an intermediate link200such that the link200rotates directly with the axle192, and, ultimately, the tilting knob116. The intermediate link200is further pivotally connected to a lifting arm202, at arm joint204. Thus, when the user rotates the tilting knob116, the tilting axle192directly rotates in the same direction. This, in turn, causes a rotation of the intermediate link200about the tilting axle192. The rotating motion of the intermediate link200causes the lifting arm202to reciprocate into or out of the housing110, thus tilting or lowering the free end206of the melt pan120, which freely rests upon the lifting end207of the lifting arm202. This pivots the melt pan120between its flat melting position, as shown inFIG. 3, and its inclined position, as shown inFIG. 4, from which melted crayon material can flow into the mold122. The lifting arm202may have notches203which engage a slot in the base110. The notches203help to hold the melt pan120in an inclined position and which make a clicking noise when the melt pan120is raised and lowered. It is to be noted that other types of mechanisms for tilting the melt pan120may be incorporated into other embodiments of the invention without deviating from the inventive scope, such as those including gears, motors, solenoids, pistons, and the like.

In order to form the liquefied crayon material into new crayons, this embodiment of the invention incorporates a removable mold122, as shown inFIGS. 7-10, which receives the liquefied crayon material draining from the inclined melt pan120. The mold122of this embodiment is a two-piece mold, with a front half208and a rear half209. The mold122includes three crayon-shaped cavities210,211,212, corresponding to the melt pan channels170,172,174. Thus, when the crayon material has melted and liquefied, the user tilts the melt pan120, as described above, and the liquid crayon material drains from each of the melt pan channels170,172,174into the mold cavities210,211,212. To facilitate the pouring of the crayon material, each mold cavity210,211,212, may include a funnel shaped entryway213,214,215. In addition, each mold cavity210,211,212may include an identification portion221below the funnel shaped entryway. In this embodiment, the identification portion221is hexagon-shaped. The identification portion helps to identify crayons made in the mold from crayons purchased by the user. The identification portion may have another shape, such as, triangle, rectangle, pentagon or other polygons, or may have other identifying features, such as, a mark or symbol.

In this embodiment of the invention, the mold may include a locking channel216in the rear mold half209, that receives a locking bead217protruding from the front mold half208. The locking bead217and the locking channel216cooperate when the mold halves208,209are assembled, to provide a secure, sealed mold122. Moreover, as illustrated inFIGS. 1 and 5, the mold122may be removable from the invention. The mold122may be secured in the base110of the invention by mold locking tabs218and219. Each tab218,219is pivotally attached to the base110, such that rotating the tabs218,219secures or releases the mold122.

It is to be noted that, although the mold122has been described with a certain number of cavities and mold portions, any number of cavities or mold portions may be utilized while keeping within the scope of the invention. For example, the mold122may include 1, 2, 4, 5, 6, or more cavities to receive the liquid crayon material. Moreover, the mold122may be made up of 3, 4, 5, 6 or more components, without deviating from the scope of the invention. Additionally, one or more portions of the mold122, or the entire mold, could be fixed to the base110of the invention, without deviating from its inventive scope.

In addition, the cavities may have different shapes. For example, the cavities may have the shape of vehicles, animals, characters, character accessories, game pieces, structures, monuments, celestial shapes, geometric shapes or other shapes. Referring toFIG. 17, the cavity410is in the shape of a boat and the cavity411is in the shape of a train. Referring toFIG. 18, the cavity412is in the shape of a lion and the cavity413is in the shape of a bear. Molds with cavities of various shapes may be included with the crayon making apparatus or may be sold separately.

In this embodiment, the mold122may be fabricated of a flexible, non-heat conductive material. This allows a user to take apart the mold halves208,209, and release the newly molded crayons from the mold122by flexing or twisting the mold halves208,209. However, other types of mold release mechanisms may be used without deviating from the scope of the invention. For example, retractable pins may be included in the mold to release the final molded product, or a mold release agent may be sprayed into the mold before molding, thus facilitating the release of the molded crayon. Additionally, many types of materials may be used in constructing the mold, not limited to flexible and non-conductive materials. For example, the mold may be formed out of metal, ceramic, or other rigid material without deviating from the scope of the invention. Thus, after the liquid crayon material is poured into the mold122, it cools and solidifies, during which time the cover112is locked in the closed position for a predetermined time. Once the new crayons have solidified and cooled, the cover112may be opened and the newly formed crayons may be removed from the mold122, as described above.

In order to lock the cover112in its closed position, thus protecting a user from the heated components of the device, this embodiment incorporates a timer220, as shown in FIG.5.FIG. 11, an exploded view of the timer220, illustrates its component parts and their arrangement. A timer control knob118, disposed outside the left side panel114of the base100, is fixed to a timer main shaft222. The shaft222extends from the timer control knob118through the left side panel114, the timer gear cover224, and the timer cam cover226, nesting in the timer base228. Between the gear cover224and the cam cover226, the shaft222is fixed to a coil spring230that powers the timer220of this embodiment.

When the timer control knob118is rotated in the winding direction, the shaft222winds the spring230so that it naturally rotates the shaft222in the opposite (unwinding) direction after the control knob118is released. Thus, the timer operates by rotating the timer control knob118in the winding direction, and releasing it, thus allowing the spring230to unwind.

To provide a calibrated, gradual release of the spring's230energy, the spring230meshes with a set of serially meshed reduction gears231,232,233,234that release the spring's230energy in a controlled, measured fashion. Moreover, an escapement235prevents acceleration of the spring's230controlled energy release by alternately meshing and disengaging with the reduction gear234. As shown inFIG. 12, the escapement235may include a shaft236about which it pivots, and two teeth237,238that alternately engage and disengage reduction gear234as it unwinds under the spring's230power. This incremental engagement and disengagement prevents the acceleration of the unwinding rate by controlling the speed of the gears231,232,233,234.

The timer220locks and unlocks the cover112by means of a locking slot242in disc246, that pivots a locking lever248between a locked position, as shown inFIG. 13, and an unlocked position, as shown in FIG.14. The locking lever248pivots about pegs250,252that are received in receptacles254,256. Near the midpoint of the lever248, a slot peg258engages the locking slot242of disc246. The locking lever further includes a notch260at its slide end262, that receives a locking tab264of the slide bar266.

Referring toFIGS. 13 and 14, as the disc246rotates, the slot peg258moves along the slot242, thus pivoting the lever248. The slot242includes a straight leg portion268and a curved leg portion270. As illustrated inFIG. 13, upon rotating the timer control knob118to its maximum winding position, the slot peg258is engaged at the locking end272of the curved leg portion270. As a result, the slide end262of the locking lever248moves fully forward. As shown inFIG. 15, this causes the notch260of the locking lever248to push the locking tab264on the lock slide266forward, sliding an engagement end274of the lock slide266into engagement with the locking notch166of the cover112. This secures the cover112in its closed position and prevents it from opening while the engagement end274remains engaged with the notch166. As the spring230unwinds, rotating the disc246, the slot peg258moves to the unlocking end276of the straight leg portion268, as shown inFIG. 14, thus pivoting the slot peg258toward the center278of the disc246. As shown inFIG. 16, the slide end262of the locking lever248thus pivots to its unlocked position, moving the engagement end274of the lock slide266out of engagement with the locking notch166of the cover112, and allowing the cover to be opened. It is to be appreciated that other types of locking mechanisms may be used, without deviating from the inventive scope, such as a locking hook, a pin in a slot, a pin in a hole, a clasp or a coupler, among others.

As shown inFIGS. 5 and 11, to prevent the operation of the timer220while the cover112is open, the apparatus100includes a stop disc279and a pivot lever280. The pivot lever280includes a tab281and pawl282. As shown inFIG. 11, the pivot lever280pivots on pins283,284that fit in to bearing recesses285,286, in the timer gear cover224and the timer cam cover226. The pawl282extends through a pawl opening287in the timer gear cover124, when the timer120is assembled.

When the cover112is in its open position, the pawl282drops into the notch288of the stop disc279, as shown in FIG.14. This prevents operation of the timer120when the cover112is open. However, when a user closes the cover112, a cover tab289(seeFIG. 5) depresses tab281of the pivot lever280, causing the pawl282to disengage from the notch288, as shown in FIG.13. Once the pawl282is clear of the notch288, the timer can be operated.

Referring again toFIGS. 13 and 14, the timer220may also control the functioning of the heating bulb134by means of a cam300on disc246. Since it is fixed to the shaft222, as described above, the disc246rotates with the shaft222. A switch302, which controls the flow of power to the bulb134, is located in close proximity to the disc246, such that the cam300can engage a switch actuator lever304when the cam300rotates into contact with the switch actuator304. Thus, when a user winds the timer220by rotating the timer control knob118in the winding direction, the disc246rotates such that the cam300comes into contact with the switch actuator lever304, depressing it and the switch plunger306. This closes the switch302, allowing current to flow to the heating bulb134. Once the knob118is released, the spring230rotates the shaft222, in turn rotating the disc246in the opposite direction. As a result, the cam300of the disc246disengages from the switch actuator lever304after a predetermined time, opening the switch302and cutting off the power source of the heating bulb134. It is to be noted that the heating bulb may operate under AC or DC power, in keeping within the scope of the invention.

As the spring230continues to unwind, the further rotation of the disc246eventually unlocks the cover by operation of the locking lever248, as described above. In order to allow for the heated components of the invention to cool, there may be included a delay between the opening of the switch302, which turns off the heating bulb134, and the unlocking of the cover112. The delay may correspond to a predetermined time interval that allows for safe access to the now-cooled crayons and heatable components of the invention.

As the spring230unwinds, the timer control118also rotates. To indicate each step of the unwinding process the invention incorporates an indicator308disposed on the left side panel114, as shown in FIG.1. The indicator308may include graphic or textual display zones310,312,314, that display the operating condition of the device as the timer120unwinds. The display zones310,312,314, may also instruct the user to perform a particular function, such as pouring the crayon material into the mold122, or opening the cover112, at a predetermined time. For example, display zone310may indicate that the crayon material is being heated. Display zone312may indicate to the user to pour the liquid crayon material into the mold using the knob116. Display zone314may indicate that the apparatus is cooling.

In addition, the indicator308may include graphic or textual display zones316,318, that display the locking condition of the cover112. For example, display zone316may indicate that the cover112is locked. Display zone318may indicate that the cover112is unlocked.FIG. 19shows one example of indicator308and display zones310,312,314,316,318.

In addition, the knob116may have an indicator340and display zones342,344which indicate the position of the knob116as shown in FIG.1.FIG. 19shows one example of an indicator340for the knob116with display zones342,344.

Thus, after the crayon material is inserted and the cover112is closed, the cover112will be locked when the user turns the knob118and activates the timer220. The timer220may then activate and deactivate the heating bulb134, as described, thus melting the crayon material. The user may then drain the liquefied crayon material into the mold122using the knob116, all while the timer220is running and the cover112is locked. After a predetermined time has run, allowing the new crayons and any heated components to cool, the timer220unlocks the cover, as described above, and the user may remove the newly molded crayons. It is to be appreciated that, in keeping with the inventive scope, other types of timing devices, such as microprocessor control, among others, may be utilized.

As an additional safety feature, the embodiment may incorporate a tilt switch320, as shown inFIG. 15, which cuts off power to the bulb134in case the base110is lifted or knocked over. The tilt switch320includes a switch lever322, connected to a plunger324. The plunger324protrudes from an opening326, and is biased to so protrude, by the lever322. The switch320also includes terminals328,330that connect to a power supply, and the bulb134, respectively, facilitating the power path to the bulb134when the switch320is closed.

When the base110is resting on a flat surface, the plunger324is pushed into the base110. In this condition, the switch lever324is pushed upwards, and power can flow to the bulb134. However, if the base110is lifted off the flat surface, or knocked over, the plunger324emerges from the opening, allowing the lever326to move downward. This causes the switch320to cut off power from the bulb134. It is to be appreciated that other types of cut-off devices may be employed, while keeping within the inventive scope. These may include mercury switches, and rolling ball mechanisms, among others.