REMOVABLE POSABLE BENDABLE TOY

An over-molded removable posable bendable toy system may have at least two end components anchored to the ends of a posable component. The over-molded removable posable bendable toy system may also have one or more body components movably engaged to the posable component to permit movement of the one or more body components between the at least two end components. An exemplary removable posable bendable toy may be removed from one toy and used in any other toy.

FIELD OF THE INVENTION

The present disclosure relates to toys that are posable, bendable, and comprise a posable component and rigid components that together make a toy that can be used and removed from any other toys or other structures depending on the compatibility between those toys or other structures with the posable component and/or rigid components of the posable bendable toy.

BACKGROUND

Linkages for toy building blocks that use a posable component covered in flexible materials are discussed and disclosed in U.S. Pat. Nos. 9,345,982 and 10,258,897, U.S. Patent Application Publication No. 2017/0056782, and International Patent Application Publication No. WO2016036675. These references teach the need for flexible materials to cover the posable component so that the cover can conform to the bending of the underlying posable component and provide flexible surfaces for connecting to other toy blocks.

Block strings made up of a plurality of rigid links separated by fixed lengths of fabric have also been disclosed, for example, those of the type disclosed in U.S. Pat. No. 6,213,839, and which are marketed and sold as Part Nos. 63141 and x127c41 by Lego®. The rigid links are fixed in position along the string and also cannot be manipulated into a position and remain in that position against the force of gravity (that is they are not posable). Further, the fabric that connects the rigid links also prevents the rigid links from changing their own position along the length of the fabric string (every component of the block string is fixed in place).

Flexible figure toys are also known, such as those disclosed in U.S. Pat. Nos. 280,986, 1,189,585, 1,551,250, 1,590,898, 2,017,023, 2,073,723, 2,109,422, 2,392,024, 2,601,740, 2,684,503, 3,019,552, 3,325,939, 3,284,947, 3,395,484, 3,624,691, 3,955,309, 4,123,872, 4,136,484, 4,233,775, 4,932,919, 4,954,118, 4,964,836, 5,516,314, 5,630,745, 5,762,531, 5,800,242, 6,155,904, 6,217,406, 6,746,303, 6,800,016, 11,103,799, and in publications JP49-18954, JP49-18955, JP61-94090, JP61-94091, JP61-94092, JP62-53686, JP62-164092, JP63-103685, WO99/39793, WO0067869, and WO0010665. Other examples of flexible doll toys and action figure toys are found in U.S. Pat. Nos. 3,277,601, 3,716,942, 4,470,784, 5,017,173, and 6,074,270, and in publication WO0108776. However, each of these disclosures related to bendable toys that permanently embed the posable component in the thickness of the toy such that the posable component, and any associated couplings, cannot be removed without destroying the toy in which they are embedded.

SUMMARY OF CLAIMABLE SUBJECT MATTER

In an exemplary embodiment, a posable bendable toy may comprise a posable component and a plurality of rigid plastic components coupled thereto, wherein the plastic components coupled to the ends of the posable component are fixedly attached and any and all other plastic components found there between are slidable. According to this exemplary embodiment, the posable bendable toy is not permanently embedded in any other structure, but may be interconnected to any toy or other object with surfaces that can connect with one or more of the rigid plastic components found on the posable component of the posable bendable toy.

In an exemplary embodiment, a posable bendable toy may comprise a posable component and a plurality of rigid plastic components coupled thereto, wherein all of the plastic components coupled to the ends and elsewhere, if applicable, are fixedly attached to the posable component but spaced apart from one another. According to this exemplary embodiment, the posable bendable toy is not permanently embedded in any other structure, but may be interconnected to any toy or other object with surfaces that can connect with one or more of the rigid plastic components found on the posable component of the posable bendable toy.

In an exemplary embodiment, a posable bendable toy may comprise a posable component that is fixedly attached to a rigid plastic component via a surface contour. An exemplary surface contour may be the product of crushing of the posable component during the manufacturing process or may be the product of mechanical or manual deformations in the posable component prior to introduction into a molding cavity used to make the posable bendable toy.

In an exemplary embodiment, a posable bendable toy may comprise a plurality of components that can interconnect to the surfaces of one another while each is individually connected via a posable component. According to this exemplary embodiment, the components of such an exemplary posable bendable toy may take a first configuration and then be transformed while still otherwise interconnected via the posable component to achieve a secondary configuration.

In an exemplary embodiment, a posable bendable toy comprised of fixed and movable components may be used as a skeleton for other connections to form different toy constructions and designs. According to this exemplary embodiment, a posable component of an exemplary posable bendable toy may be wound or twisted about the posable component of one or more other posable bendable toys to form a combined structure. Alternatively, a posable bendable toy may have components that may interconnect with other structures to form a shell or cover for the underlying posable bendable toy. Further alternatively, a posable bendable toy may have fabric or other materials removably wrapped, adhered, or looped through or about the posable component and/or the rigid components to create further variations of toy.

In an exemplary embodiment, a posable bendable toy may have a plurality of rigid components molded as one or more types of toy pieces, such as building blocks, figurine body parts, or other ornamental designs, that are interconnected by a posable component. Alternatively, certain of the rigid components may have one type of toy piece and other rigid components may have another type of toy piece. Further alternatively, a plurality of posable components may be utilized to interconnect the toy pieces in any form or variety.

In an exemplary embodiment, a molding method for an exemplary posable bendable toy may include steps to hold the posable component in place within the cavities making up the components and the path for the non-embedded parts of the posable component. One step may be to use parts of the mold to crush, pinch, or frictionally hold one or more sections of the posable component. Alternatively or additionally, the step may use a vacuum to hold the posable component to the mold. Further alternatively or additionally, the step may use magnetism, such as an electromagnet, to hold the posable component to the mold. According to each and any of the forgoing, the posable component may be straightened and finished at its ends (e.g., by deforming them or bending them) prior to insertion into the mold to facilitate anchoring of components that will over mold the same during the molding process.

In an exemplary embodiment, a posable bendable toy may be used as a substitute for any mechanically moving features of any other toys. For example, a rigid component that is molded as a ball may be used in place of a part of a toy that uses a ball-and-socket joint. As another example, a rigid component that is molded with screw threads may be used in place of a part of a toy that can mate with screw threads. As yet another example, a rigid component that is molded with a hook or loop may be used in place of a part of a toy that is sewed together using loops or threads of fabric. As yet a further example, a rigid component that is molded with one or more joints used in Lego®, K'nex®, Flexo®, or any other building block sets may be used in place of a part of a toy that mates with such joints. As yet a still further example, a rigid component that is molded to rotatably engage an opening in a toy or figurine may be used in place of the part of that toy or figurine that would otherwise occupy that opening. As still a further example, a rigid component that is molded in the shape of an accessory for an action figure or doll can be used in place of such an accessory. In another example, a rigid component may be molded into a structure that can attach itself to any other toy or figurine to allow other toys to interconnect thereto.

As used inFIGS.2B,2E,2G,2I,3A-D,3F,6A,10A-B,10K, and11A-C, the symbols “●●●” are meant to disclose the possibility of one or more intervening components2/3and/or lengths of posable component1.

In the drawings like characters of reference indicate corresponding parts in the different figures. The drawing figures, elements and other depictions should be understood as being interchangeable, rearranged, repeated, reduced, changed in size and shape, and may be combined with related features and parts within their respective embodiments and combined and modified by features, whether or not related, in any other embodiments, in any like manner and in accordance with and in furtherance of the teachings and objectives disclosed herein.

DETAILED DESCRIPTION

As may be illustratively provided for inFIG.1, an exemplary posable bendable toy10may be comprised of a posable component1with a first terminus or end1zand at least one second terminus or end1z, where the posable component1interconnects at least two end components3coupled to the posable component1by anchoring within the thickness of component3the portion of posable component1that is embedded in component3, embedded portion1e, and that also contains the terminus1z. Alternatively, the posable component1may further couple one or more body components2such that they are located between the end components3, whereby each body component2also has within its thickness an embedded portion1eof the posable component1. Each of body component(s)2and end component(s)3have internal end faces5that are the sides of the components2/3that intersect the length/axis of the posable component and share an intersection or boundary7, which may be the dividing line between the embedded portion1eand the exposed length of an exemplary posable component1. All other portions or lengths of posable component1beyond the boundaries7of a particular body component2and/or end component3may be referred to herein as exposed portions of posable component1. Exclusive to end component(s)3may be the existence of at least one free end face6, which is a face that intersects with the axis that is orthogonal to the cross-section of the posable component that has no corresponding boundary7. According to an exemplary embodiment of an exemplary posable bendable toy10illustratively provided for with respect toFIG.1, a space8may exist between every internal face5of either end components3and/or body component2. While in a preferred embodiment, the space8may be equal all about posable bendable toy10, as will be further disclosed, sliding movement of body components2along the length of posable component1may cause space8to become larger, smaller, or non-existent (e.g., the internal faces5of adjacent components2and/or an internal face5of component3and an internal face5of a component2are in physical contact with one another or abutted). In an exemplary posable bendable toy10, the embedded length of posable component1found between free end face6and internal end face5of the end component3, i.e., the embedded length having the terminus1z, may be referred to herein as the “terminal region.”

In accordance with an exemplary embodiment, an exemplary space8may be substantially the same as the length of exposed portions of posable component1between boundaries7. Alternatively, an exemplary space8may comprise a combination of unequal lengths of posable component1between an end component3and a body component2or between two body components2, such as, for example, a larger than average section8+ and a smaller than average section8−. For irregularly shaped end faces5, an exemplary space8may be calculated by measuring the distance between the closest points between each of the end faces5.

As may be illustratively provided for inFIG.1, an exemplary posable bendable toy10may have one or more features (1b,1c,1d,1x,1*) on the posable component1and/or one or more features such as item4on the component3that enable or are configured to effect anchoring between the component3and the posable component1. With further reference to the illustrative embodiments ofFIGS.2A-IandFIGS.3A-Fan exemplary component3may be anchored to the posable component1of an exemplary posable bendable toy10via one or more of the following structures that may function either as the terminus1zof the posable component1and/or be located adjacent to the terminus1zalong the posable component's longitudinal axis11in the terminal region: (i) a bent portion1b(FIGS.1,2A-B, and3B); (ii) a crushed portion1chaving one or more crushed sections1* (FIGS.1,2A-E,3A-B, and3D-E); (iii) a deformed portion1dwith one or more deformations1xand/or extensions1w(FIGS.1,2D-G, and3C-E); (iv) a residual portion1r(FIGS.2A-E,3A-B, and3D); (v) an orifice to (FIGS.2H-I. an3F); (vi) a pit1p(FIGS.2H-Iand3F); (vii) a twist1t(FIGS.2H-Iand3F); (viii) an underside1u(FIGS.2A-B,2E,3A-B, and3D); and (ix) combinations (such as combinations with a straight portion1s(FIGS.2C-G,3A, and3C-D)), patterns, angular conformations (such as shown inFIGS.3D-E) of each of (i)-(viii). In contrast to the end component3of an exemplary posable bendable toy10, an exemplary body component2may not have any of the foregoing structures on the embedded length1efound between its faces5, thereby enabling an exemplary body component2to displace, e.g., slide and/or rotate, along and/or about the length of the posable component1. In an alternative embodiment, one or more exemplary body component(s)2may have the same or similar features (i)-(ix) previously indicated in this paragraph in conjunction with the exemplary end component(s)3of the exemplary posable bendable toy10, as may be illustrated inFIGS.2H and3F. Accordingly, any component2/3may have one, a combination, or a pattern (including random patterns or otherwise) of the features (i)-(viii) in the embedded portion1efound in its material thickness. According to an exemplary embodiment, the increased variety, number, and dimension of each of the foregoing features may increase the anchoring between posable component1and end component3. According to another exemplary embodiment, the increased variety, number, and dimension of each of the foregoing features may also increase the anchoring between posable component1and body component2.

With reference toFIGS.1,2A-B, and3B, an exemplary bent portion1bof embedded component1emay be bent at an angle12to axis11that is between +/−90° or bent at an angle13to axis11that may be greater than or equal to +/−91°. An exemplary bent portion1bmay work as an alternative to or in conjunction with crushed portion1c, straight section1s, or deformed portion1dto further anchor posable component1within end component3. According to embodiments in which an embedded posable component bend1bis described or illustrated, the degree of bending of bent portion1bmay enhance the robustness of the anchoring connection between component3and embedded portion1e. For example, a bent portion1bthat creates a J-shape in the posable component1, such as shown inFIGS.1and2A-B, may provide an additional anchoring configuration between component3and embedded portion1e. Further, the more turns that bent portion1bmakes in three-dimensional space, e.g., hoop-like turns or knots, the more robust the anchoring between posable component1and component3.

In a yet further exemplary embodiment, an exemplary terminal region may have one or more of the bent portion1b, crushed portion1c, deformed portion1d, residual portion1r, twist1t, underside1u, and orifice1ooriented at an angle14with respect to one another about axis11.FIG.3Emay illustrate the potential angular offset between crushed portion1cand deformed portion1dabout axis11in an illustrative embodiment related toFIG.3D. According toFIG.3D, an exemplary plane intersecting the center of cross-sectional thickness of an exemplary deformed portion1d, plane P1, may be angularly offset by angle14from the plane intersecting the center of the cross-sectional thickness of an exemplary crushed portion1c, plane P2. Where the surfaces of1* and1xmay be irregular such that no central cross-section can be determined, plane P1may be the plane that is parallel with the surface of1xthat is closest to axis11and plane P2may be the plane that is parallel with the surface of1* that is closest to axis11. WhileFIGS.3D-Eillustrate an exemplary angular offset between a crushed portion1cand a deformed portion1d, any of the aforementioned structures may be angularly off-set in combinations to achieve increased anchoring between posable component1and a particular component2/3.

According to an exemplary embodiment, crushed portion1cmay be the result of the posable bendable toy10manufacturing process to be discussed with reference toFIGS.8A-E. Crushed portion1cmay be pinched, flattened, nicked, dented, bent, or otherwise deformed by the posable bendable toy10manufacturing process. An exemplary crushed portion1cmay be a portion of a posable component1that is both narrower in thickness but wider in width than other embedded portion1eor any other portions of posable component1. Crushed section1* may have a cross-section that differs from the cross-section of the embedded portion1eand may also have a different surface than that of the embedded portion1e. As further illustrated inFIGS.1and2A-E, an exemplary crushed section1* of an exemplary crushed portion1cmay be a flattened cylindrical shape, although other shapes may be possible depending on the geometries of the crushing mechanisms used in manufacturing posable bendable toy10. In those embodiments in which a crushed portion1cmay be described or illustrated, an opening4may be found through the thickness of an exemplary end component3. As may be illustrated inFIGS.2A-Eand3A, an exemplary crushed portion1cmay separate an opening4into a portion4A that may provide a line of sight through the material thickness of end component3to the crushed section1* and/or a portion4B that may provide a line of sight through the material thickness of end component3to underside1u. While an opening4may be found in an exemplary end component3having a crushed portion1ctherein, an opening4may be found in any exemplary body component2having a crushed portion1ctherein.

As may be illustrated byFIGS.2A-E,3A-B, and3D-E, an exemplary residual portion1rmay be located on either side of crushed section1* closest to the embedded portion1eof the posable component1nearest to opening4. Residual portion1rmay be the resultant of the processes that result in crushed portion1cand crushed section1*, such as those inFIGS.8A-E(items104/204). In an exemplary embodiment, residual portion1rmay be concentric with opening4. In another exemplary embodiment, residual portion1rmay be co-radial with opening4. In yet another exemplary embodiment, residual portion1rmay perfectly surround the opening4. In an exemplary embodiment, residual portions1rmay work with crushed portion1cto ensure that the terminal region of embedded portion1eof the posable component1is securely anchored within the end component3in which the structure exists.

In an exemplary embodiment, crushed portion1cmay be thinner and wider than embedded portion1e, such as, for example, between 25% and 75% of the thickness of embedded portion1e, while being between about 105% and about 150% as wide. In another exemplary embodiment, crushed section1* may have a surface and/or indentation that is roughened, bowl-shaped, conical, or substantially smooth. Thus, in an exemplary embodiment, an exemplary crushed portion1c, due to its dimensions and surfaces, may be prohibited from passing boundary7of the internal face5of the component2/3. In one aspect of this exemplary embodiment, the inability of crushed portion1cto translate through component3may advantageously prevent posable component1, and in particular embedded portion1e, from being dislodged from end3while an exemplary posable bendable toy10is operated.

In contrast to the crushed portion1c, bent portion1b, deformed portion1d, twisted portion1t, and straight portion is may be pre-formed on or into the posable component1prior to the manufacturing process illustrated inFIGS.8A-E.

According to embodiments in which a straight portion1sis described or illustrated, such as inFIGS.2C-G,3A, and3C-D, straight portion1smay be at a slight angle (about +/−1° to about +/−55°) to axis11provided its length at that angle is substantially straight. Any disruption in the linearity of the embedded portion1ein the terminal region would mean that there is no straight portion1s, but a bent portion1b. An exemplary posable component1may have a straight portion is that may be much shorter in length than exemplary bend section1b.

According to embodiments in which a deformed portion1dis described or illustrated, such as inFIGS.1,2D-G, and3C-E, deformed portion1dmay comprise at least one deformation1xeither acting as the terminus1zof the posable component1or the deformation1xmay be separated from the terminus1zby a distance, such as, for example, a straight portion1s. In a preferred embodiment, the deformation1xis the terminus1zfor the posable component1. An exemplary deformation1xfound in the deformed portion1dmay further comprise a deformation extension or wing1wresulting from the particular deformation1xforming process. For example, deformed portion1dmay be formed using finishing processes known to those skilled in the art, such as flattening, denting, crimping, pinching, knurling, bending, twisting, or any other such posable component1cutting and finishing processes used and practiced by Novo Precision of Bristol, Conn. As may be further illustrated inFIGS.2D-Gand3C-E, an exemplary deformed portion1dmay take the form of a pinch or flattened piece of the terminal region cross-section of posable component1. In an exemplary embodiment, the deformed portion1dmay be made to a posable component1that has been straightened, cut to length, and/or otherwise treated by wire straightening and cutting machines known to those skilled in the art, such as the #2 SFC Pneumatic Feed and Cut to Length System from Novo Precision of Bristol, Conn. By straightening the posable component1prior to making the deformation1x, the deformed portion1dmay be substantially aligned on axis11to avoid interference with the edges of an exemplary mold in which the deformed portion1dmay be placed and from which the final exemplary posable bendable toy10may be removed.

Alternatively, an exemplary deformed portion1dand deformation1xmay be applied manually or through automated pressing processes, including via use of hammers, pliers, punches, and dies, on a straightened length of posable component1. An increase in surface area of an exemplary deformation1xand/or extension1wmay have a direct effect on the robustness of anchoring between the final exemplary end component3and the terminal region of the posable component1in which the deformation1xmay be located. In an exemplary embodiment, use of a deformation1xwithin an exemplary end component3and one or more body components2may create robust connections between the over-molded structures and the posable component1so that each component3/2in the system remains in substantially the same spaced relationship (e.g., substantially the same space8throughout and/or no slack space8+, no reduced space8−, no abutment contact8&). Such an exemplary embodiment may be useful in the design of figurines and action figures using the posable bendable toy10disclosed.

As illustratively provided for inFIGS.1,2F-G, and3C, a deformation1dmay be the only deformation found on posable component1, that is, an exemplary posable bendable toy10may exist without any crushed portion1c, but would instead use deformation portion(s)1dfor substantially the same component2/3anchoring purposes. An exemplary deformation1xmay be substantially the same as an exemplary crushed section1* or it may be different in dimension, size, and angle about axis11. For example, deformation1xmay have an extension wing1wthat extends radially beyond the radius of posable component1and/or a width of crushed section1*, if such a crushed portion1cis present. Alternatively, a portion of bent portion1bmay comprise all, some, or none of deformed portion1dand/or deformation1xand/or deformation extension1w. In embodiments where portion1dis not terminus1z, an exemplary1dmay be offset from terminus1zby between about 0.5 mm and 4.0 mm, preferably about 1.0 mm and 3.0 mm, and even more preferably about 2.0 mm. In an alternative embodiment,1dmay be located on posable component1in a position that places it at distance that is between about 25% to about 75% of the length of the terminal region, preferably about 50% of the length of the terminal region. Furthermore, an exemplary deformation1xmay be between about 0.75 mm and 3.5 mm in axial length. In an exemplary embodiment, as either the axial length or width of an exemplary deformation1xincreases, the robustness of the anchoring of posable component1within end component3may also increase. In a preferred embodiment, the deformed portion1dmay occupy less than half the total length of the terminal region within an exemplary end component3. An advantage of using embodiments with only deformation portion1din the terminal region as the terminus1zor adjacent thereto is a reduction in length of posable component1to affect proper anchoring with end component(s)3. As may be illustratively provided byFIGS.1,2F-G, and3C, use of deformed portion1dand deformation1* may simplify the manufacturing process of an exemplary posable bendable toy10, e.g., space reduction $ in material needed for an exemplary end component3. Additionally, an exemplary bendable toy10using an exemplary deformation1* may avoid the need for any manufacturing process to form a crush portion1con a component3/2. Further additionally, use of deformation1* may avoid the need for an opening4in any component3/2in the finished posable bendable toy10.

Referring to the illustrative embodiments ofFIGS.2H-Iand3F, an exemplary posable bendable toy10may have no opening4in its end components3because posable interwoven component1imay be adequately anchored in component3due to its composition as a helix of multiple posable components, such as wires, being wound together. According to this exemplary embodiment, as illustratively provided for inFIGS.2H-Iand3F, an exemplary posable interwoven component1imay have a plurality of twists1tand pits1pinto which the material of an exemplary end component3and/or body component2may engage upon over molding. In some embodiments, posable interwoven component1imay have an orifice to into which material of an exemplary end component3and/or body component2may flow into and/or through during over molding. Like the deformed portion1dinFIGS.1,2D-G, and3C, an advantage of using embodiments illustratively provided byFIGS.2H-Iand3F may be the reduction in the amount of posable component length needed within an exemplary end component3, that is, less material of component3may be needed to anchor the component to the posable interwoven component1i. A further advantage of using embodiments ofFIGS.2H-Iand3F may also be to forego use of pre-formation deformation processes on posable component1while creating sufficient surface features (e.g., twists1tand pits1p) into which over-molded material can anchor.

By shifting one or more body components2of an exemplary posable bendable toy10around and about the posable component1through creation of slack spaces8+, reduced spaces8−, and contacts8&, such as inFIGS.4A-C, an exemplary posable bendable toy10may thereafter be further manipulated to form constructions from its own constituents and/or enable a wide variety of constructions not otherwise achievable with other building blocks. As may be understood from the disclosures related to each ofFIGS.4A-E, properly shaped body components2and/or end components3may be used to create transforming building blocks and/or transforming figures and other toys due to the unique ability to fold into and around one another while staying together about the posable bendable component1to which they are coupled. According to these exemplary embodiments, such exemplary posable bendable toys10may provide new ways to build transforming toys without the associated need for separate moving parts required such as gears, screws, and separate joining mechanisms. Alternatively and/or additionally, the transforming effect previously described may also be used for building blocks. Thus, a car or truck built of a building block, e.g., Lego® blocks, may be built of one or more posable bendable toys10such that they can be folded and unfolded to reveal an alternative toy comprised of the body components2and end components3used therein, e.g., a robot or figure. Thus, an exemplary posable bendable toy10having body components2and end components3shaped as different parts of figurines or robots can also be capable of transforming from one shape to another through twisting, turning, and shuffling of its constituent components2/3via creation of spaces8,8+, and8−, and contacts8&.

Depending on the type of body components2involved, a contact8& may be the surface contact between faces5or it may involve friction-fit and/or interlocking arrangements between features in faces5(e.g., snap-fit, hook, ball-socket, plug, Lego-like stud-and-cavity connection). Accordingly, a user of an exemplary posable bendable toy10may “build” structures out of its components by making contacts8& along the length of posable component1and constructing one or more combiner bodies22that can combine with one or more other body components2, end components3, and/or combiner bodies22of the same posable bendable toy10or different posable bendable toy10. In an exemplary embodiment, the spacing8dimensions of an exemplary posable bendable toy10may be such that for a linkage of “n” components, the following formula may apply: (n−1)*8=Σ(8−, 8+, 8).

Referring to the illustrative embodiments ofFIGS.4A-E, an exemplary embodiment of a posable bendable toy10may involve components2and3that may each be exemplary snap-fit interconnecting building blocks. According to this exemplary embodiment, an exemplary posable bendable toy10may be comprised of end components3(a) and3(b), which may be an exemplary Lego Item No. 3004 and Lego Item No. 3010, respectively. However, as illustrated inFIGS.4A-E, an exemplary end component3(a) may be molded to posable component1so that its studs (which are hereinafter referred to as a type of extension25from a body2and/or end3) are in the same plane as the cross-section of posable component1. An exemplary end component3(a)/3(b) may be molded to posable component1using any of the structures and methods disclosed herein. In contrast, as shown inFIGS.4A-C, the studs25of an exemplary end3(b) may be perpendicular to the axis passing through the cross-section of posable component1. Exemplary body components2(a),2(b), and2(c) may be the same or different bricks as mentioned, or any others known to those skilled in the art. Further, an exemplary posable component1may enter and exit from each such building-block shaped body2(a)-(c) at different locations that can vary from body component to body component. As may be further illustrated inFIG.4A, the spacing8between all of the ends and body components of the exemplary linkage are substantially the same.

In an exemplary transformation process illustrated byFIGS.4B-E, the exemplary posable bendable toy10ofFIG.4Amay have its ends3(a)-(b) and body components2(a)-(c) moved either around and/or along axis11of an exemplary posable component1. As provided by the white arrows, body2(a) and2(b) may each be rotated 180° about posable component1while body2(a) may be brought closer to end3(a) and body2(b) may be brought closer to body2(c) or stay at the same distance. An exemplary body2(c) may be moved closer to end3(b). During this process, in particular at the point in time during which the configuration illustrated inFIG.4Cresults, an exemplary end component3(a) and body2(a) may form a combiner body22while a slack space8+ forms between body2(a) and body2(b). According to this exemplary embodiment, the space8between body2(b) and body2(c) may remain so long as a sufficient amount of posable component1exists to accomplish the construction step. Further according to this exemplary embodiment, the prior space8between body2(c) and end3(b) may be shortened to become reduced length8−.FIG.4Cmay also provide for folding steps41,42, and43, which by way of the arrowhead direct the folding of body components2(a)-(c) and folding of end3(b) using the possibility of the posable component1. Thus, according to step41, body2(b) may be flipped on top of the underside of body2(a). According to step42, body2(c) may be flipped on top of the extensions25of body2(b) while end3(b) is not yet stabilized in place. Finally, according to step43, the exemplary end component3(b) may be bent at a substantially right angle so that a narrow space in its connection cavity9opposite its extensions25may be used to cover any excess posable component1and keep it out of sight. For the sake of clarity, an otherwise exposed posable component1does not become an embedded portion1emerely because it is kept out of sight unless in the process of being kept out of sight it is simultaneously embedded within a component2/3. Depending on the shape and contour of a particular body2and/or end3, an exemplary posable bendable toy10may be capable of being bent, rotated, and/or folded in such a way to form numerous contacts8& between its constituent components2/3and in the process “hide” the exposed posable component portion1and/or cause it to be “tucked” out of view of the resulting combiner body22using a face cavity9.

FIGS.4D-Emay provide illustrative embodiments of a novel construction or toy30that may be formed from the conversion process discussed with respect toFIGS.4B-C. InFIGS.4D-E, an exemplary construction toy30may be propped up by ends3(a) and3(b) while the extensions25of body2(a) face the support surface for the ends3(a)-(b). According to this illustrative embodiment, bodies2(b) and2(c) may be snap-fit with one another while end (3b) may be folded down so that a cavity9opposite the side of3(b) bearing the extensions25may conceal the portions of posable component1that were used to fold body2(b) on top of body2(a). As is shown via transparency inFIG.4E, each section of posable component1embedded in a body2(a)-(c) and an end3(a)-(b) is an embedded portion1e. However, as shown in the ovular dashed-line call-out nearest to end3(b) inFIG.4E, the posable component1that is concealed by end3(b) is not an embedded portion1e, but would be exposed but for the cavity9into which it may be snuggly fit. Where the components3(a)-(b) and bodies2(a)-(c) are not building blocks, but elements of a vehicle or another structure, the posable bendable toy10to which they are affixed may allow for the vehicle or structure to take two or more forms just by twisting and manipulating the posable component1to which all the components3(a)-(b) and2(a)-(c) attach.

As shown and disclosed herein, an exemplary posable bendable toy10may be bent into numerous conformations: curves, zigzags, arches, rectilinear bends, right angle bends, spirals, curls, twists, sinusoids, and combinations of the same, such as may be illustrated inFIGS.1,4D-E,5A, and6A-B. With reference to the illustrative posable bendable toy10shown inFIG.5A, an exemplary slack space8+ may be the result of translating body2components away from one another or away from an end component3. An advantage of an exemplary slack space8+ may be to allow for conformations in posable bendable toy10that may not otherwise be possible if body components2remained at spaces8from one another and/or ends3, such as wrapping an exemplary posable bendable toy10about an object or permitting a twist1twith another posable bendable toy10, as illustrated inFIGS.6A-B. Additionally, slack space8+ may be reduced in size to an exemplary space8after a desired conformation of posable bendable toy10is achieved. Another benefit for slack space8+ may be to allow sharp turns and twists in the posable bendable toy10that may not otherwise be permitted when a space8is in existence. Thus, by virtue of the ability of its components2to freely translate about posable component1, an exemplary posable bendable toy10may be able to shift its components2to enable it to increase the number of different conformations it may take in space. The ability of the various end components2to translate about posable component1may provide an advantage of increasing the number and variety of posable configurations achievable with a particular posable bendable toy10. In one aspect, body components2may be moved along the posable component1by translation, twisting, revolving, or other means of moving known to those skilled in the art depending on the particular posable component1. For example, where posable component1is an annealed wire, an exemplary body component2may slide along the length of the posable wire1. As another example, where posable component1may be a formation of different materials interwoven together, an exemplary posable interwoven component1i, then an exemplary body component2may be turned like a screw to go up and down the length of posable interwoven component1i. In an exemplary embodiment, the material of component2and the material of posable component1may be such that there is sufficient friction between the two to allow the component shift to be controlled and the component2to be able to retain its shifted position either obtained by translation or rotation about the length of the posable component1.

In another exemplary embodiment, an exemplary posable component1may be hidden from view via one or more cavities9in the surface of face5of a body2and/or end3. In another exemplary embodiment, an exemplary posable component1may be able to make tighter bends based on particular surface features in face5of body2and/or end3. As may be illustrated inFIGS.5B-G, a variety of potential surface features may increase the maneuverability of posable component1with respect to the body2or end3from which it emerges. For example,FIG.5Bmay illustrate a body2or an end3with a funnel-like boundary7. An exemplary funnel-like boundary7may permit for greater curvature by an exemplary posable component1and to allow such curvature to start before posable component1reaches the surface5of the body2and/or end3.FIGS.5C-Deach shows an exemplary cavity9running the width of face5, whileFIG.5Dshows one additional exemplary cavity9* that may be orthogonal to cavity9. According to an exemplary embodiment, cavity9/9* may be one half the width of an exemplary posable component. Alternatively, cavities9/9* may be deep enough into surface5to completely hide a posable component1. As Illustrated inFIGS.5C-D, those skilled in the art would understand a plurality of angular arrangements between the cavity9and cavity9*, such as acute angles and overlaps, spirals, and/or other labyrinthine grooves in face5. As illustrated inFIG.5E, an exemplary body2/end3face5may have the boundary7surrounded by one or more cavities9cinto which excess posable component(e.g., slack space8+) may be pushed so that a contact8& may be formed between the instant face5inFIG.5Eand another adjacent face5(not shown). As may be illustrated inFIG.5F, an exemplary pair of cavities9cmay be combined with an exemplary cavity9* so that the groove of9* intersects with cavities9c. And while boundary7may show a circular opening, any other polygonal opening may be utilized depending on needs, such as hexagonal chamfered opening7inFIG.5G. Any of the embodiments illustratively disclosed with respect toFIGS.5B-Gmay be interchanged, increased in size, number, frequency, and proximity of one another and/or may be used in any variety or combination about one or more sides of an exemplary body component2and/or end component3.

Alternatively, an exemplary posable bendable toy10may be wound or wrapped about another posable bendable toy10via its posable component1segments between each body component2and/or between each body component2and end component3, as may be illustrated inFIGS.6A-B. According to the illustrative embodiments ofFIGS.6A-B, a single exemplary posable bendable toy10A may be a scaffold for connecting numerous other exemplary posable bendable toys10, such as, for example, illustrated posable bendable toy10B, to form a combination20. According to another exemplary embodiment, posable component1belonging to posable bendable toy10B may be connected to posable bendable toy10A via a twist1tabout the posable component1of posable bendable toy10A. Accordingly, each of posable bendable toys10A and10B may be stably held in place between the faces5of each body2and/or ends3within the locus of twist1t. The tightness of the twist1tmay dictate the rigidity between the posable bendable toys10A and10B to allow the combination to stably maintain each of their bent configurations in space. Alternatively, the friction between components2/3implicated in any twist1tmay enhance the rigidity between posable bendable toys10A and10B. For example, exemplary components2/3may form snap-fit arrangements whenever engaged in or part of a twist1t. Moreover, a plurality of posable bendable toys10A/10B may be coupled in posable component-wrapping arrangements to form combination20.

Posable component1may be any type of bendable wire that can be bent with a minimal amount of force while still being capable of maintaining the last position it was in after being bent, in particular, it can hold its bent position against the forces of gravity. As one example, one such type of wire may be rated “dead soft” or modelling wire, which may be used to create figurines in the sculpting arts (also referred to as “armature wire”). An exemplary wire1may be sized and shaped appropriately for the particular linking applications and methods disclosed, and may have cross-sections that are round, half rounded, square, or other polygonal cross-sections. Typical appropriate wire1material may be made out of steel, aluminum, bronze, copper, oxidized copper, galvanized steel, and alloys of the same. A preferable wire1material may be galvanized annealed steel, such as type made in accordance with ASTM A641. Such wire1material may be between 30 AWG and 14 AWG, and preferably, 18 AWG and/or 1.01 mm (0.0402 in.) outer diameter. In alternative embodiments, wire1may be a combination of smaller diameter wire that is twisted or formed into a helix, such as, for example, a twisted helix of two dead soft 30 AWG wires, and/or the posable interwoven component1iillustrated inFIGS.2H-Iand3F. In further alternative embodiments, wire1may be electrically conductive, magnetic, non-conductive, non-magnetic or combinations of the same to enhance uses of the posable bendable toy10. In an aspect of the two aforementioned wire embodiments, an exemplary posable interwoven component1imay be a twisted helix of one magnetic wire of one gauge and another wire that is not magnetic. In yet another aspect, the posable interwoven component1imay be composed of a plurality of metal wire constituents and/or non-metal components, such as, for example, a yarn, string, or fabric constituent, a dissolvable constituent, such as a poly-vinyl alcohol (PVA) yarn, string, tape, or thread, a low-melting point constituent, or combinations of the same. According to this exemplary type of hybrid posable interwoven component1i, an exemplary fabric constituent may allow material being over-molded onto the posable interwoven component1ito embed itself into the pores of the fabric and thereby hold to the fabric and metal wire constituents simultaneously. According to another exemplary embodiment of a hybrid posable interwoven component1i, an exemplary dissolvable constituent may be dissolved in response to material engaging the rest of posable interwoven component1iduring the posable bendable toy10forming process and, in dissolving, provide gaps or voids1owithin the posable interwoven component1ihelix to allow material making up the posable bendable toy10components to flow through and/or adhere (e.g., see orifices to inFIGS.2H-Iand3F).

In an alternative embodiment, the portions of wire1that are not embedded in a body component2or an end component3may be exposed so as to be in contact with the fingers of a user and/or may be coated with flexible material, such as a rubber or silicone. It is preferred that any such coating does not restrict or impede the ability of wire1, component2, and/or component3to achieve a desired conformation. In other words, according to this preferred embodiment, if wire1, component2, and/or component3would achieve a substantially different conformation in the absence of wire1coating, then the coating thickness may be too thick. In an exemplary embodiment, the coating of flexible material on exposed portion of wire1may be no greater than about 0.1% to about 5% of the thickness of the exposed wire1portion. In another exemplary embodiment, the coating of flexible material cannot exceed the thickness of either component2and/or component3. Posable component1may be a substantially smooth wire or may be knurled, stamped, or otherwise acted upon to create contours or deformations1xin its surface prior to introduction into the components2/3, posable bendable toys10, and systems/combinations/constructs disclosed herein. For example, an exemplary wire1may be pinched, knurled, or stamped at any point along its length, but preferably near its terminal ends, prior to being used or positioned in an exemplary mold for making an exemplary posable bendable toy10.

An exemplary body component2may be made of one or more of the following moldable materials, including, but not limited to, PMMA, ABS, PA, PETG, PS, PC, PP, PE, PEEK, PET, PLA, cyanate esters, epoxies, polyesters, polyurethanes, silicones, rubbers, vulcanized rubbers, aluminum, bronze, steel, alloys, and combinations of the same. An exemplary end3may be made of the same or a similar material as body2. Additionally, any of the aforementioned materials may be in any color known to those skilled in the art and include their translucent, transparent, clear, and combined versions of the same. In an exemplary embodiment, the material used in posable bendable toy10components2and3may be optically clear, translucent, capable of glowing in the dark, capable of changing color in response to one or more of heat, pressure, liquid, or other chemical interactions, and/or combinations of the same. In a preferred embodiment, each body2and end3is a rigid component of posable bendable toy10, preferably made of ABS or high impact polystyrene. Alternatively, each body2and end3may be made out of a recyclable plastic material.

An exemplary body component2and/or end3may be cylindrical in shape or have any other circular or rounded cross-section, polygonal cross-section, e.g., any cross-section with a shape having n+3 sides (where n is an integer ≥0), or combinations of the same. Further, any of ends3and/or bodies2may be spherical, polyhedron, combinations of the same, with or without additional fillets and/or chamfers on one or more surfaces or edges. Alternatively, ends3and/or bodies2may possess any number and combination of potential surface contours (in addition to or instead of those illustrated inFIGS.5B-G): threading for screw-like attachments, domed or balled portions for ball-and-socket joints, circular bumps, longitudinal ridges, finned sections, hooks, tabs, snap-fit extensions (either indentation or the hooks themselves), hoops, and holes (either partially into the thickness of the component or a through-hole). Additionally, ends3and/or bodies2may be amorphous forms shaped for particular needs as are disclosed herein. In an exemplary embodiment, the cross-section of component2and/or end3may be such to allow it to friction-fit within an opening in a building block known to those skilled in the art, such as, for example, the circular hole of a Lego® Erling brick (Lego® Design ID Nos. 4070, 4070a, 30069, and 35388) and/or the circular hole of an exemplary Lego® technic brick (Lego® Design ID Nos. 6541, 3700). According to the aforementioned exemplary embodiment, the diameters of such openings in such building blocks are approximately 3.2 mm to approximately 4.8 mm. Thus, while faces5/6are illustrated as substantially circular and flat faces of cylindrical ends3and cylindrical bodies2inFIGS.1,2A-I,3A-F,5,6A-B, and6E-G for example, faces5/6may be any shape or shapes in combination and/or may have contours and surfaces that are not flat and/or may be irregular, such as inFIGS.5B-Gand9C-D.

Alternatively, as shown inFIGS.4A-Eand9C-D, body2and/or end3may have more complex three-dimensional shapes, such as the shape and dimensions of building blocks known to those skilled in the art, such as, for example, Lego® blocks or bricks and their variants, K'nex, PicassoTiles®, Duplo®, Rasti blocks, Flexo, Brix Construx, and magnetic building blocks. According to this alternative, body2and/or end3may take the form of any existing Lego® brick. Further alternatively, end3may be one size and type of shape or building block and body2another size and type of shape or building block, such as, for example, a Lego® brick end3followed by a K′nex part as a body2of the posable bendable toy10. Accordingly, body2and end3may be one or more of the foregoing sizes, shapes, and brick types and geometries to enable posable bendable toy10to be combined and/or used with any building block known to those skilled in the art and/or other type of toy, whether or not a building block. For example, end3may be shaped to be held by an action figure while a first body2may be shaped to connect with a Lego® block, a second body2may be shaped to connect to a Flexo block set, a third body2may be shaped to hold a pencil used for writing, and the opposing end3may be designed as a plastic insert shaped to fit within a power port for a smart phone or other electronic device (e.g., USB or USB-C) or another port found on similar devices (e.g., audio jacks, HDMI ports, ethernet ports, telephone ports, coax cable ports, and/or wall outlets). Accordingly, the variability of the body components2and end components3may increase the versatility and enjoyment of the posable bendable toy10.

Further alternatively, an exemplary body2and/or exemplary end3of a posable bendable toy10may be shaped as a part of an action figure in whole or in part provided that the action figure does not inhibit the possibility of the exposed parts of the exemplary posable component (such as illustrated inFIG.9C). For example, an exemplary end3may be shaped in the form of a hand, a plurality of exemplary body components2may be shaped in the form of the wrist, forearm, elbow, and upper arm, and the other exemplary end3may be the shoulder. As another example, each exemplary end3may be shaped in the form of a foot and a plurality of exemplary body components2may be portions of a leg on either side of a body component2shaped like a torso. As yet another example, exemplary end3may be the head of a dinosaur and the other exemplary end3the tip of the tail. According to the immediately aforementioned example, the plurality of body components2may be shaped like the neck, body and tail of the dinosaur whereby one or more of the body components2also allow for interconnections with another linkage that is for the arms and hands, while another linkage forms the legs and feet. The person of ordinary skill in the art can take any figurine, doll, or known plaything and design it so that each of its parts may be segmented (e.g., separated by lengths of exposed wire1) and made into a series of individual or interwoven posable bendable toys10.

The exemplary posable bendable toys10,10A, and10Baccording to the illustrative embodiments ofFIGS.1,2A-I,3A-F,4A-E,5A, and6A-B and their related and interrelated disclosures may be made from plastic injection over-molding of the embedded posable component1(or other like processes known to those skilled in the art, such as for example, ABS injection molding) as may be illustrated inFIGS.7A-Eand8A-G or by embedding the posable component1through additive manufacturing, as may be shown inFIGS.12A-E.

Where injection molding is used to manufacture an exemplary posable bendable toy10, the exemplary posable bendable toys10described may be injection molded in either horizontal or vertical presses. As an injected molded product, an exemplary posable bendable toy10may be fabricated using a plurality of mold structures and mechanisms. Any machinable or moldable materials and methods known to those skilled in the art may be used to fabricate the molds and components disclosed herein, such as aluminums, steels, or particular polymers and elastomers. To the extent an element of an injection mold is not expressly stated for any particular embodiment, such as, for example, cooling channels, release contours, or surface treatments, those skilled in the art would understand that such element is inherent in injection molding technologies or injection molding methods and should be considered to also be present in any of the embodiments and disclosures illustrated and/or described with respect toFIGS.7A-Eand8A-G. Those skilled in the art would understand the design and implementation of the peripheral components used in such injection molds and mechanisms to take plastic in raw form (pellets or liquid) and inject it into the mold constructs illustratively and otherwise disclosed herein. What follows are disclosures of the exemplary inventive molds for injection molding of exemplary posable bendable toys10.

An exemplary mold base100may be illustrated byFIG.7A. An exemplary mold base100may comprise a working face100ain which there may be (i) one or more orientation zones140to allow for orienting with adjacent mold parts; (ii) one or more alignment cavities143-144for use in placement of a posable component1within the mold base100by automated or manual placement means; and (iii) a work zone110where one or more exemplary posable bendable toy10is manufactured. Opposite the working face100ais the rear face100b, which may be the foundation for other mechanisms used in an exemplary manufacturing process. An exemplary cover mold200may be illustrated byFIG.7B. An exemplary cover mold200may comprise a working face200ain which there may be (i) one or more orientation zones140to allow for orienting with adjacent mold parts and (ii) a work zone210where an exemplary posable bendable toy10is manufactured in conjunction with mold base100. Opposite the working face200ais the rear face200b, which may have additional features similar to rear face100bof mold base100. In an exemplary embodiment, where mold base100is immobile in an exemplary mold press (horizontal or vertical), then mold cover200is mobile. According to this exemplary embodiment, an exemplary immobile mold base100may contain one or more features in the working zone110to hold posable component1therein independently of or in conjunction with mold cover200during the injection molding process. In another exemplary embodiment, the aforementioned mobile and immobile roles of mold base100and mold cover200may be interchanged and/or shared with any other mold components depending on the surfaces necessary to make an exemplary posable bendable toy10. According to the aforementioned exemplary embodiments disclosed with respect to mold cover200, an exemplary mold cover200may provide the equal and opposite halves of each of the structures in mold base100and/or working zone100a.

With reference toFIGS.7A and7C, an exemplary working zone110may comprise half cavities102and103that are interconnected by channels107through cavity partitions108. An exemplary half cavity102may have two walls105, one adjacent to each channel107flowing into the half cavity102. An exemplary half cavity103may have a wall106, for which there is no channel107, and a wall105, which like wall105for half cavities102, is adjacent a channel107flowing into half cavity103. As further illustrated inFIG.7A, a crush pin104may extend upwardly from a surface of half cavity103, although an exemplary half cavity103may not have any such crush pin extending upwardly from its surface. An exemplary crush pin104may be integrated with or mechanically fastened within a cavity102/103of mold100, and preferably, within each end cavity103. An exemplary pin104may be made of any rigid material that can be integrated into cavity103during machining of mold100(in which case the pin104may be made from the same material substrate as mold100). Alternatively, an exemplary pin104may be configured for mechanical fastening with mold100through front face100aand/or rear face100b, for example, by being a cylindrical part that screws into mold100, being configured to be friction fitted into an appropriately sized hole in mold100, by being adhered or bonded to mold100via chemical adhesives, glues, arc or laser welding, or via any other mechanical fastening techniques known to those skilled in the art. While at least one pin104may be found in each cavity103, a plurality of pins104may be used in any of cavities102and/or103in an exemplary mold100.

As may be illustrated inFIGS.7A-Cand8A-E, an exemplary crushing pin104may be located anywhere along the axial length of end cavity103, but preferably is more proximal to wall105than wall106. In an exemplary embodiment, an exemplary pin104may be located in alignment with the central axis of cavity103and/or be located at a distance that is no more than between about 15% to about 50% of the overall length of end cavity103. While an exemplary pin104may be cylindrical in shape, pin104may be any variety of sizes, shapes, and/or cross-sections, depending on needs. In one example, an exemplary pin104may be spherical, domed, cupped, or chamfered. Alternatively, pin104may have non-circular cross-sections, such as rectilinear shapes, so as to be a cubic or prismatic polyhedron. Pin104may also be magnetic, such as a neodymium magnet, or an exposed portion of an electromagnet whose electromagnetism may be controlled through timing circuitry known to those skilled in the art. Additionally, an exemplary pin104may allow passage of vacuum (VAC) to hold posable component1resting upon its surface. An exemplary pin may have contours at its apex104*, such as flat, grooved, circular, domed, or other types of surfaces and/or sharp points, that enable crushing of posable component1during the molding process to form an exemplary crushed portion1cin the posable component1.

Referring to either ofFIG.7A or7C, an exemplary working zone110may also have a plurality of ejector pin ports121and passages122running through the thickness of mold base100. In an exemplary embodiment, ejector pin ports121may only be located within either or both of half cavities102and/or half cavities103and translate from rear face100bto the cavity interior where it is used to eject a finished component2and/or3. In another exemplary embodiment, passages122may only be located in channels107and connect to mechanisms in the rear face100bof mold base100. With further reference toFIG.7A, an exemplary mold base100may have an injected plastic feeding system comprised of a sprue115that feeds injected plastic into runners116, that flows through branches117and enters one or more half cavities102/103by way of a gate118. While a specific form of injected plastic feeding system may be illustrated byFIG.7A, those skilled in the art may vary the shape and features of the sprue115, runners116, branches117, and gates118as is known in the art to enable a complete and/or sufficient manufacture of posable bendable toy10. In an exemplary embodiment, one or more of the runners116and branches117may be comprised of more channels than just a single channel, such as, for example, in stepped, zig-zag, or other configurations that may lead to balanced filling of the cavities102/103. Alternatively, an exemplary mold base100may have a working zone110that is devoid of an injected plastic feeding system runners116, branches117, and/or gates118, as may be illustrated with respect toFIG.7B, when that system is present in an exemplary mold cover200.

With reference toFIGS.7B and7D, an exemplary working zone210may comprise half cavities202and203that are interconnected by channels207through cavity partitions208. Each half cavity202may have two walls205, one adjacent to each channel207flowing into the half cavity202. Each half cavity203may have a wall206, for which there is no adjacent channel207, and a wall205, which like wall205for half cavities202, is adjacent a channel207flowing into half cavity203. Like the exemplary mold base100illustrated inFIG.7A, a crush pin204may be present in a surface of half cavity203and/or202of an exemplary cover mold200. Referring toFIG.7D, an exemplary working zone210may have a plurality of ejector pin ports121running through the thickness of cover mold200(from rear face200bto cavity surface adjacent face200a) while mold base100inFIG.7Cdoes not have these features. In another exemplary embodiment, passages122may only be located in channels207of an exemplary mold cover200instead of in the mold base100ofFIG.7C. With further reference toFIG.7B, an exemplary mold cover200may have an injected plastic feeding system comprised of just a sprue115that feeds injected plastic into mold base100using runners116, branches117, and gates118interconnected to one or more half cavities102/103. While a specific form of injected plastic feeding system may be illustrated byFIG.7B, those skilled in the art may vary the shape and features of the sprue115, runners116, branches117, and gates118as is known in the art to enable a complete manufacture of bendable component10, such as by placing runners116, branches117, and/or gates118into the working zones110and/or210of exemplary mold base100and/or mold cover200either in whole or in part. Alternatively, an exemplary mold cover200may have a working zone210that is devoid of an injected plastic feeding system runners116, branches117, and/or gates118, as may be illustrated with respect toFIG.7B. As illustrated inFIG.7D, an exemplary sprue115may be divided into multiple sprue points115ato allow for complete injection/filling of the cavities102/202and103/203of the combination of mold base200and mold cover100, such as, injection molding through a manifold or like injection molding structure (not shown).

With further reference to the illustrative embodiment ofFIG.7D, an exemplary path215of an exemplary injected plastic feeding system may be shown in an exemplary mold cover200within its working zone210. While path215may be shown as being a section of mold cover200, the same or similar path215may be found in an exemplary mold base100. Path215may provide a closer view of a sprue point115athat feeds into runner116, branch117, and a plurality of gates118. As illustrated, gates118may take the form of a “Y” that may advantageously simultaneously feed two volumes separately formed from the combination of half cavities102and202and/or half cavities103and203or two volumes separately formed by the combination of two half cavities102and two half cavities202. According to the exemplary embodiment ofFIG.7D, by placing the gates118adjacent to the walls105/205of a given half cavity102/103/202/203, the resultant injection-molded product may be removed from the molds100/200and thereafter be cleaved from the plastic that had filled gates118without any residual plastic interfering with the outer peripheries of the components102/103formed thereby. In other words, positioning gates118to feed behind the walls105that will become the internal surfaces5of exemplary components2/3may allow the removal of the final posable bendable toy10while substantially reducing and/or eliminating the possibility of residual plastic from the manufacturing process resulting on the outermost surfaces of the components2/3, as may be seen inFIGS.5A and6B. An exemplary mold result70illustrating the advantages of gate118position on the final resulting injection-molded product may be provided inFIGS.10A-C. In an alternative embodiment, gates118may be positioned to feed into sides of the cavities102/103and/or202/203besides the walls105/205, respectively.

FIG.7Eillustrates a cross-section of an isometric view of the abutment between face100aof mold base100and face200aof mold cover200just prior to injection molding of the whole cavities and channels formed by the combination of the mold parts. The solid line to which the annotation100a/200apoints represents the demarcation between mold base100and mold cover200in the exemplary cross-section ofFIG.7E. As illustrated inFIG.7E, an exemplary half cavity103may be abutted with an exemplary half cavity203to form a volume V3into which injected plastic may flow. As illustrated, an exemplary ejector pin passage121may be shown in the half cavity203and through which an ejector pin may travel to expel the completed end component3that was formed with injected material within volume V3during the injection molding process. Similarly, an exemplary half cavity102may be illustrated in abutment with an exemplary half cavity202to form a volume V2into which injected plastic may flow. Walls105and205may abut to form the extremities of the volumes V2made from exemplary half cavities102and202whereas walls105and205and walls106and206abut to form the extremities of the volumes V3made from exemplary half cavities103and203.

A may be further illustrated by the cross-sectional view of the mold parts100and200depicted inFIG.7E, an exemplary gate118may be exposed within volume V3. According to the illustrative embodiment ofFIG.7E, an exemplar mold cover200may be of the type depicted inFIG.7Din which the injection molding feeding system comprised of sprue points115a, runners116, and oscillating branches117may be present. As may also be understood with reference toFIG.7E, an exemplary passage122may extend into the volume VC formed from the abutment combination of channel107and channel207. As described, VC may be filled entirely by the posable component1during the manufacturing of exemplary posable bendable toy10. In other words, VC may be intended so as not to be filled with any injected material to result in exposed portions of posable component1. However, in the event VC may be filled in whole or in part by injected material, VC may be dimensioned accordingly so that any amount of injected material found therein can be either peeled away or broken away once an exemplary posable bendable toy10is in early stages of use by an end user. The “Y” shape of the gates118may once again be visible inFIG.7Eto provide the advantage of preventing any flash or extra plastic from being present on the outer surfaces of the components2and/or3formed in volumes V2and/or V3, respectively. As may also be illustrated byFIG.7Eis the strategic placement of gates118to sufficiently fill each of the component volumes V2/V3forming the end product posable bendable toy10.

FIGS.8A-Gillustrate an exemplary manufacturing methodology using one or more of the components, features, and embodiments described in and/or illustrated viaFIGS.7A-E. It should be understood that mold base100and mold cover200may have one or more of the features depicted in each other's drawings, may have variability in those features' size, configuration, order, orientation, and placement, and may be modified by persons skilled in the art to adequately achieve the desired shape, size, and functionality of any given component(s)2, component(s)3, posable component1, and overall posable bendable toy10. As used in FIGS.8A-E, the symbols “●●●” are meant to disclose the possibility of additional lengths of posable component1and/or components2/3. The symbols “∘∘∘” are meant to disclose the possibility of one or more additional mold sections, cavities, or channels and/or different portions of any mold100/200structures.

As may be further illustrated with respect to the illustrative embodiments ofFIGS.8A-G, an exemplary passage122may be the conduit for other components and mechanisms for use in manufacturing an exemplary posable bendable toy10, such as: (i) vacuum/suction VAC; or (ii) magnetic mechanisms M (either permanent or controllable/electromagnet). Additionally, as may be found with reference to the closing step between mold parts100and200illustrated inFIGS.8A-G, exemplary channels107/207may retain an exemplary posable component1within one of its contours using one or more of the following: (i) a clamping channel207* to frictionally hold a cross-section of the posable component1; (ii) a vacuum/suction VAC that creates suction through passage122that holds the surface of the posable component1into the channel107/207; or (iii) a magnetic source (either permanent or controllable/electromagnet) M that resides within passage122that attracts an appropriately magnetized posable component1into channel107/207. Where a crushing pin104/204may be used, an exemplary vacuum suction VAC or magnetic source M may cause posable component1to be held in contact with the apex104*/204* of pin104/204in addition to the troughs of channels107/207. In another alternative embodiment, wire channel107/207may qualify as a clamp channel207* through use of a high-temperature resistant elastomer gasket or layer G on one of the channel107/207surfaces. Where a gasket G may make up the clamp channel207* in whole or in part, it may enable the clamping of the posable component1within the volume VC formed by the contact between mold base100and mold cover200. Exemplary high-temperature resistant gasket G materials may include silicones, ethylene acrylic elastomers, such as Vamac® and Kalrez® made and sold by Dupont. The clamp channel207* (with or without a gasket G) may also be used in mold100to affect the same purposes as described above and illustrated inFIGS.8F-G.

With reference toFIG.8A, an exemplary loading step801may be illustrated. According to an exemplary embodiment, a posable component1having two pre-formed deformations1xfound in deformed portions1dproximal to the respective terminus1zat each end of posable component1may be disposed above the locations in mold base100where it is to be located. This may be done via automated or manual means. Exemplary manual loading steps801may include using a trained operator or a team of operators to place the posable component1within mold base100along an assembly line and/or rolling the posable component1along surface100auntil it falls into the proper channel107. In an exemplary rolling loading step801, an exemplary posable component1may be rolled along one or more barriers with protrusions designed to fit within one or more of the alignment grooves143in mold surface100a. Alternatively, an exemplary automated loading step801may involve each posable component1being picked up or lifted and placed into channel107using robotic arms of two or more degrees of freedom (such as, for example, a Mecademic Meca500 6-axis robot arm, made by Mecademic Robotics, Montreal, Canada), automated vacuum loading systems with end effectors that utilize one or more of magnets, tweezers, or vacuum-assisted tweezers, such as the ESD-Safe Tweezer-Vac™ Continuous Vacuum System with Pick-Up Tool that is manufactured and sold by Virtual Industries, Inc. of Colorado Springs, Colo. or one or more of the vacuum pick-ups manufactured and sold by EIS Inc. of Atlanta, Ga. According to another exemplary embodiment, an exemplary posable component1may be loaded into mold base100(whether manually or through robotics/automation) as a substantially straightened, pinched, and/or cut wire, such as wire straightened, pinched, and/or cut by Novo Precision of Bristol, Conn. or Little Falls Alloys of Paterson, N.J. In a preferred embodiment, an exemplary wire1will be straightened and have at least one “pinch” deformation1xproximal to each terminus1zto serve as the anchoring deformed portion1d.

According to another aspect of the exemplary embodiment illustrated byFIG.8A, posable component1may be a specifically configured posable component1so as to be in alignment with one or more of the channels107in mold base100when disposed therein. In a preferred embodiment, specifically configured posable component1may take the form of a substantially straightened and cut wire, such as a wire between 30 AWG and 14 AWG, and preferably, 18 AWG and/or 1.01 mm (0.0402 in.) outer diameter that has been straightened, cut to length, and/or otherwise treated by wire straightening and cutting machines made and sold by Novo Precision of Bristol, Conn. Referring still toFIG.8A, an exemplary posable component1may have deformations1xthat may face in any circumferential direction about component1axis11when loaded within mold base100. As may be further illustrated inFIG.8A, posable component1in an exemplary loading step801may be brought into mold base100via magnetic attraction to magnetic source M or be brought into mold base100via a suction or vacuum source VAC. According to this exemplary embodiment, use of magnetic source M and/or vacuum source VAC may cause posable component1to be disposed within channels107in mold base100and remain in place while the rest of the manufacturing process continues. While not shown, those skilled in the art would readily appreciate a variety of ways to control magnetic source M as an electromagnet through mold base100's thickness. Alternatively, magnetic source M may be a permanent magnet that is affixed within mold base100. While not shown, those skilled in the art would readily appreciate a variety of ways to control vacuum source VAC by use of hoses or other vacuum tubing and arrangements behind mold base100. Again, while magnetic source M and vacuum source VAC may be illustrated in an exemplary mold base100, they may similarly be found in an exemplary mold cover200, depending on needs.

With reference toFIG.8B, an exemplary approach step802may be illustrated showing the posable component1loaded within mold base100according to loading step801but now ready for advancement of mold cover200. As shown inFIG.8B, the loading step801may be complete once posable component1is nested within channels107of mold base100. Alternatively, the loading step801may be complete once posable component1is sufficiently stabilized atop one or more surfaces in mold base100, which may include channels107, cavities102/103, magnets M, and/or atop apex104* of crush pin104. As previously described, in any or all of the aforementioned completed loading steps801, magnetic source M and/or vacuum source VAC may still be on and/or controlled to maintain posable component1within its loaded position following step801. As illustratively provided for according toFIG.8B, the machinery used to hold mold base100may be the same machinery that controls the approach of mold cover200towards mold base100surface100a. According to the illustrative embodiment ofFIG.8Ban exemplary mold cover200may also have a crush pin204with an apex204* that may extend beyond mold cover surface200a, while the apex104* of crush pin104remains slightly below mold base surface100a. Alternatively, and additionally, a clamp channel207* may be provided in the mold cover200so as to force posable component1into friction fit within the combination of clamp channel207* and corresponding channel107. The reference “F-G” may be a selective cross-section of clamp channel207* and channel107with respect to posable component1that may be further illustrated and explained with reference toFIGS.8F-G. An exemplary approach step802may be timed according to when posable component1is secured within mold base100and/or channels107and/or cavities102/103. Alternatively, an exemplary approach step802may take place once the means for loading posable component1(manual or automated) are no longer within the working zone110aand/or disposed in front of mold base100.

Referring toFIGS.8A-B, it should be appreciated that any of the features of mold base100and/or mold cover200may be modified as needed to ensure proper holding of posable component1within the volumes formed by the closed mold parts100/200(that is, reduced and/or substantially eliminated movement of posable component1within volumes VC, V2, and/or V3). For example, while a clamp channel207* may be shown for an exemplary mold base200according to the illustrative embodiment ofFIG.8B, the same or similar clamping surfaces may be found as part of channels107of mold base100.

With reference toFIG.8C, an exemplary closing step803may be illustrated showing the posable component1held between one or more features (magnet source M, vacuum source VAC, clamp channel207*, crush pins104/204) of mold base100and/or mold cover200when surfaces100aand200aare in contact with one another. As shown inFIG.8C, the closing step803may result in the formation of volumes V3and V2partially occupied by either the terminus1zand terminal regions of posable component1or other lengths of posable component1. Unlike inFIG.7E, the volume VC that would otherwise exist upon contact between channel107and207/207* may not be present following an exemplary closing step803because it preferably is filled substantially entirely with a portion of posable component1. Alternatively, any portions of VC that may not be filled with posable component1may be substantially free of any injection molded material delivered into the volumes V3/V2during the process. Further alternatively, for any injected material that may find its way into the channel107/207/207* volume VC, it may be removed through use and/or flexing of the resulting posable bendable toy10.

As shown inFIG.8C, the closing step803may result in the formation of the crushed portion1cby virtue of the difference in space between crushing pins104and204. As shown inFIG.8C, an exemplary clamping channel207* may be advantageously placed near the deformed portion1din end cavity103/203. According to this exemplary embodiment, an exemplary clamping channel207* may be placed nearest to end cavities103/203to ensure little or no movement by the portion of posable component1that is not held by any other mechanism, such as, for example, a crushing pin104/204and/or magnet M or vacuum VAC. In embodiments where crushing pin104/204may be used, an exemplary clamping channel207* may be placed distal from the terminus1zand any other retention mechanisms M or VAC since the mold will take advantage of the clamping provided by crushing pin104/204. An exemplary closing step803as may be illustrated byFIG.8Cmay advantageously hold posable component1in a substantially taught or stretched position to sufficiently resist movement and/or deflection by injected material entering the surrounding volumes V2and V3in which it may be found.

With reference toFIG.8D, an exemplary molding step804may be illustrated showing the injection of molten plastic (shown in hashed lines) into each of volumes V2and V3about the portions of posable component1found therein to form components2and3of posable bendable toy10. While not shown, those skilled in the art may understand that the injection molding feeding system may be allowing for injection material to enter the volumes V2and V3from a position that facesFIG.8D(out of the page and flowing into the page) or from a position that originates behindFIG.8D(behind the figure and flowing out of the page toward the viewer). As may be appreciated fromFIG.8D, the deformations1xin the terminal regions of posable component1and/or the crushed portion1cformed via an exemplary closing step803may prevent the material making up end components3from dislodging from posable component1when used. That is, the molding step804may enable injected material to intimately embed itself around and/or into the spaces formed by each deformation1x, extension surface1w, bend1b, crushed section1*, orifice1o, pit1p, and/or twist1tin posable component1, and in particular, in the terminal region of the posable component1. According to an exemplary embodiment, an exemplary molding step804may involve injection of one or more of the following materials: PMMA, ABS, PA, PETG, PS, PC, PP, PE, PEEK, PET, PLA, cyanate esters, epoxies, polyesters, polyurethanes, silicones, rubbers, vulcanized rubbers, and combinations of the same. Alternatively, certain volumes V2/V3may be filled with one type of material while other volumes V2/V3may be filled with a different type of material during molding step804.

With continued reference toFIG.8D, it may also be appreciated that posable component1may remain held by the clamping channel207* and/or magnetic source M, which may be a specifically designed magnetic source that can resist repeated high temperatures (e.g., a high temperature neodymium permanent magnet or a steel core electromagnet with windings located on another side of the mold100/200in which it is found). In one aspect, the vacuum source VAC previously used to stabilize posable component1as perFIGS.8A-C, may be turned off during an exemplary molding step804to avoid injected material being drawn into the passages122. However, those skilled in the art may “close” the vacuum passage122using an ejector pin in the passage122in much the same way that any ejector pin passage121may similarly be closed during an exemplary molding step804.

With reference toFIG.8E, an exemplary release step805and ejecting step806may be illustrated showing the removal of mold cover200from contact with mold base100and the use of ejector pins124to eject the finished posable bendable toy10from the molds100/200. As may be illustrated inFIG.8E, the posable bendable toy10may be ejected in the configuration in which posable component1was inserted. In other words, if posable component1was inserted into mold base100as a substantially straightened posable component1, then posable bendable toy10may be ejected in a substantially straightened conformation. As depicted inFIG.8E, the terminus1zadjacent to crushed portion1cmay be shown with a straight section1srather than the deformation1xand deformed portion1dillustrated inFIGS.8A-D. This substitution may be understood based on disclosures in which the various features on a posable component1may be interchanged and used in numerous forms, conformations, angles, and frequencies.

An exemplary posable bendable toy10ejected according to an exemplary ejection step806may appear as the mold result70shown in one or moreFIGS.8114, assuming molds100/200were designed for manufacturing a plurality of posable bendable toys10per injection step804. As illustrated inFIGS.8114, an exemplary mold result70may comprise the end components3and body components2of an exemplary posable bendable toy10. While not shown, an exemplary mold result70may comprise just end components3of an exemplary posable bendable toy10meant to have only two end components3. Additionally, an exemplary mold result70may comprise the remainder injection material from the injection molding step804, such as, legs15and15a, spine16, arms17, and fingers18. Those skilled in the art would understand that each of leg15a, spine16, arm17, and finger18may be the injection-molded results of the injection molding process804through sprue points115a, runners116, branches117, and gates118, respectively.

FIGS.8H-Imay also show how the fingers18of mold result70allows for advantageous release of the components2/3from the mold result70to be independent posable bendable toys10. Fingers18advantageously comprise extremely small amounts of injection material interconnecting the component2and/or3to the remainder of the arms17and spine16of the mold result70. As such, fingers18may be frangible and/or relatively weaker in torsion and bending than any of the other remainder portions of the injection molding process804. Further, because fingers18are connected only to faces5of the components2and/or3, breakage of fingers18from the mold result70may not affect the overwhelming majority of visible surfaces of the resulting components2and/or3.

FIG.8Jillustrates an exemplary release step807in which numerous advantages provided for in the manufacture of posable bendable toy10may be understood. According toFIG.8J, an exemplary release step807involves rotating the body components2of the mold result70until the adjoining fingers18break. In so doing,FIG.8Jtakes advantage of two different advantages disclosed: (i) the free rotation of body components2; and (ii) the location and configuration of fingers18. Thus, an exemplary release step807may provide for the ease of removal of posable bendable toys10from the mold result70while resulting in a posable bendable toy10whose surfaces are substantially free of the results of the injection molding process804. The term “substantially free” as used in this paragraph only is meant to refer to the fact that marks from ejector pins124in components2/3may be unavoidable during the ejection step806and, depending on whether it is used, the openings4A and4B are necessary results of the manufacturing process if crushed portion1cis meant to be used on the posable component1to retain the same in a body component2and/or end component3. Further, to the extent a body component2is meant to be static with respect to posable component1in the final posable bendable toy10, the same may still be twisted off of a finger18by spinning one or more portions of the other movable components2while attached as mold result70. If all components2/3of a posable bendable toy10in the result70are static, then a user can bend the entire toy10into and out of the plane of the spine16until it breaks away. In an alternative embodiment, the fingers18formed in the result70may be made so as to be more frangible to allow for easier removal of the posable bendable toy10from the result70.

While cavities102/202and/or103/203may have heretofore been illustratively shown as cylindrical elements, they may be any other shapes known to those skilled in the art, such as, for example, building blocks or parts/components/accessories of other toys and figures. For example, cavity102/202may each be one half of the negative of a Lego® block while cavity103/203may each be one half of the negative of a K′nex® building piece. Any building block or building toy component known to those skilled in the art may have a cavity102/202/103/203made of it in an exemplary mold100and mold half200. If a three-piece mold or a greater number of mold parts are necessary to form a particular cavity102/202/103/203, those skilled in the art would be capable of implementing the inventive embodiments herein as long as at least two of any plurality of mold parts can serve as a mold100and/or200while sufficiently holding an exemplary posable component1therein (e.g., using magnetic sources M, vacuum sources VAC, clamping channels207* with or without gaskets G, or crush pins104/204). In other words, mold100may be a single construct or a combination of a plurality of mold parts and mold200may be a single construct or a combination of a plurality of mold parts.

Additionally, a mold100/200may also allow for the use of a plurality of posable bendable toys10to interconnect numerous volumes V2and V3formed by an exemplary mold. An example of this may be had with reference toFIGS.9A-B. As illustratively provided for inFIGS.9A-B, an exemplary mold base100may have within it a plurality of body cavities102A,102B,102C1, and102C1, and a plurality of end cavities103A,103A1,103B,103Cand103C1in which there may be found one or a plurality of posable components1A,1B, and1C, respectively, having any of the features described and illustrated inFIGS.2A-I, which may include one or more deformations1xin deformed portions1dand/or terminal regions that will be subject to crushing by a crush pin104so as to form a crushed portion1cand corresponding crushed section1*. Additionally, as illustrated inFIG.9A, an exemplary mold base100may have numerous faces106A.106B,106C,105A,105A1and105C1similar to faces105/106previously described.FIGS.9A-Bmay also illustrate channels107A,107B, and107Cat different depths from mold base surface100atowards the rear face100bof mold base100. Accordingly, different elevations in the various channels may allow for a first posable component1Ato be disposed above a second posable component1Bwhile a third posable component1Cmay be disposed under the second posable component1B. In this way, an exemplary mold base100may accommodate more than one posable component in different orientations while laying the foundation for manufacturing a construction30, such as the one illustrated inFIGS.9C-D.

With continued reference toFIGS.9A-B, an illustrative mold100for a construct30may be comprised of an end cavity103Ain which there is found a surface for creating a cavity109in the final end component3Amade thereby. Alternatively, a crush pin104Aand104Cmay occupy end cavities103A1and103C1, respectively. An exemplary body component102C2may have one or more indents125that may form extensions25on a given body component2C2made thereby (as shown inFIG.9C). Unique to a mold base100and/or mold cover200for an exemplary construct30are the various intersection cavities and intersection retention components. As illustrated inFIGS.9A-B, an exemplary shared body cavity102S may be a body cavity in which more than one length of posable component is present within the walls105S (as illustrated, posable components1Band1Aeach have lengths spanning shared body cavity102S). The result of over molding the posable components1Aand1Bmay be the shared body2S and embedded portions1eAand1eBillustratively provided for inFIG.9C. A further unique feature may be the end body132in which the terminal region of a posable component may be found along with another portion of another posable component that is not the terminal region, such as, for example, the terminal region of posable component1Band a non-terminal portion of posable component1Cfound within the end body cavity132as illustrated inFIG.9B.

An end body cavity132may serve as a body cavity to at least one of the posable components running through it (inFIG.9B, this would be posable component1C) and may serve as an end cavity to at least one of the posable components running through it (inFIG.9B, this would be posable component1B). Assuming the posable component1Bhad a terminal region with one or more bends1b, deformation portions1d(such as a preformed pinch or dent in the terminal region of an exemplary posable component), twists1t, orifices1o, or combinations of the same, then the terminal region of the particular posable component may be over-molded along with the adjacent non-terminal portion of the additional posable component (as shown inFIG.9B, that would be posable component1C). However, where the terminal region of the posable component found in the end body cavity132requires a crushed section1cand/or the non-terminal region of the adjacent posable component requires a crushed section1c, then an exemplary mold base100may use a multi-crush pin144within end body cavity132. Following an exemplary manufacturing process as described inFIGS.8A-G, the result of injection molding end body cavity132may be end body32as illustrated inFIG.9C. A more detailed discussion of use and embodiments of an exemplary multi-crush pin144may be had with respect toFIGS.9E-H. While not illustrated inFIGS.9A-B, those skilled in the art may include within an exemplary mold base100and/or mold cover200for construct30any sprues115/215, runners116/216, branches117/217, and gates118/218for injection molding within the cavities in the mold surface. Furthermore, any features previously disclosed with respect to mold100and/or200ofFIGS.7A-EandFIGS.8A-E(e.g., passages122, tunnels121) may also be included in the mold100and/or corresponding mold200ofFIGS.9A-Bin like or similar kind, functionality, and placement.

Referring toFIG.9C, an exemplary construct30may be the product of applying the manufacturing steps801-807as illustratively provided for inFIGS.8A-Gto the mold base100illustrated inFIGS.9A-B. As may be illustrated inFIG.9C, the construct30may have a hand3Awith an extension25and cavity9(not shown), that is formed using cavity103AfromFIGS.9A-B. Hand3Amay be connected by posable component1Ato shared body2S in which posable component1Ais embedded to connect arm part2Athereto (arm part2Abeing the result of injection molding cavity102AofFIG.9Awhile posable component1Ais within—as shown inFIG.9B). Hand3A1differs from hand3Ain that hand3A1was formed using a crushing pin104Ain the end cavity103A1as shown inFIGS.9A-B. As previously described, a process in which crushing pin104is employed necessarily will leave behind an opening4, which may be illustrated for hand3A1inFIG.9C. Head3Bmay be illustrated as being interconnected to shared body2S and end body32via posable component1B. Unlike hand3A1, use of deformation1xat the terminal region of posable component1Bin cavity103Bpermits the final end component3to be without any holes4through the surface. However, the other end of posable component1Bmay have been subjected to crushing via multi-crush pin144, the results of which being crushed portion1con the terminal region of posable component1Bfound within end body32, as viewable inFIG.9C.

With continued reference toFIG.9C, an exemplary foot3Cmay be the product of over-molding the terminal region of posable component1Cin cavity103Cin which two deformed portions1dmay have been provided as shown inFIG.9B. The foot3Cis interconnected to leg2C1and end body32via posable component1C. As illustrated inFIG.9C, posable component1Cmay be able to slide through end body32(much like a mobile body component2may do along a posable component1in prior embodiments). Thus, end body32may possess the functionalities of an end component and those of a body component simultaneously. Those skilled in the art would recognize the leg2C2as being the same as or similar to a building block for interconnections with compatible toys, as shown inFIGS.4A-E. Leg2C2may be the result of manufacturing with the cavity102C2illustrated inFIGS.9A-B. In contrast, foot3C1may be manufactured from cavity103C1and crushing pin104Cillustrated inFIGS.9A-B. The resulting terminal region found within an exemplary foot3C1may have both a crushed portion1cfound between openings4in the foot3C1and a bend1band deformed portion1das well. The exemplary construct30may take the form of a figurine as shown and/or a hybrid figurine with interconnecting building block compatibilities.

With reference to the illustrative embodiment ofFIG.9D, an exemplary construct30may be comprised of any number and variety of end components3, body components2, shared body components2S, and end bodies32. In addition to providing illustrations of features from other figures on one or more portions of posable components1Aand1B, such as a deformation1dthat acts as the terminus1zfor posable component1A,FIG.9Dmay illustrate the versatility and endless permutations of components2/3that may be available for use in making a construct30using the disclosures herein. Worthy of mention is the strategic placement of opening4with respect to certain of the building block components3and2found along posable component1A. As illustrated, an exemplary opening4may be made so as not to interfere with the interconnection capabilities of the building block end component3, that is, the opening4may be found between extensions25, which may take the form of Lego-like studs, illustrated to the left of shared body2S, so that the same interconnecting capabilities are not hampered by the presence of opening4. Alternatively, as illustrated inFIG.9D, an exemplary body component2located on the same posable component1Amay also have an opening4through the thickness of its hollow extension27, but not for the purpose of creating a crushed portion1con the posable component1A, but rather, to allow the resulting building block component2(which in this case is an Erling Lego brick having one of the following Lego Design ID Nos. 4070, 87087, 87069, 99206, 11211, and 30414) to be useable as such a building block while still allowing for translation up and down the posable component1A. Also worthy of mention is the rectilinear-shaped hole4shown in the end3on posable component1B. Furthermore, shared body2S may allow for slack spacing8+ and reduced spacing8− for the body components2disposed along posable components1Aand1B. As may be understood by a person of ordinary skill in the art, an exemplary construct30may comprise at least one component2/3that is shared by a plurality of posable components1, which as shown inFIG.9C, may be posable components1Band1Csharing body end32and posable components1Aand1Bsharing body2S.

FIG.9Dmay also illustrate how a component like shared body2S may be spherical so that its boundaries7may be located about an equator and poles that are at right angles from one another. In an embodiment, posable components1Aand1Bmay intersect within shared body2S in any formation, including a non-contact arrangement, a wound or wrapped arrangement (e.g., as may be shown inFIGS.6A-B), a friction or other type of weldment (heat or laser), an adhesive-enabled joint, a knotted configuration, or as part of a crushed fitting or deformation fitting). The same or similar type of arrangement may be provided for the intersections between posable components1A,1B, and1CinFIG.9C. That is, where a posable component1B and posable component1C inFIG.9Cmay interact in body end32via multi crush pin144, alternatively posable component1B may be adjoined to posable component1C by a twist1t(as shown inFIGS.6A-B) or may be welded, adhered, knotted, or merely overlaid one another. In an exemplary embodiment, a plurality of posable components1may be able to interlink with one another via one or more of the pre-loaded posable component surface features (not crushed portion1cwhich only forms during the bendable linkage10formation process) that are described and illustrated with respect toFIGS.2A-Band2D-I and3B-F (e.g., a deformation1xfriction fitting within another deformation1x, a bend1bfriction fitting within a deformation1x, a twist1twrapped about a deformation1x). As an exemplary spherical body2has only one surface, a spherical body2's outermost face may always be an interior surface5. However, where an ending3may be spherical in shape, that surface may always be an exterior surface6.

Referring now to the illustrative embodiments depicted inFIGS.9E-H, which disclose, among other things, the multi-crush pins144and244of exemplary mold base100and/or mold cover200as described with respect to construct30, as illustratively provided for inFIGS.9A-C. As illustrated inFIGS.9E-H, an exemplary multi-crush pin144may be used with a plurality of posable components (e.g.,1Aand1B) and may comprise a pin apex104*, a pin shoulder104a, a pin arm104b, and shoulder region104a*. In an exemplary embodiment, as illustratively shown inFIGS.9E-F, pin shoulder104aand pin arm104bmay be any other shapes or combination of shapes that may allow one posable component to bypass another section of the mold in which it is found. In one exemplary embodiment, a first posable component1Amay be oriented to rest on apex104* of an exemplary multi-crush pin144in an exemplary mold base100for a construct30. A second posable component1Bmay be oriented substantially orthogonal to the first posable component1Aso that it may have a cross-section located between pin arm104band pin144and spaced above shoulder region104a*. In an aspect of this exemplary embodiment, one of pin arm104bor pin144may have a contour for receiving the cross-section of second posable component1Bso that it may be suspended above shoulder region104a*. In another additional aspect of this exemplary embodiment, the cross-section of second posable component1Bmay rest directly on shoulder region104a*. With respect to this additional aspect, by resting second posable component1Bon shoulder region104a*, second posable component1Bmay avoid any form of crushing operation in the cavity and when over-molded by injected material, such as plastic or rubber, the second posable component1Bmay be only exposed on one hemisphere when viewed from the exterior surface of the final construct30and/or posable bendable toy10(assuming such a pin104is used) in which it may be found. In other words, a shared body2S or an end body32in which an exemplary multi-crush pin144and posable component arrangement as depicted inFIG.9F, may have only one opening through which the uncrushed surface of posable component1Bmay be visible as opposed to two openings through which a crushed section1* or an under surface1uof posable component1A, following crushing, may be visible.

According to the exemplary embodiments illustrated inFIGS.9G-H, an exemplary second mold200for use in making a final construct30may have a complementary pin244with multiple contact surfaces204* and204a*. In an exemplary embodiment, pin204may be shaped so that contact surface204* is larger than apex104* and contact surface204a* is larger than shoulder region104a* but not so large as to contact apex104*. As may be further shown with reference toFIG.911, an exemplary contact surface204a* as previously described may be shaped so that when an exemplary pin244impacts posable component1B, the posable component1Bcross-section located on and/or above shoulder region104a* may be crushed between pin arm104b, pin shoulder104a, and pin144. In an exemplary embodiment, a crushed posable component1Bmay have a deformation region consisting of an underside1uand a deformation extension1w. In a further exemplary embodiment, a crushed posable component1Amay have a deformation region1cwith one or more residual posable component surfaces1radjacent to the contact surface204* and apex104*. According to these embodiments, multiple lengths of posable component may be held within molds100and200for an exemplary construct30or posable bendable toy10and simultaneously over-molded with plastic following an injection process.

A particular advantage to having a gap between shoulder region104a* and a cross-section of posable component (here posable component1B) may be to allow additional plastic material to over mold the deformed portion of posable component1Bin construct30. Further, while a pin144shown inFIGS.9E-Hmay be utilized for the posable components of a construct30, the same of similar pin144may be used to form a posable bendable toy10of the type described here. In other words, pins144and244shown in any other figures may be separately stamped, printed, or otherwise molded and be mechanically interchanged with pins104and204shown in any other figures (e.g., by being screwed in or otherwise snap-fit or held within the cavities102/103/202/203of the molds100/200in which they are used).

The exemplary posable bendable toys10, combinations20, and constructs30may be used with numerous add-ons and connections to increase use and enjoyment of systems made thereby. For example, as illustrated inFIGS.10A-J, two fragments40A and40B of a figure may each have connectors44opposite their finished surfaces42and separated from the connecting face41by a material thickness43. Exemplary fragments40A/B may be configured to use connectors44to attach onto or receive within themselves the surface(s) of an exemplary component2and/or3, as may be illustrated byFIGS.10A-BandFIGS.10D-Eand10G. When fragments, such as the ones illustrated and depicted as40A and40B inFIGS.10A-I, are interconnected via a component2/3, they may combine to become a shell45, as illustrated inFIGS.10B and10J. However, as illustrated inFIGS.10F-Gand10J, a combination of fragments40A/B may be combined with another shell45Bto form a combination of shells46. Further alternatively, a shell45Cmay also be snapped to a body component3or an end component3through a unique gapped snap arrangement that allows the component2/3to pass through the shell45Cand then be snapped thereto, as illustratively provided for inFIGS.10H-I. As illustrated by shell45Ban exemplary connector44may allow for slipping the cross-section of components2/3there through, as an alternative to the snap-fit arrangements of fragments40A/B and shell45B. In an alternative embodiment, exemplary connectors44may allow for attachment to any exposed portion of posable component1and/or into any opening4or other contour found on surfaces of components2/3(e.g., screw threads, fins, spherical surfaces). It should be understood that an exemplary fragment40A/40B or shell45B/45Cmay be configured to friction fit onto any part of an exemplary posable bendable toy10using grooves, hooks, clasps, magnets, screw threads, and other mechanical attachments to substantially hide the posable bendable toy10from view and instead present a figure or other toy comprised of the shells45.

Referring toFIG.10K, a posable bendable toy10may be dimensioned and sized to hold a fabric body50via through-holes52formed by pieces of fabric in the body. An exemplary fabric body50may be cloth piece Lego Part Number 86297. Due to its possibility, an exemplary posable bendable toy10may use the gaps8between each of the internal faces5of body components2to retain the fabric holes52of an exemplary cloth part or fabric accessory50and provide structure to its otherwise flimsy and flowing texture. As such, the exemplary posable bendable toy10described may be used to form wings, tails, webs, and other intricate patterns using the fabric50via the interconnections between exposed wire portions1and openings52in the fabric50.

According to the illustrative embodiments ofFIGS.11A-F, an exemplary posable bendable toy10may be fabricated using additive manufacturing processes, such as, for example, 3D printing. In a first step illustrated byFIGS.11A and11D, an exemplary additive manufacturing process may form base layers2qand3qhaving receiving layers2rand3r, respectively, atop a work surface1000. Unlike base layer2q, a base layer3qmay have a barrier end6qand a terminal receiving layer6r. Exemplary base layers2qand/or3qmay be manufactured using any additive manufacturing devices or methods known to those skilled in the art. Exemplary base layers2qand/or3qmay also be made out of any material useable with such additive manufacturing devices. According to an exemplary embodiment, each of the base layers2qand3qofFIGS.11A and11Dmay be still molten and/or not fully cured so that additional material may continuously be added to the cupped features throughout the process until completed.

In a second step illustrated byFIGS.11B and11E, an exemplary posable component1may be placed into the receiving layers2rof each base layer2qwhile its terminal region is placed into the base layer3qwithin receiving layer3r. Such placement is contemplated while each feature of the base layers2q/3qis still substantially able to be built upon through additive manufacturing. An exemplary posable component1may be pre-deformed to have a deformed portion1dadjacent the terminus1z. In an exemplary embodiment, the terminus1zmay be substantially flush or at a minimum will not exceed the boundary6qand terminal receiving layer6r.

In a third step illustrated byFIGS.11C and11F, an exemplary posable component1resting within the receiving layers2rand3ratop base layers2qand3q, respectively, may be enclosed within the base layers by corresponding completion layers2sand/or3susing the same or different 3D printed material. According to this exemplary embodiment, molten material will be layered on top of posable component1so that it may fill whatever surfaces that may exist on posable component1as a result of deformed portion1d, bend1b, twist1t, pit1p, or orifice1o.

According to the illustrative embodiments and steps ofFIGS.11A-F, an exemplary posable component1may be placed in the base layers2q/3qand between the receiving layers2r,3r, and6rin a sufficient amount of time to achieve a completion layer2s/3sthat will be integral with the receiving layers and the base layers. In a preferred embodiment, the posable component1may be placed in the base layers2q/3qand within receiving layers2r/3r, respectively, in approximately 1-2 minutes leaving only one minute for the additive manufacturing of the completion layers2s/3sto begin. Depending on the curing times of the filament used to create base layers2qand3q, those skilled in the art would understand to time the supply of posable component1to the 3D printing process so that it reduces the chance of full curing of the base layers2q/3qand/or receiving layers2r/3r.

With reference to the exemplary embodiments illustrated inFIGS.12A-E, an exemplary mass production process for manufacturing an exemplary posable bendable toy10using additive manufacturing may be provided. According to the illustrations, each ofFIGS.12A-Emay show how an additive manufacturing device having a nozzle55may create base layers2qand3qwith their respective receiving layers2rand3ron work surface1000while a manipulator55may obtain an exemplary posable component1with pre-formed features (e.g., bend1bor deformed portion1d) from repository500. Manipulator55may use magnetism, as illustrated inFIGS.12A and12Eto grab a posable component1and await a point in the additive manufacturing process when nozzle55may be out of the way, such as may be illustrated inFIG.12B. According to the process depicted inFIG.12C, manipulator56may move an exemplary posable component1from the repository500to the work surface1000where it will place the posable component within the receiving layers2rand3rof the base layers2qand3q, respectively. Once complete, nozzle55may substantially immediately resume the additive manufacturing of the components while manipulator returns to the repository500, as may be shown inFIG.12D. As may be illustrated inFIG.12E, an exemplary posable bendable toy10may be formed on the work surface1000following disposition of the completion layer3sand2sand simultaneous embedding of the posable component1therein.

It should be understood that the embodiments using the enumerated structures, features, and methods described are not limited to those expressly disclosed and/or illustrated, but encompass all varieties and variations. First, every feature in any figure may be used in place of the same or a similar feature in another figure or embodiment, unless otherwise expressly limited by function. Second, every physical feature in any figure may be used in conjunction with any other feature in any other figure such that all permutations achievable by such conjunctive use are hereby disclosed. Third, to the extent reference is made to a particular building block, figurine, toy, or other similar structure, it should be understood that all known building blocks, figurines, toys, and any other similar structures are equally applicable and may be substituted in place of any expressly disclosed building block, figurine, toy, or other similar structure used by or formed by the disclosed features herein, e.g., any fragments40and shells45/46. Fourth, all sizes and dimensions of any embodiment are contemplated without restriction unless otherwise stated. Fifth, all embodiments may be used to modify any other embodiment to achieve a desired purpose, whether or not the desired purpose is expressly stated.

Many further variations and modifications may suggest themselves to those skilled in art upon making reference to above disclosure and foregoing interrelated and interchangeable illustrative embodiments, which are given by way of example only, and are not intended to limit the scope and spirit of the interrelated embodiments of the invention described herein.