Toy figure with articulating joints

A toy figure having multiple articulating limbs connected to the torso by pivot joints that are molded in a vertical injection molding step that forms and pivotally interconnects, in situ, one member of the pivot joint to a second, pre-formed member of the pivot joint.

BACKGROUND OF THE INVENTION

Toy figures with articulating limbs are generally known. Toy figures having a large number of articulating limbs are not widely available because of expenses associated with manufacturing and assembling the completed toy figure. Additionally, as the toy figures decrease in size below about 10-12 inches in overall length, the costs of manufacture and assembly increase considerably because of difficulty in constructing and attaching small limbs with multiple movable joints. A further problem in providing relatively small toy figures with multiple articulating parts concerns producing small joints that are durable and have the close tolerances necessary to provide sufficient friction between the moveable surfaces of the joints necessary for proper operation of the joints. Also, it has long been a goal to combine realistically articulating limbs with adjacent body parts in a manner which minimizes any undesirable gaps so that the outer surface of the articulating figure has a relatively continuous, life-like appearance.

It would therefore be very desirable to provide a toy figure with multiple articulating limbs having improved joint construction with increased durability for manipulation through a variety of realistic poses. It would also be desirable to provide methods which reduce the amount of time and labor needed for assembling toy figures of various sizes, including small sizes, having articulating limbs. It would also be very desirable to provide toy figures, especially toy figures with an overall length less than about 10 inches, that provide improved joint operation. Furthermore, it would be very desirable to enable the manufacture of toy figures with realistic articulating limb and torso parts having outer surfaces free of screws or other visible fasteners and having reduced gaps between the connected parts.

SUMMARY OF THE INVENTION

The present invention provides toy figures having articulating limbs with a large number of joints. The toy figures of the present invention include one or more pivotally connected parts having a first joint member made of a first material, preferably a first thermoplastic material, and a second joint member made of a second thermoplastic which has a melting point that is less than that of the first material. The first and second joint members are advantageously pivotally connected to one another in an in situ injection molding method of the invention. Thus, in another of its aspects, the present invention includes a method of connecting a first joint member and a second joint member in an in situ injection molding process, wherein the first joint member is formed of a first material and the second joint member is formed of a second material which is a thermoplastic material, wherein the first joint member is inserted in a predetermined position into an injection mold, as an insert part, and the second thermoplastic composition is injected to form the second joint member around the first joint member, pivotally connecting the two. In a presently preferred embodiment, the first thermoplastic composition is an acrylonitrile butadiene styrene (ABS) and the second thermoplastic composition is a polyvinylchloride (PVC) composition having a melting point of about 160° C. and the difference in melting points is at least about 70° C.

In another of its aspects, the present invention includes a method for making an articulating limb having first and second limb segments connected by an elongate member. The elongate member is formed of a first material and the first and second leg segments are formed from a second material having a melting point lower than the melting point of the first material. In this method, the elongate member is placed into an injection mold having a cavity for forming the first limb segment and a cavity for forming the second limb segment. The elongate member is positioned in the injection mold such that one end of the elongate member is within the first cavity and the other end of the elongate member is within the second cavity. The second material is then injected into the mold at a temperature equal to or higher than the melting point of the second material but lower than the first material's melting point. In this manner, the first and second limb segments are formed around the elongate member, the first limb segment being connected to one end of the elongate member, and the second limb segment being connected to the elongate member's other end.

DETAILED DESCRIPTION OF THE INVENTION

Reference is made toFIG. 1of the drawings which depicts a toy figure designated by reference numeral10. ToyFIG. 10includes a trunk12and limbs including a left arm14, a right arm16, a left leg18, and a right leg20, as well as a head22.

In a preferred embodiment, left arm14and right arm16, which are shown in different orientations inFIG. 1, comprise a plurality of arm segments designated by numerals24,42,58,66,80and102. These arm segments are interconnected at joints14a, b, c, d, eandfand16a, b, c, d, eandf, respectively, to provide articulating left and right arms14and16. Since the two arms14and16and the two legs18and20, as well as the component parts thereof, are mirror-images of each other, we will describe the details of left arm and left leg14and18, it being understood that the corresponding right arm and right leg16and20are comprised and assembled identically.

With reference toFIGS. 1 and 2, first arm segment24has a generally spherical top portion26with a short trunk26adepending therefrom and integrally formed therewith to give the appearance of a left shoulder and approximately the upper ⅓ of the upper arm. Spherical body26has an arcuate opening27into the interior of first arm segment24. A joint member25having a lever arm28is pivotally attached to first arm segment24at joint14a. Lever arm28terminates at one end in a disk30and at the other end in a ring31. Ring31has a bore for mounting joint member25. Ring31of lever arm28extends through arcuate opening27and is pivotally mounted on pivot pin33formed in the first arm segment as described below.

This mounting of joint member25inside trunk12permits first arm segment24to pivot at joint14athrough an arc A of approximately 90°. Thus, when first arm segment24is mounted to trunk12, as described more fully below, arm segment24is capable of pivoting within the arm hole36of the trunk such that the gap between the outer surface of body26of the first arm segment and the circular edge38of arm hole36is small at all positions of first arm segment24along arc A.

First arm member24further comprises a disk32spaced apart from a bottom surface of body26aby a short shaft34, by way of which first arm segment24is rotatingly connected to second arm segment42. As best seen inFIG. 2, second arm segment42has complementary second arm segment shells42aand42bwhich are attached by way of a cylindrical pin50in second arm segment shell42ahaving a bore52therein for receiving assembly pin54extending from the inside surface of second arm shell42b. When these second arm segment shells are assembled, disk32of the first arm segment is seated in a corresponding circular interior space46with shaft34extending through a bore in top wall44of second arm segment42, the bore being formed by complementary semi-circular cut-outs48aand48bin top wall44. With disk32positioned in interior space46and resting against the interior surface44aof top wall44, second arm segment42is capable of rotating 360° about the axis of shaft34at joint14bwith respect to first arm segment24. Additionally, second arm shell42has an arcuate opening56extending along the curved body surface of second arm segment42adjacent pin50which permits movement at joint14c, as explained below.

Left arm14further comprises a third arm segment58which acts as a double pivot member. Third arm segment58has a plate60with bores62and64extending transversely therethrough at the opposite ends of the plate. Third arm segment58is connected through bore62to pin50in second arm segment42to provide joint14c, a pivot joint.

Left arm14further includes a fourth arm segment66which is pivotally connected to third arm segment58at joint14d. Fourth arm segment66comprises complementary fourth arm segment shells66aand66b. Fourth arm segment shell66ais provided with a pivot pin68which passes through bore64to provide pivoting motion. Pin68has a bore70therein to mate with complementary assembly pin71in fourth arm segment shell66b. As will be appreciated from an inspection ofFIGS. 1 and 2, fourth arm segment66is analogous in structure and function to second arm segment42, albeit shorter in overall length and inverted with respect to the orientation of second arm segment42. Thus, fourth arm segment66has a circular interior space72(analogous to circular interior space46) and a bottom wall74defining semi-circular cut outs74aand74bdefining a bore76in communication with interior space72.

Fourth arm segment66thus is connected to third arm segment58by inserting pin68through bore64of the third arm segment58to provide joint14d. Thus it will be appreciated that third arm segment58provides a double pivot member which allows second arm segment42and fourth arm segment66to independently pivot with respect to third arm segment58at joints14cand14d, respectively.

When the second arm segment and fourth arm segment are pivoted toward each other, each of the respective arm segments are capable of pivoting through an arc of about 90° (represented by B and C) such that the second and fourth arm segments may be pivoted a total of approximately 180° with respect to one another with the third arm segment thus functioning as an elbow joint. Because the third arm segment58uses a double pivot arrangement whereas a natural human elbow joint has a single pivot point, the second and fourth arm segments are spaced apart from each other.

As best seen inFIG. 1, when left arm14is fully extended lengthwise, third arm segment58abuts end wall56aof arcuate opening56in the bottom of second arm segment42and end wall78adefining arcuate opening78of the fourth arm segment to provide a continuous outer arm surface. Third arm segment58is provided with wing-like extensions80which extend outwardly and curve slightly downwardly from the outer edge83to fill in the gaps caused by the pivotal attachment of second and fourth arm segments42and66at opposite ends of third arm segment58, as needed to assure that articulating left arm14has a full range of motion about third arm member58. The wing-like extensions thus allow arm14to exhibit a relatively continuous outer arm surface where second and fourth arm segments42and66are joined to third arm segment58without interfering with the pivoting arm segments.

Left arm14further comprises a fifth arm segment80which is rotatingly connected to fourth arm segment66at joint14eby lower arm joint member82. Joint member82comprises a disk84and a plate86spaced apart from each other by a short shaft88. Fifth arm segment80comprises complementary shells80aand80bhaving a pivot pin90with a bore92therein with complementary fifth arm segment shell80bhaving an assembly pin94extending therefrom to fit within bore92. Fifth arm segment80also has a circular interior space96and a top wall98with a bore100therethrough in communication with interior space96. As will be appreciated from an inspection ofFIGS. 1 and 2, fifth arm segment80and fourth arm segment66are essentially identical in structure and operation but are of different respective dimensions. When fourth and fifth arm segments66and80are rotatingly connected at joint14eby lower arm joint member82, fourth and fifth arm segments66and80are mated at their respective walls74and98with shaft88extending through bores76and100and with disk84seated on the interior surface of wall74and plate86seated on the interior surface of wall98. Thus fourth and fifth arm segments66and80are capable of rotating with respect to one another 360° about shaft88, with disk84rotating in interior space72.

Left hand102, which is discussed in detail below, includes a ring104with a central bore106. Ring104is spaced apart from the bottom wall108of left hand102by shaft110. Left hand102is pivotally connected at joint14fto fifth arm segment80by way of the mounting of ring104on pivot pin90, with shaft110extending through an arcuate opening91in arm segment80. Left hand102therefore pivots on pivot pin90.

In another embodiment shown inFIGS. 17-22and particularly suitable for toy figures three inches or less in overall height, left arm14comprises a first arm segment500, a second arm segment505, and an elongate member510. As shown inFIGS. 17-21, first arm segment500has a proximal end515and a distal end520, second limb segment505has a proximal end525and a distal end530, and elongate member510(as shown inFIG. 22) has a first end535and a second end540.

Proximal end515of first arm segment500is adapted to be connected to upper torso250of the toy figure. In the preferred embodiment, connecting member565(shown inFIG. 21) connects proximal end515to upper torso250. Connecting member565has a body-part end590comprising a disk575, and a limb end595comprising a ring580defining an aperture585. Proximal end515of first arm segment500comprises an integrally formed interior pivot pin600(seeFIG. 19) and defines a slot560. A pivotal connection between arm segment500and connecting member565is formed with ring580extending through slot560into the interior of arm segment500and pivot pin600extending through aperture585. Body-part end590of connecting member656is rotatably connected to upper torso250by seating disk575within a mounting structure analogous to the mounting structure described in more detail below with respect to disk30.

Distal end520of first arm segment500is connected to first end535of elongate member510. In the embodiments shown inFIGS. 17,19,20,22,41, and42, distal end520of first arm segment500is pivotally connected to first end535of elongate member510, with first end535comprising a ring542defining an aperture545and distal end520comprising pivot pin550extending through aperture545. (A perspective view of an embodiment of such an elongate member510is shown inFIG. 40.) In the embodiments shown inFIGS. 23,24,25,37,38and39, distal end520of first arm segment500is rotatably connected to first end535of elongate member510, with first end535comprising disk251and distal end520defining a circular interior space560capturing disk251.

Proximal end525of second arm segment505is connected to second end540of elongate member510. In the preferred embodiments, the second arm segment's proximal end525is either pivotally (seeFIGS. 19,20,22,23,24and35) or rotatably (seeFIGS. 37,38,39,40,41and42) connected to the elongate member using a pivot pin or a disk, respectively, in a manner analogous to that described above with respect to distal end520.

In one embodiment, left leg18comprises a plurality of leg segments which are interconnected at a series of joints to provide the articulating leg whose structure and movement correspond to arm14described above. Thus, leg18comprises first, second, third, fourth and fifth leg segments124,142,158,166, and181which are analogous to the left arm segments24,42,58,66and80, as well as to the right arm segments24r,42r,58r,66rand80rand right leg segments124r,142r,158r,166rand181r.

With reference toFIGS. 1 and 2, first leg segment124has a generally spherical top portion126with a short trunk126adepending therefrom and integrally formed therewith to give the appearance of a left hip and approximately the upper ⅓ of the upper leg. Spherical body126has an arcuate opening127into the interior of first leg segment124. A joint member125having a lever leg128is pivotally attached to first leg segment124at joint18a. Lever leg128terminates at one end in a disk130and at the other end in a ring131. Ring131has a bore for mounting joint member125. Ring131of lever leg128extends through arcuate opening127and is pivotally mounted on pivot pin133formed in the first leg segment as described below.

This mounting of joint member125inside trunk12permits first leg segment124to pivot at joint18athrough an arc D of approximately 90°. Thus, when first leg segment124is mounted to trunk12, as described more fully below, leg segment124is capable of pivoting with respect to trunk12such that the gap between the outer surface of body126of the first leg segment and the circular edge138of leg hole136is small at all positions of first leg segment124along arc D.

First leg member124further comprises a disk132spaced apart from a bottom surface of body126aby a short shaft134, by way of which first leg segment124is rotatingly connected to second leg segment142. As best seen inFIG. 2, second leg segment142has complementary second leg segment shells142aand142bwhich are attached by way of a cylindrical pin150in second leg segment shell142ahaving a bore152therein for receiving assembly pin154extending from the inside surface of second leg shell142b. When these second leg segment shells are assembled, disk132of the first leg segment is seated in a corresponding circular interior space146with shaft134extending through a bore in top wall144of second leg segment142, the bore being formed by complementary semi-circular cut-outs148aand148bin top wall144. With disk132positioned in interior space146and resting against the interior surface144aof top wall144, second leg segment142is capable of rotating 360° about the axis of shaft134at joint18bwith respect to first leg segment124. Additionally, second leg shell142has an arcuate opening156extending along the curved body surface of second leg segment142adjacent pin150which permits movement at joint18c, as explained below.

Left leg18further comprises a third leg segment158which acts as a double pivot member. Third leg segment158has a plate160with bores162and164extending transversely therethrough at the opposite ends of the plate. Third leg segment158is connected through bore162to pin150in second leg segment142to provide joint18c, a pivot joint.

Left leg18further includes a fourth leg segment166which is pivotally connected to third leg segment158at joint18d. Fourth leg segment166comprises complementary fourth leg segment shells166aand166b. Fourth leg segment shell166ais provided with a pivot pin168which passes through bore164to provide pivoting motion. Pin168has a bore170therein to mate with complementary assembly pin171in fourth leg segment shell166b. As will be appreciated from an inspection ofFIGS. 1 and 2, fourth leg segment166is analogous in structure and function to second leg segment142, albeit slightly shorter in overall length and inverted with respect to the orientation of second leg segment142. Thus, fourth leg segment166has a circular interior space172(analogous to circular interior space146) and a bottom wall174defining semi-circular cut outs174aand174b(shown with phantom lines) defining a bore176in communication with interior space172.

Fourth leg segment166thus is connected to third leg segment158by inserting pin168through bore164of the third leg segment158to provide joint18d. Thus it will be appreciated that third leg segment158provides a double pivot member which allows second leg segment142and fourth leg segment166to independently pivot with respect to third leg segment158at joints18cand18d, respectively.

As best seen inFIG. 1, when left leg18is fully extended lengthwise third leg segment158abuts end wall156aof arcuate opening156in the bottom of second leg segment142and end wall178adefining arcuate opening178of the fourth leg segment to provide a continuous outer leg surface.

When second leg segment and fourth leg segment are pivoted toward each other, each of the respective leg segments are capable of pivoting through an arc of about 90° (analogous to arcs C and D) such that the second and fourth leg segments may be pivoted a total of approximately 180° with respect to one another with the third leg segment thus functioning as a knee joint. Because the third leg segment158uses a double pivot arrangement whereas a natural human knee joint has a single pivot point second and fourth leg segments are spaced apart from each other. To fill the gap in the outer surfaces of the second and fourth leg segments142and166where they attach to third leg segment158, third leg segment158is provided with wing-like extensions180which extend outwardly and curve slight downwardly from the outer edge183of third leg member158to fill in the gaps between second and fourth leg segments142and166which are needed to assure that articulating left leg18has a full range of motion about third leg member158. The wing-like extensions thus allow leg18to exhibit a relatively continuous outer leg surface where second and fourth leg segments142and166are joined to third leg segment158.

Left leg18further comprises a fifth leg segment181which is rotatingly connected to fourth leg segment166at joint18eby a disk184spaced apart from fifth leg segment181by a short shaft188. Fifth leg segment181has a bore190extending therethrough at its lower end. When fourth and fifth leg segments166and181are rotatingly connected at joint18eby inserting disk184into interior space172of fourth leg segment166, fourth and fifth leg segments166and181are mated at their respective walls174and198with shaft188extending through bores176and with disk184seated on the interior surface of wall174. Thus fourth and fifth leg segments166and181are capable of rotating with respect to one another 360° about shaft188, with disk184rotating in interior space172.

Left foot202includes L-shaped left foot shells202aand202b. Left foot shell202ahas a pivot pin204having a bore206therein positioned at the upper portion of the “L” and a pivot pin208having a bore211therein positioned at the terminal end of the base of the L. Foot202further comprises large toe member210and smaller toe member212, which have respective proximal ends210aand212a, and bores210band212bextending transversely therethrough. Toe members210and212are pivotally mounted on pivot pin216and fifth leg segment181is mounted to pivot pin204. Left foot shell202bconnects to foot shell202aby mating assembly pins214and216which fit in bores206and211.

In another embodiment shown inFIGS. 17,18,26and27and particularly suitable in toy figures three inches or less in overall length, leg18comprises a first leg segment605, a second leg segment610, and an elongate member615. First leg segment605has a proximal end620and a distal end625, and second leg segment610has a proximal end630and a distal end635. Elongate member615(seeFIG. 25) has a first end640and a second end645.

Proximal end620of first leg segment605is adapted to be connected to lower torso252. In a preferred embodiment, shown inFIGS. 17,18and28, proximal end620is rotatably connected to hip segment660, which in turn is connected to lower torso252. In this embodiment, proximal end620of first leg segment605comprises a disk655captured by an internal space665formed by hip segment660. Hip segment660is connected to lower torso252in a manner described below.

Distal end625of first leg segment605is connected to first end640of elongate member615. In the embodiments shown inFIGS. 17,26,27,44, and45, distal end625is pivotally connected to first end640, with first end640comprising a ring647defining an aperture650and distal end625comprising pivot pin652extending through aperture650. (A perspective view of an embodiment of such an elongate member615is shown inFIG. 43.) In the embodiments shown inFIGS. 29,30,36,46,47and48, distal end625of first leg segment605is rotatably connected to first end640, with first end640of elongate member615comprising disk642and distal end625defining a circular interior space632capturing disk642.

Proximal end630of second leg segment610is connected to second end645of elongate member615. In preferred embodiments, the second leg segment's proximal end630is either pivotally (seeFIGS. 17,26,27,2930, and36) or rotatably (seeFIGS. 43,44,45,46,47, and48) connected to the elongate member615using a pivot pin or a disk, respectively, in a manner analogous to that described above with respect to distal end625.

With further reference toFIGS. 1 and 2, trunk12comprises an upper torso250and a lower torso252pivotally and rotatingly connected to one another at joint12a. As best seen inFIG. 1, upper torso250has a reduced lower end256which is defined by a gently tapering wall258having a collar which is partially seated in upper opening260in lower torso252. Upper opening260thus forms a substantially circular seat to meet with the reduced end256of upper torso250such that trunk12is capable of articulating when upper torso250and lower torso252are connected by body joint254. In a particularly preferred embodiment, upper torso is capable of pivoting left to right with respect to the lower torso over an arc of about 30° (e.g., 15° to each side) of an upright position and is capable of pivoting front to back by approximately 30° (5° back and 25° forward) to simulate a range of motion about the waist of a human being. Body joint254, which is more fully described below with reference toFIGS. 9-11, functions as a ball and socket joint.

In one embodiment, the head22of toyFIG. 10is substantially hollow and cast of a thermoplastic resin such as PVC, preferably using a rotational molding technique as known in the art. The base261of the head has an involuted hemispherical bottom wall262defining a cavity263with a bore264therethrough at the top of the hemisphere. Head22is attached to upper torso250by a head joint member266which has a generally spherical body with an upper portion267supporting a mushroom-shaped attachment member270which is sized and shaped to snap-fit through bore264and be retained within the interior space of head22with the upper surface267of head joint266residing in cavity263. Joint266has a second attachment disk269(analogous to disk30of joint member25) which is pivotally connected inside of joint member266via lever arm274in an analogous manner to the slot280connecting lever arm28and first arm segment24as discussed below. When head22is connected to trunk12, head22is capable of pivoting about a pivot joint located in head joint266(analogous to the pivot joint in first arm segment24) as well as rotating about disk269. Thus, head22is capable of swiveling and nodding relative to torso250.

In another embodiment shown inFIGS. 17,32and33and particularly suitable in toy figures three inches or less in total length, head22is attached to upper torso250by lever arm670. As shown inFIGS. 31-33, lever arm670has a proximal end690and a distal end685.

Proximal end690of lever arm670is adapted to be attached to upper torso250. In a preferred embodiment, proximal end690extends through slot700formed in the bottom of head22and comprises a disk695. Disk695is rotatably captured within slot280in the same manner as disk39described below.

Distal end685of lever arm670is located within the interior of head22and, in a preferred embodiment comprises a ring675defining an aperture680. Head22has an internal pivot pin705extending through aperture680to pivotally connect head22to lever arm670.

Torso250includes slots280for the rotational attachment of left arm14, right arm16and head22. Attachment of left arm14will now be described, it being understood that right arm16and head22are similarly attached. See FIG.4. Left arm14is connected to upper torso250at arm hole36by seating disk30within a mounting structure comprising a slot280defined by vertical upstanding, parallel spaced walls282and284. Wall284has a semi-circular cut-out286along its exposed edge and the opposite wall282has a horizontal upstanding ridge288formed on its inner surface290. Disk30of first arm member24is provided with a groove37which is complementary to ridge288and acts as a detent when a disk30is rotated within slot280. Torso shell250ais provided with a complementary mounting structure (not shown). Thus, when complementary upper torso shells250aand250bare mated edgewise, the open ends of the complementary mounting structures including particularly their respective upstanding walls abut to form a retention seat for disk30of first arm segment24with shaft28of arm joint24extending through the abutting semi-circular cut-outs286in the abutting wall such that left arm member24and thus left arm14is rotatingly attached to upper torso250. A disk attached to a shaft member (e.g., disk30attached to shaft28) and a retention seat (e.g., slot280with wall284having a bore therethough to rotatingly seat disk30) are an example of complementary joint members or attachment means which comprise a rotational joint which may be used to connect adjacent body parts of toy FIG.10.

Upper torso250and lower torso252are connected at joint12aby a body joint member254having a rectilinear portion300with a pair of laterally-extending rails302extending from the side walls304of body300. Body joint member254further comprises a ball-member306, rotatingly and pivotally mounted in body300and having a shaft308depending therefrom and connected to a plate310.

Portion300of body joint member is seated within torso250using a mounting structure281that is different than previously described for seating disk30of first arm segment24in slot280. Thus, mounting structure281has a bottom wall312having a semi-circular cut-out314. Bottom wall312is connected to a pair of upstanding parallel spaced side walls316, which side walls have complementary rectangular cut-outs318. Body300of body joint254is seated on bottom wall312with notches318engaging rails302of the body joint and shaft308extending through cut-out314and through the opening at the bottom of upper torso250. In an embodiment shown inFIGS. 17 and 34and particularly suitable in toy figure is three inches or less in overall length, portion300is sized so as to occupy a substantial portion of the upper torso250.

Lower torso252has yet another type of mounting structure, designated by reference numeral283, which includes an upper plate320having a semi-circular cut-out322at its edge. Top plate320has a pair of parallel reinforcing side walls324to add structural support to top wall320. Complementary top plate and reinforcing side plates are formed on lower torso shell252awhich complementary walls abut when the shells252aand252bof lower torso252are mated edgewise to capture plate310beneath top wall320. As will be appreciated, the length of shaft308is predetermined so that when body300is seated on bottom wall312and plate310is seated beneath top wall320, the reduced end256of upper torso is pivotably and rotatably seated in substantially circular opening260of lower torso252.

Turning toFIG. 3, assembly of actionFIG. 10proceeds with step-wise connection of the components of the limbs and torso of actionFIG. 10using an ultrasonic welding apparatus. The ultrasonic welding apparatus comprises base350and an ultrasonic horn352that resonates at a sufficiently high frequency, for example 20 kHz-40 kHz, with power output of from 1000 watts to about 4000 watts to heat the surfaces of parts which are housed within the ultrasonic welding apparatus and causes the surfaces of the plastic parts to be welded together edgewise. As known in the art, the duration of power of the ultrasonic welding apparatus may be controlled to assure a good weld of the intended abutting surface.

Referring toFIGS. 3-5, in a presently preferred embodiment of the present invention, the ultrasonic welding assembly is carried out in a series of steps to join the limb segments into articulating limb subassemblies and attach the limb subassemblies to one another to form a completed limb, and then to connect the completed limbs to the upper and lower torsos250and252and the upper and lower torsos250and252to each other.

As shown inFIG. 3, arm shell42ais inserted into ultrasonic base350and connected to first arm segment24by inserting disk32into receptacle46. Third arm segment58is connected to the pin50of arm shell42athrough the bore62in plate60and arm shell42bis mated edgewise with complementary arm shell42awith assembly pin54being received in bore52of pin50. When arm shells42aand42bare mated, disk32(and thus first arm segment24) is rotationally captured in interior space46of second arm segment42and third arm segment58is captured and pivotally mounted on pivot pin50of second arm segment42. Then, ultrasonic energy is applied to weld arm shells42aand42b(preferably formed of ABS) edgewise without adversely affecting the above-described rotational and pivotal connections. The assembly so formed is a first left arm subassembly.

In the next step of assembling the left arm, arm shells66aand66bof the fourth arm segment66are brought together for ultrasonic welding with attaching pin71being received in bore70after connecting the first left arm subassembly (completed in the prior ultrasonic welding step) by connecting pin68through bore64of third arm segment58extending from the first left arm subassembly and by inserting disk84of lower arm joint82into receptacle72. After completion of the second ultrasonic welding step, a second left arm subassembly is provided which is connected, in a third ultrasonic welding, to fifth left arm segment80and left hand102. In this third ultrasonic welding step arm shells80aand80bare mated edgewise and welded essentially as described above to capture plate86of lower arm joint82in receptacle96and to capture ring104pivotally mounted on pin90. After the third ultrasonic welding step the left arm14is complete.

The left leg is assembled in essentially the same manner using three ultrasonic welding steps as described above for assembly of the left arm. Thus, referring toFIGS. 1 and 2, in step (1), left first leg segment124, left leg shells142aand142band third left leg member158are joined in an ultrasonic welding step to provide a first leg subassembly; in step (2), a further ultrasonic welding step, the first leg subassembly is pivotally connected by way of bore164in the portion of third leg member158, extending from the first leg subassembly to pin168of leg shell166aand to fifth leg segment181by inserting disk184into a receptacle172to form a second leg subassembly; and in step (3), toe members210and212are pivotally mounted on pin208and pin204is pivotally mounted through bore190of fifth leg segment181and the foot shells202aand202bare brought together edgewise with assembly pins214and216being received in bores206and210, respectively, prior to ultrasonic welding to capture second leg subassembly via bore190and to capture toe members210and212to complete left leg18.

Right arm16and right leg20are assembled in the same manner as left arm14and left leg18.

Referring now toFIG. 4, the left arm14and right arm16are connected to upper torso250by inserting disks30into slots280. The head22(previously joined to head joint266) is connected by inserting disk269into slot280. And, body300of body joint254is seated on bottom plate312with rails302received in notches318of side plates316. Then upper torso shells250aand250bare aligned edgewise with complementary slots located near the respective arm holes and opening at the top and bottom of the torso for the head joint266and body joint254abutting to capture disks30(arms14and16) and269(head22) and rails302(body joint254), followed by ultrasonic welding to provide an upper torso250having a left arm14, a right arm16, a head22and a body joint254.

With reference toFIG. 5, the leg assemblies and lower torso are attached to the completed upper torso (1) by seating plate310beneath upper wall320so that shaft308extends through semi-circular cut-out322, and (2) by positioning disks130in the interior space330defined by lower torso walls332and334with shafts128extending through cutouts332and334of lower torso252. In this orientation, the spherical outer walls126and126rof first leg segment124and124rare flush against the concave sidewalls336and338of lower torso252. Then lower torso shells252aand252bare mated edgewise and connected by ultrasonic welding to capture upper torso250and left and right legs18and20, thereby completing the assembly of action FIG.10.

In another embodiment shown inFIGS. 17,18and28and particularly suitable for use in toy figures three inches or less in overall length, the leg and hip assemblies are attached to lower torso252by means of shaft member710. Shaft member710is captured within a cavity715formed by lower torso252. Shaft member710has a first end720and a second end725projecting from lower torso252, each end comprising a substantially spherical ball member730.

Hip segment660of each leg and hip assembly737comprises a pair of complimentary shells745and750defining a cavity735for capturing spherical ball member730, thereby rotatably connecting hip segment660to shaft member710. Hip segment660also defines slot740to accommodate the pivotal movement of shaft member710in relation to hip segment660. In the preferred embodiment, a projection755is situated on shaft member710and is captured by cavity715to keep shaft member710from rotating or moving laterally within cavity715.

In yet another of its aspects, the present invention entails an injection molding method for producing a joint in which a first joint member is pivotally connected to a second joint member. This method comprises the steps of:

(i) inserting a first joint member having a first portion with a substantially circular bore into an injection mold having inner walls defining a cavity for forming at least the second joint member, so that the first joint member is positioned in the injection mold so that the first portion is maintained in spaced relation to the walls of the mold and a second portion of the first joint member is outside of the mold cavity; and

(ii) injecting a thermoplastic composition into the cavity of the mold under suitable injection molding conditions so that the thermoplastic composition fills the cavity and engulfs the first portion of the first joint member and fills the bore to form in situ a joint including a second joint member with a molded-in-place pivot pin pivotally connecting the first joint member to the second joint member, wherein the injecting step is carried out under injection molding conditions that do not adversely affect the shape and structural integrity of the first joint member.

In another of its aspects, the present invention includes a method for making an articulating limb having first and second limb segments connected by an elongate member. The elongate member is formed of a first material and the first and second leg segments are formed from a second material having a melting point lower than the melting point of the first material. In this method, the elongate member is placed into an injection mold having a cavity for forming the first leg segment and a cavity for forming the second limb segment. The elongate member is positioned in the injection mold such that one end of the elongate member is within the first cavity and the other end of the elongate member is within the second cavity. The second material is then injected into the mold at a temperature equal to or higher than the melting point of the second material but lower than the first material's melting point. In this manner, the first and second limb segments are formed around the elongate member, the first leg segment being connected to one end of the elongate member, and the second limb segment being connected to the elongate member's other end.

In another of its aspects, the present invention entails an injection molding method for making a ball and socket joint for pivotally connecting a first joint member to a second joint member comprising the steps of:

(i) inserting a joint member having a first portion with a substantially spherical ball member into an injection mold having inner walls defining a cavity for forming at least the second joint member, the first joint member is positioned in the injection mold so that the major portion of the ball member is maintained in spaced relation to the walls of the mold and a minor portion of the ball member of the first joint member is outside of the mold cavity; and

(ii) injecting a thermoplastic composition into the cavity of the mold under suitable injection molding conditions so that the thermoplastic composition fills the cavity and engulfs the major portion of the ball member of the first joint member to form the second joint member including a socket pivotally connecting the first joint member to the second joint member, wherein the injecting step is carried out under injection molding conditions that do not adversely affect the first joint member.

The term “suitable injection molding conditions” means temperature, time and pressure conditions as known in the art which allow a flowable thermoplastic composition to be introduced into the cavity of an injection mold so as to fill the cavity. As will be appreciated by those of ordinary skill in the art, such suitable injection molding conditions may be routinely determined depending upon the selected thermoplastic material. Also, by the phrase “injection molding conditions that do not adversely affect the first joint member,” it is meant temperature, time and pressure conditions less than those which would cause either the first joint member having a bore therethrough or the first joint member comprising a ball member of a ball and socket joint, to melt, distort or fuse to the second joint member so that the first and second joint members are unable to pivot properly with respect to each other.

In the methods of the present invention for pivotally connecting a first joint member to a second joint member, it is preferred to use a vertical injection machine because of the relative ease with which an insert part may be oriented and held in the mold during the molding process. However, other injection molding apparatus, including conventional horizontal injection molding machines, may be used with suitably designed molds.

In the injection molding process of the invention, a first rigid joint member is made of a first material which has a higher melting point than the second joint member. The first material may be any suitable material for an insert part including plastic, metal or the like, so long as the first material has a melting point sufficiently above the melting point of the second thermoplastic material used in the claimed process. It is presently preferred, however, that both the first joint member and the second joint member be made of first and second thermoplastic materials, respectively. Also, it is preferred that the first joint member be injection molded.

In a particularly preferred embodiment, the first thermoplastic material will have a melting temperature that is at least about 30° C. higher than the second thermoplastic material. The first thermoplastic composition more preferably will have a melting point which is from about 50° C. to about 300° C. higher than the second thermoplastic material, and most preferably about 70° C. to about 140° C. higher than that of the second thermoplastic material. Suitable first thermoplastic materials may have a melting point in the range of 200° C. to 350° C. and suitable second thermoplastic compositions may have a melting point in the range of 140° C. to 180° C. or more. Presently preferred first thermoplastic compositions include polycarbonate having a melting point of about 300° C., nylon having a melting point of about 300° C., acrylonitrile-butadiene-styrene (ABS) having a melting point of about 230° C., polyoxymethylene resin (POM), (e.g., POM known by the brand name Celcon), having a melting point of about 260° C., and the like. Presently preferred second thermoplastic compositions include polyvinylchloride or Kraton (a brand name of styrene butadiene, a synthetic rubber composition) having a melting point of about 160° C. In particularly preferred embodiments of the invention, the first plastic composition is ABS and the second plastic composition is PVC.

It has been surprisingly found that where the second plastic composition is relatively soft compared to the first plastic composition a sufficient coefficient of friction between the first and second joint members results to permit relative movement while insuring that, once moved, the members will remain in their new relative positions. This applies as well to other pairs of joint members (including joint members formed separately and then assembled) used to form a pivot joint or a rotational joint of toy FIG.10.

Referring toFIGS. 6-8, one embodiment of the molding method of the present invention is illustrated.FIG. 6shows an insert piece25′ comprising ring31having a bore35transversely therethrough and a disk30′ having notches380cut in the circumferential edge30eof the disk. Ring31and disk30′ are at either end of lever arm28. Ring35has keys382protruding inwardly towards the center of bore35. Keys382serve to increase pivotal friction between ring31and a pivot pin33formed therethrough in the molding method of the present invention. Notches380serve to prevent relative rotation between disk30′ and disk30formed over disk30′ in the molding process.

With reference toFIG. 7, first joint member25′ (preferably made of ABS) is placed in a vertical injection mold388which parts along line389so that a portion of lever arm28and ring31extend into a first cavity390of the mold388and a portion of lever arm28and the notched disk portion extend into a second cavity392of the mold388. As shown in this figure, an intermediate portion of the lever arm is held in mold388so that it is not in communication with either first cavity390or second cavity392. As will be understood by those skilled in the art, the second thermoplastic composition used to fill first cavity390and second cavity392is injected under injection molding conditions using runner391, which is in communication with the first cavity and a second runner (not shown) which is in communication with the second cavity.

FIG. 8shows the first arm segment24after completion of the injection molding process with a portion of ring31and disk30′ shown in phantom lines encased in the second thermoplastic composition used in the injection step. As best seen inFIG. 7, pivot pin33is formed in situ through bore35of ring31.

It will be appreciated that right arm segment24r, left leg segment124and first right leg segment124rare formed in an analogous manner.

An embodiment of the molding process of the present invention for producing a ball and socket body joint254is illustrated inFIGS. 9-11. Body joint254comprises a first joint member450(shown inFIG. 9) and a second joint member300which are capable of pivoting and swiveling relative to one another. First joint member450includes a ball member306and a plate310spaced at either end of a shaft308. First joint member450is made of a first thermoplastic composition, preferably ABS. As shown inFIG. 10, first joint member450is inserted into mold460so that a major portion of ball member306(at least greater than half of its surface area and preferably more than 75% of its surface area) is positioned within mold cavity462and a minor portion of ball member306(less than half of its surface area) as well as shaft308and plate310are positioned within mold460so that they are outside of communication with mold cavity462. In an injection molding step, a second thermoplastic material is injected into mold cavity462to establish second joint member300which has an interior surface which is formed around the outer surface of ball306to establish the socket of body joint254.FIG. 11shows the completed body joint254with a major portion of ball306(shown in phantom lines) residing within body300of body joint254.

An embodiment of the molding process of the present invention for making an articulating arm having first and second arm segments connected by an elongate member is illustrated inFIGS. 19,35,39and42. The elongate member510is formed of a first material and the first and second arm segments500and505are formed from a second material having a melting point lower than the melting point of the first material. In this method, the elongate member is placed into an injection mold800having a cavity805for forming the first arm segment500and a cavity810for forming the second arm segment505. The elongate member510is positioned in the injection mold such that elongate member's first end535is within the first cavity805and the elongate member's second end540is within the second cavity810. The second material is then injected into the mold800in the manner described above at a temperature equal to or higher than the melting point of the second material but lower than the first material's melting point.

In this manner, the first and second arm segments are formed around the elongate member. In one embodiment, shown inFIG. 19, the first arm segment500forms pivot pin550within aperture545of the first end of the elongate member510, and the second arm segment505forms a pivot pin803within aperture807of the second end540of the elongate member510. In another embodiment, shown inFIG. 39, first end535of elongate member510comprises disk251and first arm segment500forms circular interior space560capturing disk251, while second end540of elongate member510comprises disk900and second arm segment505forms circular interior space905capturing disk900. In other embodiments, first end535of elongate member510comprises a disk and second end540of the elongate member comprises a ring defining an aperture (seeFIG. 35) or vice versa (see FIG.42).

A variation of the molding process described above, can be used to make an articulating arm as described above and further comprising a connecting member565having a body-part end590adapted to be connected to the body part and a limb end595attached to the distal end515of first arm segment500. The connecting member565can be made from either the same material as the elongate member510or a third material having a melting point higher than the second material's melting point. In this method, the connecting member565is, like the elongate member510, inserted into the injection mold800but is positioned in the injection mold800so that the limb end585is located within the first cavity805. The second material is then injected into the first and second cavities805and810of the mold800under injection molding conditions permitting the second material to fill the first and second cavities805and810and form the first arm segment500and the second arm segment505. The distal end520of the first arm segment500is then formed around the first end535of the elongate member510, the proximal end515of the first arm segment500is formed around the limb end595of the connecting member565, and the proximal end525of the second arm member505is formed around the second end540of the elongate member510. Where the connecting member590is made from the first material, the injecting step is carried out at a temperature lower than first material's melting point but higher than the second material's melting point. Where the connecting member590is made from a third material, the injecting step is carried out at a temperature below the lower of the first and third material's melting points but higher than the second material's melting point.

Another embodiment of the molding process of the present invention for making an articulating leg having first and second leg segments connected by an elongate member is illustrated inFIGS. 26,36,45and48. The elongate member615is formed of a first material and the first and second leg segments605and610are formed from a second material having a melting point lower than the melting point of the first material. In this method, the elongate member615is placed into an injection mold815having a cavity820for forming the first leg segment605and a cavity820for forming the second leg segment610. The elongate member615is positioned in the injection mold815such that the elongate member's first end640is within the first cavity820and the elongate member's second end645is within the second cavity825. The second material is then injected into the mold at a temperature equal to or higher than the melting point of the second material but lower than the first material's melting point.

In this manner, the first and second leg segments are formed around the elongate member615. In one embodiment, shown inFIG. 26, the first leg segment605forms a pivot pin652within aperture650of the first end640of the elongate member615, and the second leg segment610forms a pivot pin830within aperture835of the second end645of the elongate member615. In an alternate embodiment, shown inFIG. 48, first end640of elongate member615comprises disk642and first leg segment605forms circular interior space632capturing disk642while second end645of elongate member615comprises disk910and second leg segment610forms a circular interior space915capturing disk910.

In other embodiments, first end640of elongate member615comprises a disk and second end645of elongate member615comprises a ring defining an aperture (seeFIG. 36) or vice versa (see FIG.45).

Another aspect of the inventive molding process, a method for making a head that is pivotally connected to a lever arm, is illustrated inFIGS. 31-33. The lever arm670has a distal end685defining an aperture680and the head22has an internal pivot pin700extending through the aperture680to pivotally mount the lever arm670to the head22. The method comprises the steps of first inserting the lever arm670into an injection mold830having inner walls defining a cavity835for forming the head22. The lever arm670is formed from a material having a given melting point and is positioned in the injection mold so that the distal end685is located within the cavity835. Next, a sufficient quantity of a first thermoplastic material is injected into the cavity835mold under injection molding conditions permitting the thermoplastic material to fill the cavity835to form the head22and to fill the aperture680to form a pivot pin705extending through the aperture680. This injecting step is carried out at a temperature that is at least 30° C. less than the given melting point of the lever arm.

In another of its aspects, the present invention entails a method for making a body part having pivotable digits, such as a hand102of a toyFIG. 10having pivotable finger members400,402, and404. Referring toFIGS. 12-16, this embodiment of the invention uses injection molding to incorporate into an articulable joint, in situ, an insert piece comprising molded finger members400,402,404. These finger members are each molded of a first thermoplastic material, preferably ABS, generally in the shape of naturally-positioned, relaxed fingers. Finger members400,402, and404, each of which has a proximal end400a,402aand404a, with a respective bore400b,402band404b, extending transversely therethrough for receiving a pivot pin406on which finger members400,402and404are pivotally mounted on the pin, as shown in FIG.14. The pivotally mounted finger members are centered on pivot pin406with clearance at each end of the pin (i.e., between finger member400and pin head408, and between finger member404and pin fastener410). As best seen inFIGS. 13 and 14, the proximal ends of the finger members,400a,402aand404a, have a combined width that is less than the length of pivot pin406. In this configuration having the combination of finger members400,402and404pivotally attached to pin406constitutes a first joint member (pivotally mounted on pin406to be used) as an insert part for injection molding of left hand102. Additionally, a second insert part for injection molding of left hand is provided by wrist joint member412(preferably made of ABS) consisting of shaft414attached at one end to disk416and at the other end to a ring418. Ring418has a bore420therethrough and notches422to prevent relative rotation of the ring with respect to bore liner424(made of second thermoplastic material) which is molded to the ring in an injection molding step. See also FIG.16. Bore liner424increases pivotal friction achieved when hand102is pivotally mounted on pivot pin90of fifth arm segment80during assembly of left arm14to resist unintended movement of joint14f. SeeFIGS. 1 and 2.

As depicted inFIG. 16, left hand102is completed in a vertical injection molding step wherein the exposed ends of pivot pin406(including head408and fastener410) and wrist joint member412are positioned opposite each other in insert mold430having a first cavity432sized and shaped to form the body436of hand102including a thumb438. Hand portion436, the shape of which is defined by the shape of the mold, forms around and captures pin406(preferably encasing pin head408and fastener410) to secure the fingers pivotally to hand436and also forms around shaft414and disk416of wrist joint member412. Second cavity434defines the surface of bore liner424which is formed simultaneously with hand portion436to complete left hand102in the molding process. The injection mold430maintains the finger members400,402and404outside of communication with the cavity of the injection mold so that the material used in forming hand portion436does not fill the areas between the finger members. The molding does, however, form flush with the exposed sides400cand406cof finger members400and406, thereby capturing the ends of pivot pin406along with pin head408and pin fastener410.

Applicants' foregoing description of the present invention is illustrative. Other modifications and variations will be apparent to those of ordinary skill in the art in light of applicants' specification, and such modifications and variations are within the scope of their invention defined by the following claims.