Apparatus and methods for launch toys having rotatable projectile carriers

A projectile launch apparatus for discharging a NERF™ brand dart, or toy launchers each having a rotatable dart carrier in either a gun-like or rifle-like configuration. Each of the apparatus includes an energy creation system embodying a cylinder housing a piston and a launch spring, a handle for priming the apparatus, and components for causing the dart carrier to rotate about an axis perpendicular to the longitudinal axis of the launch apparatus.

FIELD OF THE INVENTION

The present invention relates generally to projectile launch apparatus, systems, and methods, and more particularly to projectile launchers having rotating barrel carriers to enable an operator to bring a multitude of projectiles into a launch position quickly and easily.

BACKGROUND OF THE INVENTION

U.S. Pat. No. 5,343,850 for a “Double Shot Projectile Launcher” to Steer purports to disclose a double barrel launcher using a bellows for generating a blast of compressed air. The path of the compressed air is determined by manipulation of a trigger that operates a slide valve. The slide valve aligns openings to clear an air path to one of two projectile supporting launch tubes. When the slide valve misaligns the openings to the launch tube, the air path is blocked. Griffin, et al. U.S. Pat. No. 5,535,729 to Applicant's Assignee for “Projectile Launcher” discloses an air gun having a fixed plurality of launch tubes and a rotatable cylinder and piston for directing a blast of compressed air to a distribution manifold which directs the air to each of the launching tubes sequentially whether loaded or not. The compressed air is first directed axially from the piston, then radially in one of the distribution passages, and finally axially to the aligned launch tube. Various toy and game launchers using high-pressure air are known in the art of interest, including Nugent U.S. Pat. No. 8,567,378, and Nugent U.S. Pat. No. 8,875,688 to Applicant's Assignee. Also, various valves and triggers are known in the art, including safety valves exemplified by U.S. Pat. No. 5,529,050.

SUMMARY OF THE INVENTION

The present invention relates to unique toy projectile launch apparatus where each launcher includes a rotatable dart carrier, an energy creation system, a priming handle for compressing a launch spring, and components for causing the carrier to rotate.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Five embodiments of toy projectile launch apparatus are illustrated, each with at least one rotatable barrel, to enable the toy launch apparatus to launch one or more projectiles quickly, some in a first mode, then have the barrels rotate, and thereafter, launch one or more projectiles in a second mode.

Eight Shot Toy Launch Apparatus

One embodiment of a toy launch apparatus is shown inFIGS.1-7, where an eight shot apparatus20is illustrated. Referring first toFIGS.1and2, the toy launch apparatus20includes a blaster or simulated gun-like outer housing22, with a rearward grip24, and left and right forward support arms26,28. The toy launch apparatus20also includes a priming handle30extending downward from the grip24, a trigger32mounted to the outer housing22, an eight shot barrel carrier34having eight barrels36,38,40,42,44,46,48,50,FIG.6, mounted to the support arms26,28of the outer housing22, and a rotational handle52mounted to top of the outer housing22for causing the barrel carrier34to be rotated 180°. Having a rotational barrel carrier allows an operator to carry more ready-to-launch projectiles before having to reload.

Energy Creation System

The eight shot toy launch apparatus20includes an energy creation system60,FIGS.3and4, located in the grip24for developing a high-pressure slug of air for launching a toy projectile, such as a dart10,FIGS.8and9. The energy creation system60embodies a piston62,FIG.4, in a cylinder64,FIG.4, and a launch spring66in the cylinder64below the piston with the priming handle30connected to the piston62. High-pressure air generated by the energy creation system, when the spring and piston are released, flows from the cylinder64through an extended air conduit67to an air connector68and then to the barrel carrier34. After loading darts in the barrels, an operator is able to pull the priming handle30downward causing the piston62to compress the launch spring66and become restrained. An earlier filed U.S. Pat. No. 10,823,527, entitled Toy Launcher Apparatus With Few Parts and Quick and Easy Assembly, illustrates and describes, in detail, the energy creation system60, and is incorporated herein by reference.

Rotatable Carrier

The eight shot carrier34,FIG.6, is configured with the eight barrels divided between two modules, a forward facing module70and a rearward-facing module72. Each module70,72include a bank of barrels74,76. Next to each bank of barrels is a passageway structure or valve system78,80for automatically cascading each slug of high-pressure air from the cylinder64to each dart-loaded barrel in sequence while ignoring barrels that are empty. Once a dart is launched from its corresponding barrel, that barrel is closed off to high-pressure air. After priming the apparatus, the next slug of high-pressure air is directed to the next loaded barrel in a module. An earlier filed U.S. Pat. No. 8,567,378, entitled Air Path and Safety Valve System for Toy Launchers, illustrates and describes, in detail, the valve system and is incorporated herein by reference. After all or some of the loaded barrels in the forward facing bank of barrels are discharged, the operator may simply rotate the carrier34to bring a fresh bank of barrels with its own valve system to face forward and present four more or less darts to a discharge position.

Well-known safety features are included in all of the embodiments disclosed here so that a toy launch apparatus cannot be used to discharge an inappropriate object, such as a pencil. Safety components may include spike and a valve as disclosed in U.S. Pat. No. 8,875,688, which is incorporated herein by reference. The spike and valve are configured to receive a dart, like a dart10,FIG.8, which has a central opening18to receive the spike and a ring shaped rear surface16to open a valve to allow high-pressure air to enter when the dart is inserted in a barrel. Other safety components may be configured for projectiles having other configurations.

Rotation System

In the middle of each carrier is a center block82,FIG.6, which is rotatably mounted to the outer housing22. Mounted to the center block82is a gear train84used to rotate the barrel carrier34and a clutch86, to insure that the carrier only rotates one way, clockwise. AtFIGS.3,6and7, a rubber bumper35is provided as part of the rotating structure stop which helps to dampen sound and stop the rotating piece hitting at the rubber bumper35when the barrel carrier34is rotated 180° and thus decreasing the loud sound at the end of the stroke. Also embodied in the center block82are two 90° inlet connectors88,90,FIG.7, mounted to the valve systems78,80. Each inlet connector, such as the inlet connector88, connects at one end92to a corresponding valve system, such as the valve system78, and at the other end94, to the air connector68and to the long air conduit67so as to direct a slug of high-pressure air from the cylinder64to a loaded barrel when in a first mode. However, when in a second mode, before rotation, the barrel carrier is separated from the source of high-pressure air. Rotation of the carrier results when the rotational handle52moves rearward and then returns, the return being by the operator or by a return spring. On the return, the handle does not engage any of the gears. Once the carrier34is rotated, the inlet connector90is engaged with the air connector68.

Along the left hand side of the toy launch apparatus20, the conduit67is along side of a link96,FIG.5, and an elongated cam98. The link96and the cam98are connected to the handle52. When the rotational handle52is moved rearward, the link96moves the cam98rearward to cause the air connector68to move laterally away from the inlet connector88. On the right hand side of the toy apparatus20, the rotational handle52is also connected to a rack99,FIG.6, which is engaged with the gear train84to flip or rotate the carrier34through 180°. After rotation, the inlet connector90assumes the upper position and is aligned with the air connector68, such that when the rotational handle52moves forward to finish the rotation cycle the air conduit67and the energy creation system60are align with the module72which is now facing forward.

When all four darts (or less) of one module are discharged, the operator may reload with four or less new darts; or, more likely during a “battle,” the operator may simply rotate the carrier 180° to bring the second module of the carrier into launching position, facing forward. As mentioned, the two modules70,72are identical. The eight shot toy launch apparatus20includes a rotation system embodying the rotational handle52. The rotational handle52is connected to the rack99and the rack is connected to the gear train84, which embodies a small gear100,FIG.6, connected to a large gear102. The gears100,102are mounted to the center block82to transfer the linear motion of the rotational handle52to rotational motion causing the carrier34to rotate. The clutch86allows rotation one-way, clockwise. Just prior to the actual rotation, the handle52, the link96and the cam98cause a slight separation of the air conduit67and the air connector68from the carrier34and the inlet connector88.

Trigger Assembly

The toy launch apparatus20includes a trigger assembly104,FIG.4, formed by the trigger32and a pivotal latch106. When the launch apparatus is primed, a lower end108of the latch106is received by a recess in the piston62to restrain the launch spring66in a compressed configuration. Retracting the trigger32causes the latch106to pivot and release the piston62and the launch spring66, and cause a high-pressure slug of air to be transmitted from the cylinder64, through the conduit67into the valve system78and to the barrels of the bank74facing forward, resulting in the launch of a dart.

Operation

In operation of the eight shot toy launch apparatus, the operator may load a dart into each of the eight barrels (or less than eight if desired). The operator may then prime the toy launch apparatus by pulling down on the priming handle30. When the trigger is pulled, a dart is discharged. The operator may then prime the launch apparatus several more times and pull the trigger after each priming cycle to launch the remaining darts in a first module. Thereafter, the operator may then load four more darts (or less) or he/she may pull the rotation handle52to rotate the carrier34and position the second module forward to enable four more darts (or less) to be discharged.

An example of a suitable projectile to be used in all five embodiments is illustrated inFIGS.8and9, and is in the form of a colorful toy dart10. The dart10is formed of soft foam and is marketed by Hasbro Inc. of Rhode Island under the brand NERF®. The dart includes a foam nose portion12, a foam tubular body portion14with a ring shaped rear surface16, and a central opening18. The rear surface16and the central opening18act in conjunction with each other to meet safety criterions that prevent the launch of inappropriate objects.

It is noted that there are dozens of different dart or projectile configurations in the marketplace (and others may be configured in the future). Projectiles having other geometries and sizes may be used with the toy launch apparatus described herein provided that the barrel and ancillary components are modified according.

Sixteen Shot Toy Launch Apparatus

FIGS.10-17illustrate two more embodiments, namely, two versions of a toy launch apparatus150, with a blaster outer housing152,FIGS.10and11, and in simulated rifle configuration inFIG.12. The outer housing152includes a rearward grip154and a forward support arm156. Left and right rotatable barrel carriers158,160, each with eight barrels, such as the barrel162, are rotatably mounted to the support arm156. A priming handle164is mounted to an upper portion of the outer housing152. A trigger166, a pump-style rotational handle168for causing the carriers158,160to rotate, and a foldable stock170are all mounted to the outer housing152. The stock is folded inFIGS.10and11, and unfolded inFIG.12.

The sixteen shot toy launch apparatus150is similar to the eight shot toy launch apparatus20but has two carriers158,160having a total of sixteen darts. The sixteen shot launch apparatus150includes an energy creation system172,FIG.13, embodying two pistons174,176and two launch springs178,180disposed in two cylinders (not shown, but each is like the cylinder64,FIG.3) mounted in the outer housing152and positioned in a configuration generally parallel to a longitudinal axis of the toy apparatus150. Each cylinder, piston and launch spring set is ducted to a separate carrier. A connector and manifold combination182,FIGS.13and15, transfers high-pressure air from the energy creation system172to the carriers158,160by way of a valve system, such as the valve systems184,FIG.10, which is very much like the disclosure in U.S. Pat. No. 10,823,527, which is incorporated herein by reference. The priming handle164extends from both sides of the toy launch apparatus150. Two darts, one from each carrier, may be launched after each priming cycle, pull rearward and then a push forward. In the alternative, a return spring may be used.

Each carrier158,160of the sixteen shot apparatus150is nearly identical to the single carrier34of the eight shot launch apparatus20. For example, the carrier158is configured with the eight barrels divided between two modules, a forward facing module190,FIG.12, and a rearward-facing module192. Each module includes a bank of barrels194,196. Next to each bank of barrels are the valve systems, such as the valve system182, for automatically cascading high-pressure compressed air from one dart-loaded barrel to the next barrel having a loaded dart. Once a dart is launched from its corresponding barrel, that barrel is closed off to high-pressure air from the energy creation system until the barrel is reloaded with a dart. After priming the apparatus, the next slug of high-pressure air is directed to the next loaded barrel in the module as disclosed in detail in U.S. Pat. No. 8,567,378 and incorporated herein by reference. Like the eight shot apparatus, the sixteen shot apparatus includes safety spikes and valves. After some or all of the loaded barrels in a bank are discharged, the operator may rotate the carriers to bring a fresh bank to face forward and present eight more darts to discharge positions. The operator may rotate the carriers back and forth, if desired, until all of the darts have been discharged, or some or all of the barrels may be reloaded at any convenient time.

Rotating the barrel carriers158,160is accomplished by two racks that are connected to the pump-style handle168, such as the rack200,FIG.14having gear teeth202at a distal end portion204. The racks200,206are positioned adjacent the right and left carriers158,160. A gear train is connected to each carrier, such as the gear train208,FIG.17, which is connected to the right side carrier158, and the gear train210,FIG.13, connected to the left carrier160. When the pump handle168is moved rearward, the racks200,206and their corresponding gear trains208,210cause the two carriers158,160to rotate 180°. However, before the carriers are able to be rotated, a third rack212,FIG.14, also connected to the pump handle168and having gear teeth214spaced away from the distal end portion215operates a gear and cam combination216,FIGS.13,16and17, that abuts against a flange217,FIG.15, of the connector/manifold182. During the early part of the rotation cycle, the third rack212enables the gear/cam216to push the connector/manifold182away from the energy creation system172because the gear teeth214of the rack212engage the gear/cam216, which moves the connector/manifold before the gear teeth202engage the gear trains208,210to rotate the carriers.

In operation, the sixteen shot toy launch apparatus150may be primed by an operator who pulls the handle164to compress the launch springs. In this first mode the high-pressure air is able to communicate from the cylinders to the barrels; but, in a second mode, before rotation, the cylinders and the barrels are separated. When it is time to rotate the barrel carriers the operator pulls the handle168rearward to disengage the connector/manifold from the valve systems and to then rotate the carriers through 180°.

Thirty-Two Shot Toy Launch Apparatus

The next embodiment is a thirty-two shot toy launch apparatus220, detailed inFIGS.18-31. The toy launch apparatus220is configured similar to the sixteen launch apparatus150, but instead of having one carrier to either side of a support arm, the thirty-two shot toy launch apparatus220has a package of barrels222,224,FIGS.18and19to each side of a support arm226. Each package, such as the package222, includes an outer carrier228and an inner carrier230. The toy launch apparatus220includes a simulated rifle-like outer housing232with a rearward stock234and the forward extending support arm226. The left barrel passage222has a total of sixteen barrels, such as the barrel236, with eight barrels facing forward. The right barrel package224also has a total of sixteen barrels with eight barrels facing forward. The packages of barrels222,224are rotatable simultaneously. A priming handle238is mounted to a lower portion of the outer housing232adjacent a grip239. A trigger240and a grip-style rotational handle242for causing the packages with the carriers to rotate are also mounted to the outer housing232.

As mentioned each of the barrel packages222and224includes outer and inner carriers, such as the outer carrier228and the inner carrier230, of the package222, and each of the four carriers of the apparatus220is configured like the carrier34,FIG.6, with a forward facing module260,FIG.24, a rearward facing module262, a bank of barrels, such as the bank264, a valve system, such as the valve system266, as described in detail in U.S. Pat. No. 8,567,378, and incorporated herein by reference, and a center block268having switching valves described below. Like the above-mentioned embodiments, the thirty-two shot apparatus include safety spikes and valves.

The thirty-two shot apparatus220has a very similar energy creation system244,FIGS.20and21, as the sixteen shot apparatus150. The thirty-two shot apparatus220includes the energy creation system that embodies two pistons246,248, and two launch springs250,252mounted in two cylinders254,256and are disposed generally parallel to the longitudinal axis of the toy apparatus220. The priming handle238,FIG.22, is connected to the energy creation system244by a gear train258and two priming racks260,262,FIGS.21and23, to compress the launch springs250,252. The pistons, launch springs and cylinders of the energy creation system244are described in detail in U.S. Pat. No. 10,823,527, and is incorporated herein by reference.

The rotational system of the toy apparatus220includes the rotational handle242and a rack270,FIG.25, having side cams272,274for disengaging a main air connector276,FIGS.26and27, from switching valves278,280,FIG.27, mounted to each of the barrel packages222,224. Each switching valve, such as the switching valve280, is connected to a helical cam282,FIGS.27and28, includes a cylindrical body284with a helical groove286and a longitudinal return groove288.

A switching valve is mounted in each barrel package222,224and each switching valve, such as the switching valve278,FIG.29, includes two pins, like the pins290,FIGS.29and30, that ride in the helical groove286, a switch link292, a stationary mount294, an air director296, a rotating body298, and two air connectors300,302. Having the two switching valves, the toy launch apparatus220is able to have a launch pattern304,FIG.31, which shows a discharge sequence of the darts in the thirty-two barrels of the apparatus.

In operation, after loading the barrels, the operator may prime the apparatus by pulling the priming handle238forward and then rearward, and when appropriate, pulling the trigger240rearward. Like the eight and sixteen shot apparatus, the thirty-two shot apparatus operates in a first mode where the energy creation system communicates high-pressure air to the barrels, but is a second mode the barrels are separated from the energy creation system. Once all sixteen darts that are facing forward are discharged (or if desired, less then sixteen darts), the operator may rotate the barrel packages and repeat the process.

Ten Shot Toy Launch Apparatus

Yet another embodiment of a toy launch apparatus having a rotatable barrel carrier is illustrated inFIGS.32-35. The apparatus320is designed with a simulated rifle-like outer housing322having a rearward stock324and grip326, and a forward support arm328. Mounted to the support arm328is a disc-like barrel carrier330having ten recessed barrels, such as the barrel332. A dual purpose handle334,FIG.33, is mounted to the left side of the outer housing322, and a trigger336is located adjacent to the grip326.

The toy launch apparatus320includes an energy creation system in the form of a cylinder338,FIG.34, having a piston and launch spring (not shown) as already described above and referencing U.S. Pat. No. 10,823,527, which is incorporated herein by reference. The trigger336is connected to the piston such that a pull on the trigger releases the launch spring and the piston to create a slug of high-pressure air. The cylinder is connected to first and second conduits340,342and an inlet connector344,FIG.35, in the hub of the carrier330. The inlet connector344is connected to safety components to prevent inappropriate objects from being discharged. The safety components may include the spike and valve mentioned above covered by a cap having a curved end surface which mates with a curved end surface of each barrel, such as a barrel346. In one mode high-pressure air may flow from the cylinder338to the one of the barrels but in a second mode the cylinder and the barrels are separated. The mating curved surfaces allow the first and second conduits340,342and the inlet connector344to be separated from the barrels when the carrier begins to rotate. As rotation begins the valve is closed and the barrel end slides away over the cap. When the inlet connector344is aligned with the barrel346, a slug of high-pressure air emitted from the cylinder338travels along the conduits and the inlet connector to the barrel346, which is shown pointed forward and aligned with a longitudinal axis of the toy launch apparatus320.

The barrel carrier330includes a ratchet348having ten teeth, such as the tooth350, in a circular pattern. Mounted to interact with the ratchet348are a pusher component352in a pusher bracket353and a lock component354in a lock bracket355. A sliding cam rod356operates the pusher and lock components352,354.

In operation, when the operator moves the dual purpose handle334two events take place. One event is that the piston is retracted to compress the launch spring thereby priming the launch apparatus320. The other event is that the barrel carrier330is rotated thirty-six degrees in a clockwise direction, as symbolized by the arrow360, to move the barrel362downward to replace the barrel346. This is accomplished by the cam rod356moving rearward with the handle334as symbolized by the arrow364. The cam rod includes a cam surface366, which abuts a slanted surface368of the pusher bracket353causing the pusher component352to move upward against a tooth370of the ratchet348and against a pusher bracket biasing spring372. The tooth370of the ratchet retracts the pusher component352against a biasing spring374. At the same time, the cam rod356releases support of a lock bracket355allowing a tooth378to push the lock component354downward as the carrier rotates. When the handle334is moved forward to finish its rearward and forward cycle, the pusher bracket353and pusher component352move downward under the influence of the biasing spring372while the pusher component352moves outward under the influence of the biasing spring372under the next tooth384of the ratchet. Simultaneously, the lock bracket355moves the lock component354upward under the influence of the biasing spring386to lock the tooth388of the ratchet348. When the trigger336is pulled the dart in the barrel362is launched.

It is to be noted that in the alternative, each of the toy launch apparatus embodiments 20, 150, 220, 320 may have more or less barrels than shown and may be configured accordingly. The links, gear trains and rack may also be aligned differently and still function in an acceptable manner. Also in the alternative, the outer housings may have other design themes.

All of the embodiments described here have barrel carriers that are mounted so as to have an axis of rotation that is perpendicular to the longitudinal axis of the toy launch apparatus which offers a novel experience for the operators.

It is further noted that words such as “forward,” “rearward,” “beneath,” “upward,” downward,” “horizontal,” “vertical,” “upper,” “lower,” “back,” “front,” “rear,” “top” and “bottom,” as well as other similar positional terms, refer to components or elements of the toy launchers as they are viewed in the attached drawings, or in relationship to the positions of the apparatus as they will typically be deployed and moved during use by an operator, or to movements of elements based on the configurations illustrated.

It may now be appreciated that the toy apparatus disclosed in detail above have great entertainment value, are fun to use and easy to operate. The toy apparatus are robust and have a relatively simple structure that may be produced at a reasonable cost.

From the foregoing, it can be seen that there has been provided a detailed description and features for improved toy launch apparatus. While particular embodiments of the present invention have been shown and described in detail, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim is to cover all such changes and modifications as fall within the true spirit and scope of the invention. The matters set forth in the foregoing description and accompanying drawings are offered by way of illustrations only and not as limitations. The actual scope of the invention is to be defined by the subsequent claims when viewed in their proper perspective based on the prior art.