Toy audio device

Abstract: A toy audio generating device 10 is disclosed for use as an accessory to another toy, for example as a backpack for a toy action figure. The toy audio device 10 comprises a receptacle 42 defining an enclosure 40 containing a speaker 12 and plural batteries 22 laid out side-by-side adjacent the end of the speaker 12 opposite the sound projecting portion of the speaker 12. A printed circuit board 14 containing circuitry for generating audio signals is located in a space alongside the speaker 12 under a side wall 46 of the enclosure 40. A switch 16 for activating sound generation is mounted to that side wall 46 and directly contacts the printed circuit board 14.

Description: This invention relates to a toy audio device, and in particular to an audio device adapted for detachable mounting on another toy. In FR 2572300 a toy representing an object or person is provided with audio means comprising printed circuit tracks in the body of the toy bearing audio data, and a device detachably mounted in said body to cooperate with the printed circuit tracks, the device having a conventional battery power source, a micro-processor and a loudspeaker. A presently commercially-available backpack accessory for toy action figures forms an audio device but which supplies only sound effects. That backpack accessory comprises two receptacle halves each open at one end. The two receptacle halves when joined define a single enclosure in which is mounted an audio generating system. The audio generating system includes a PCB and a speaker which are mounted in one receptacle half and three batteries which are mounted in the other receptacle half offset from the speaker and PCB. The PCB is disposed extending parallel to the face of the speaker coil offset to one side of the speaker, with the coil partially disposed in a recess in an end of the PCB. Three button-cell batteries are provided mounted axially aligned extending in a row in a battery compartment adjacent to the end of the PCB opposite the end with the recess. Push button switches for activating the audio generating system project from the rear of the backpack. The speaker faces the front of the backpack, the backpack front being adjacent the action figure when the backpack is mounted to the back thereof. The commercially-available backpack described above has certain limitations. For use with a 3 3/4 inches (95 mm) toy action figure, the backpack is bulky and disproportional to the toy action figure in heigth, width and thickness. Specifically, the backpack is wider and thicker than a typical 3 3/4 inches (95 mm) action figure, and is more than half the height of a 3 3/4 inches (95 mm) action figure. The speaker is positioned to project sound out of the front of the backpack which, when the backpack is mounted to the action figure, is closely adjacent the solid back of the action figure, which can affect sound volume and quality. That commercially-available backpack generates only sound effects, and a separate control is provided to activate a single selected sound effect per control. According to the invention, there is provided a battery-powered toy audio device attachable to or arranged to form part of a toy action figure and comprising a structure which defines an enclosure and which has a sound transmitting portion, a speaker mounted in said enclosure having a sound projecting portion facing said sound transmitting portion, circuitry disposed in said enclosure for generating audio signals, the speaker being coupled to said circuitry to produce audio in response to said audio signals, the circuitry being powered by a plurality of miniature disc-like batteries held in said enclosure in a side-by-side grouping with an end face of each of said batteries in a common plane which is opposite from and overlapping an end face of the speaker, said plane not intersecting said speaker, and means accessible from outside the enclosure for activating the device. With the batteries so disposed it is possible to provide a toy audio device reduced in size in at least one dimension relative to a comparable device having disc-like batteries which are axially aligned, typically in a separate battery compartment. By providing the batteries laid out in a side-by-side flat grouping opposite and overlapping the speaker coil end face the overall height of the device can be reduced, which can be particularly relevant to a device in the form of a backpack accessory, which can then be brought more into proportion with a smaller toy action figure such as one of height 3¾ inches (95 mm). In one preferred embodiment of the toy audio device is configured as a backpack accessory for a toy action figure, the battery grouping is located directly opposite the end of the speaker which is formed by the speaker coil. Both the speaker end formed by the coil and the opposite end which projects sound from the speaker define parallel speaker end faces. If the sound projecting end of the speaker is disposed facing the back of the backpack, the batteries are disposed between the coil end of the speaker and the front of the backpack. Thus, in this embodiment, the battery end faces extend in a vertical plane as does the sound projecting and coil end faces of the speaker. However, the sound projecting end face of the speaker may face the top or bottom of the backpack, in which case, the battery end faces will extend in a horizontal plane. In another embodiment, the toy audio device may be a weapon and the particular disposition of the battery grouping will depend upon the size and configuration of the weapon. In one configuration, the audio device comprises a single receptacle having an open end and a flat cover plate or lid therefor. With a single receptacle, all of the components are mounted in a common member including the batteries which are located adjacent the enclosure open end which is closed off by the lid. The lid is removable to provide easy access to the batteries for replacement purposes and can be constructed as a relatively simple plate-like element for easy attachment and detachment from the receptacle member. In the case of a backpack accessory, this allows the speaker to be positioned with its sound generating end face facing the rear of the backpack (which does not face the toy action figure) for better sound projection with less sound volume reduction or distortion than if the speaker sound projecting end face faced the front of the accessory and the solid back of the action figure. The PCB may be mounted in a number of ways depending upon the desired size and shape of the device. For example, the PCB may be mounted in a plane perpendicular to the plane of the battery end faces to one side of the battery grouping and the speaker, or the PCB may be mounted parallel to the plane of the battery end faces and opposite and overlapping the battery grouping. In the case of the backpack accessory, as presently preferred, the PCB is mounted perpendicular to the plane of the battery end faces to one side of the battery grouping and the speaker. The means for activating the audio generating system comprises at least one manually operable switch. The preferred PCB mounting arrangement described above for the backpack accessory has the advantage that the switch or switches can be mounted directly to the PCB or to directly contact the PCB (without wires) with the actuating portion or button of the switch extending from a side of the backpack, preferably the top of the backpack relative to its mounting to a toy action figure. In a preferred embodiment a switch construction of the conductive rubber type is employed in which a conductive member is moved into and out of direct contacts with the PCB. Such a mounting arrangement with a switch button or buttons actuated from the top also helps reduce the overall thickness of the backpack accessory. The invention will now be described in greater detail with respect to a preferred embodiment thereof, illustrated in the accompanying drawings, which is given by way of example. In the drawings, in which like references denote the same or corresponding parts: Fig. 1 is a schematic circuit diagram of sound generating circuitry contained within the device according to the invention, namely the backpack accessory depicted in Fig. 2; Fig. 2 is a rear perspective view of a toy action figure having attached thereto a backpack accessory according to the invention including an audio generating system; Fig. 3 is an exploded view of the backpack accessory of Fig. 2; Fig. 4 is a sectional view of the backpack accessory of Fig. 2 taken along the line 4-4 of Fig. 2; Fig. 5 is a sectional view of the backpack accessory of Fig. 2 taken along line 5-5 of Fig. 4; Figs. 6 and 7 are respective plan views of the battery base plate and the lid of the backpack accessory depicted in Fig. 3; and Fig. 8 is a schematic view showing electrical inter-connection of the batteries of the backpack accessory depicted in Fig. 3. Fig. 1 shows schematically the circuitry for an audio generating system 10 for a toy audio device according to the invention. Audio generating system 10 comprises the following components: a speaker 12 or like electrical-to-sound transducer, a PCB 14 (Fig. 3) containing an integrated circuit (IC) 15 which combines speech and sound effects synthesizers as well as the logic or switching circuitry which responds to one or more externally actuated controls such as switches 16 and 17, a separate transistor 18 as an output amplifier, resistor 19, a capacitor 20 and batteries 22A-C for powering the audio generating system. Resistor 19 may be 470 ohms and transistor 18 may be a type 90131. Transistor 18 and resistor 19 may be incorporated into IC 15. IC 15 may be a Windbond W52300 series ADPCM voice synthesizer. Speaker 12 may be of the type comprising a ferrite core coil which vibrates a mylar cone. The power rating of speaker 12 may be a about 70mw to 100mw, and its size may be approximately 21mm in diameter by 7mm in height. Switches 16 and 17 may be micro-miniature switches of the conductive rubber type, which may be about 8mm diameter and 7mm in height. Inexpensive miniature batteries 22A-C of the button-cell type are preferred. Since each battery of that type generates only 1.5 volts, and the audio generating circuitry (e.g., IC 15) typically requires at least about 4 volts, three batteries 22A-C connected in series providing 4.5 volts are required. One aspect of the present invention relates to the layout of these components inside the accessory to reduce size and improve sound quality, and to enhance and facilitate use by a child. Fig. 2 shows a typical articulated toy action figure 30 as a spaceman, carrying a backpack accessory 32 incorporating the audio generating system 10 in accordance with the invention. The invention is not limited to a spaceman action figure, or to articulated action figures, but is applicable to other figures. Also, the invention is not limited to figures portraying humans, but is also applicable to figures and objects which portray non-humans, creatures and inanimate objects. For example, the invention is applicable to vehicles, e.g., land, sea, air and space vehicles. The invention is also not limited to backpack accessories, and is applicable to other accessories such as weapons, vehicle parts, and vehicle accessories to a "mother" vehicle. The accessory has means for removably attaching it to the action figure or other toy object. In the case of a backpack or weapon accessory for an action figure, a projection and a receptacle may be provided for mounting the accessory to a toy action figure. Referring to Fig. 4, backpack 32 is provided with a projection 36 which snaps into a receptacle 37 in the back of the action figure 30. Figs. 3-5 illustrate the backpack 32 and the components of the audio generating system 10. Backpack 32 defines an enclosure 40 formed by a box-like receptacle 42. Receptacle 42 is open at one end 43. A lid 44 closes the open end 43 of receptacle 42 and the enclosure 40 therein. Receptacle 42 has side walls 46-49 and an end wall 50 which define enclosure 40. For convenience, receptacle side walls 46 and 47 may be referred to as the backpack top and bottom (or top and bottom walls), respectively, receptacle side walls 48 and 49 as the backpack sides or side walls, receptacle end wall 50 as the backpack rear or rear wall, and lid 44 as the backpack front or front wall. Rear wall 50 has slotted openings 52 (Fig. 4) to allow sound waves to emanate from enclosure 40. The components of audio generating system 10 are mounted within enclosure 40 as follows. Speaker 12 is mounted with its cone or sound projecting part 56 adjacent and facing slotted openings 52 in rear wall 50, batteries 22A-C are mounted in a side-by-side generally flat grouping adjacent the flat end face 57 of coil or magnet 58 of speaker 12, and PCB 14 is mounted in a space 60 above speaker 12 and batteries 22A-C. A shoulder 64 projects inwardly in enclosure 40 from side wall 48 spaced from top wall 46, and another shoulder 65 projects inwardly in enclosure 40 from side wall 49 spaced from top wall 46 the same distance as shoulder 64. Each shoulder 64, 65 extends sufficiently from and sufficiently along the respective side wall to function as an opposed bracket for supporting PCB 14 thereon, and shoulders 64 and 65 are spaced sufficiently from top wall 46 to provide a clearance space 60 between shoulders 64, 65 and top wall 46 which can accommodate PCB 14 with circuit components thereon. Shoulders 64 and 65 extend from rear wall 50 the full extent of side walls 48 and 49, respectively, less the thickness of lid 44 so that lid 44 when mounted to receptacle 42 is flush with the edge of side walls 48 and 49. Speaker 12 is mounted in enclosure 40 so that the cone or sound-generating part 56 thereof is adjacent and faces slotted openings 52, and speaker coil or magnet 58 is facing the front of the backpack. Sound projecting part 56 ends in a plane defining a face 68 having a peripheral edge. The speaker faces 57 and 68 are the end faces of speaker 12 and extend parallel to each other. An adhesive may be used between the peripheral edge of the sound-projecting part 56 of speaker 12 and rear wall 50 to mount the speaker to rear wall 50. A base plate 70 having mechanical structure 72 for positioning and holding batteries 22A-C is disposed adjacent speaker coil 58 extending parallel to face 57 thereof, and parallel to front and rear walls 46, 47, i.e., extending vertically in Figs. 2 and 3. Battery base plate 70 has cutouts 76 at the top thereof to accommodate shoulders 64, 65 and is configured to fit snugly within enclosure 40. The mechanical structure 72 of base plate 70 which receives and supports three button-cell batteries 22A-C in a flat, side-by-side equilateral triangle grouping comprises a center post 78 with three curved side surfaces 79 to accommodate a circular edge portion of each battery 22A-C, and three surrounding shorter posts 81 each with three curved side surfaces 83 to accommodate another circular edge portion of each battery 22A-C. Referring to Figs. 3 and 6, base plate 70 also includes electrical contacts 85-87 mounted thereon to contact one terminal of each of the three batteries 22A-C. Printed circuit traces 89 and 90 for the battery interconnections are located on the back side of the plate 70. Trace 89 at the left connects the lower left contact 85 for battery 22A to a point 92, which in turn is connected to a point 93 on PCB 14 by a wire 94. Trace 90 at the right connects the battery contacts 85 and 86 for batteries 22B and 22C. PCB 14 having mounted thereto IC 15 and other necessary components (not shown) such as a transistor 18, discrete capacitor 20 and resistor 19 is positioned in space 60 above the shoulders 64 and 65 as described above. Top wall 46 has apertures 16, 17 positioned over PCB 14. These apertures 95, 96 receive switches 16, 17, of the conductive rubber (or insulating rubber with a conductive insert) type. PCB 14 has spaced traces 100 underlying each switch 97, 98. When the button 112 of a switch 16, 17, is pressed, a conductive portion of the pressed switch shorts across the spaced traces 100 to effect a switching function. Referring to Figs 3 and 7, further structure 102 for holding and electrically connecting batteries 22A-C is mounted on inside of lid 44. Structure 102 comprises battery contact springs 103 and 104 mounted to lid 44 by pins 105 snap fitted into holes 108 in springs 103 and 104. As shown schematically in Fig. 8, the bottom contact spring 103 interconnects the facing negative side of battery 22A with the facing positive side of inverted battery 22B. The upper contact spring 104 interconnects the negative side of battery 22C and a contact point 107 on PCB 14. The upper edge 106 of spring 104 makes direct contact with point 107 when the various components are assembled into receptacle 42 (see Fig. 4). Lid 44 has a configured tab 110 (Figs. 3 and 7) at the bottom edge thereof, and bottom wall 47 of receptacle 40 has a complementary opening 111 therein sized to receive projection 110 in snap-lock fashion. Two screw holes 115 are provided at the top of lid 44, and shoulders 64 and 65 have threaded holes 116 therein for receiving screws 118. Thus, lid 44 is secured to receptacle 40 by the screws 118 and the snap-locking of tab 110 in opening 111. Backpack 32 is assembled as follows. Speaker 12 is secured to receptacle 40 as described above. Point 93 of PCB 14 is connected to point 92 contact 85 on trace 89 by wire 94. Switches 16, 17, are positioned with their activating buttons 112 protruding through holes 95, 96. PCB 14 is mounted in space 60 with base plate 70 extending adjacent and parallel to speaker coil end face 57. Batteries 22A-C are inserted between posts 78 and 81 in the equilateral triangle grouping defined by posts 81. Lid 44 is screwed and snap-locked to receptacle 40 as described above. When lid 44 is assembled to receptacle 40, the contact springs 103, 104 make contact with and press the batteries 22A-C against base plate 70. A snug fit between the lid 44 and the base plate 70 is provided so that the batteries 22A-C are firmly urged against the base plate 70 by spring action which prevents front-to-rear movement of the batteries. Up-down and side-to-side movement of the batteries is prevented by a snug fit of the batteries between the side walls 28, 29 and wherein the top wall 26 and posts 81. The combination of the spring contacts 103, 104, the traces 89, 90, the battery arrangement with one battery 22B inverted, provide in a very simple and economic manner the necessary 4.5 volts to the PCB 14 to power the circuitry thereon. Arranging the batteries side-by-side in the flat grouping shown consumes less space than the known axially aligned arrangement referred to above. By causing certain components to provide multiple functions, a more compact audio accessory has been provided. For example, the base plate 70 not only isolates batteries 22A-C from speaker 12, but also serves as a PCB to serially interconnect batteries 22A-C in cooperation with contact springs 103, 104. Similarly, contact springs 103, 104 not only contribute to the serial interconnection of the batteries, but also assure good electrical contact thereto while assisting in maintaining the batteries in position. The provision of PCB 14 on top, parallel to and under the top wall 46, allows switches 16, 17 to be conveniently placed on top where they are easily accessible for activation of the sound generating system. The use of two screws 18 and tab 110 to hold the lid 44 in place automatically completes the mechanical assembly of the enclosure, and also assures that the PCB and the batteries are properly anchored. In the embodiment illustrated, two separate switches 16, 17 are provided, a first to activate the circuitry to provide a first verbal expression and/or sound effect, and a second to activate the circuitry to provide a second verbal expression and/or sound effect. Closing switches 16 and 17 in given sequences or holding a switch activated for a given time causes audio generating system 10 to sound speech phrases and/or sound effects in various combinations. The logic for achieving such variation in the preferred embodiment is mask programmed into chip 15, or alternatively provided by optional logic circuitry 24, or both. In the preferred embodiment, IC 15 is a Windbond W52300 Series ADPCM voice synthesizer. That IC includes four trigger inputs, two of which 26 and 27 are designated in Fig. 1. IC 15 includes a read only memory (ROM) which can be partitioned into four sections, each of which can be read out in response to given trigger inputs according to the mask programming of the chip. IC 15 may be mask programmed to operate in a direct trigger mode in which a sound effect or speech phrase is sounded only upon actuation of a switch, or in a serial-trigger mode in which a single actuation of a switch causes a series of speech phrases and/or sound effects to be sounded. In the direct trigger mode, each switch actuation may cause the same or a different sound to be generated. In the preferred embodiment, IC 15 is mask programmed in the serial trigger mode to sound a speech phrase followed by a sound effect for each actuation of a switch. With two switches 16, 17 and a four ROM partition, actuation of switch 16 will cause a first speech phrase and first sound effect to be sounded, and actuation of switch 17 will cause a second speech phrase and a second sound effect to be sounded. For example, for a spaceman toy action figure, actuation of switch 16 causes audio system 10 to sound "check it out.", followed by a spaceship sound effect, and actuation of switch 17 causes audio generating system 10 to sound "they're moving" followed by a large vehicle sound. While the invention has been described and illustrated in connection with preferred embodiments, many variations and modifications as will be evident to those skilled in this art may be made therein without departing from the scope of the invention. The invention as set forth in the appended claims is thus not to be limited to the precise details of construction set forth above and such variations and modifications are intended to be included within the scope of the appended claims.

Claims: A battery-powered toy audio device (32) attachable to or arranged to form part of a toy action figure (30) and comprising a structure defining an enclosure (42,44), said structure having a sound transmitting portion (52), a speaker (12) mounted in said enclosure and having a sound projecting portion (56) facing said sound transmitting portion, circuitry (10,14) disposed in said enclosure for generating audio signals, the speaker being coupled to said circuitry to produce audio in response to said audio signals, and means (16,17) accessible from outside the enclosure for activating the device, characterised in that the circuitry is powered by a plurality of miniature disc-like batteries (22A,22B,22C) held in said enclosure in a side-by-side grouping with an end face of each of said batteries in a common plane which is opposite from and overlapping an end face (57) of the speaker, said plane not intersecting said speaker. The toy audio device of claim 1 wherein said batteries (22A,22B,22C) are disposed in said grouping on a same side of said common plane. The toy audio device according to claim 1 or claim 2 comprising a printed circuit board (14) on which said circuitry (10) is mounted, said printed circuit board being disposed in said enclosure (42,44) adjacent said speaker and having a major surface generally perpendicular to said common plane. The toy audio device according to any one claims 1 to 3 comprising a printed circuit board (14) on which said circuity (10) is mounted, spaced shoulders (64,65) in said enclosure (42) supporting said printed circuit board adjacent said speaker (12) with a major surface of said printed circuit board generally perpendicular to said plane of said battery end faces. The toy audio device according to any one of claims 1 to 3 wherein said enclosure (42) is of rectangular cross-section formed by a rectangular end wall (50) and four rectangular side walls (47-49), said end wall (50) including said sound transmitting portion (52) of the enclosure, a shoulder (64,65) projecting from each of two opposed side walls (48,49) equally spaced from an adjacent side wall to define a space between said shoulders and said adjacent side wall, said printed circuit board (14) being disposed in said space and held therein by said shoulders, said speaker (12) being disposed between said printed circuit board (14) and the side wall opposite said adjacent side wall with said sound projecting portion (56) facing said sound transmitting portion (52) of said end wall. The toy audio device according to claim 5 wherein said adjacent side wall (46) has an opening (95,96) and said switch (16,17) comprises a resilient member (112) mounted in said opening (95,96) and having an electrically conductive portion positioned so as to contact said printed circuit board (14) when pressed. The toy audio device according to any of the preceding claims wherein said activating means (16,17) comprises at least one switch (16,17) mounted to said enclosure to contact directly and cooperate with said printed circuit board (14). The toy audio device according to any of the preceding claims wherein the batteries are held by mounting means comprising a plate-like member (70) having a surface defining said common plane and means (72) for positioning the batteries (22A,22B,22C) side-by-side in said grouping with a face of each battery contacting and parallel to said surface, said plate-like member (70) being located between said speaker end (57) and said batteries. The toy audio device according to claim 8 wherein said speaker (57) has a flat end face, said plate-like member (70) extending parallel to said speaker end face opposite thereto and overlapping said speaker end face. The toy audio device according to claim 9 wherein a printed circuit board (14) of said circuitry extends perpendicular to said speaker end face (57) and said plate-like member (70). The toy audio device according to any of the preceding claims wherein there are three said batteries (22A,22B,22C) and they are positioned at vertices of an equilateral triangle. The toy audio device according to any of the preceding claims wherein said enclosure (42,44) comprises a receptacle (42) having an open end and a lid (44) closing said open end. The toy audio device according to any of claims 8 to 10 together with claim 12 wherein means (102,103,104,107) for electrically interconnecting said batteries comprising electrical contact members (89,90,103,104) are disposed on said plate-like member (70) and on said lid (44). The toy audio device according to claim 12 or claim 13 comprising at least one fastener (118) and cooperating means (115,116) on said lid and said receptacle (42) for removably fastening said lid to said receptacle. The toy audio device according to any of claims 12 to 14 having means (36) coupled to said lid (44) for removably attaching said device to another toy. The toy audio device according to any of claims 12 to 15 wherein the lid (44) is fastened to said receptacle (42) and cooperates with said plate-like member (70) to hold the batteries between said plate-like member and said lid. The toy audio device according to any one of claims 1 to 12 comprising first and second plate-like members (70,44) between which said batteries are disposed, said plate-like members each having means (102,103,104,107) for interconnecting said batteries, said first plate-like member (70) being adjacent said speaker end. The toy audio device according to claim 17 wherein said enclosure (42,44) comprises a receptacle (42) having an open end closed by said second plate-like member (44). The toy audio device according to claim 17 or claim 18 wherein said enclosure (42) is rectangular in cross-section, and said first and second plates (30,44) are also rectangular and sized to fit snugly in said enclosure. The toy audio device according to any of the preceding claims wherein said circuitry (10) comprises means for storing (15) at least one sound effect and at least one verbal message. The toy audio device according to any of the preceding claims configured as a backpack (32) and including means for removably attaching (36,37) said device to a toy action figure (30). In combination, a toy action figure (30) and the device (32) according to any of the preceding claims mounted thereto. The toy audio device according to any of the preceding claims configured as a removable accessory (32) for a toy action figure (30) and the like.

Inventors: CHU DAVID KI KWAN, GOLDBERG HARVEY, LEBENSFELD STEVEN, MA HUNG WAI, CHU, DAVID KI KWAN, GOLDBERG, HARVEY, LEBENSFELD, STEVEN, MA, HUNG WAI
Applicants: CHU DAVID KI KWAN, GOLDBERG HARVEY, LEBENSFELD STEVEN, MA HUNG WAI, CHU, DAVID KI KWAN, GOLDBERG, HARVEY, LEBENSFELD, STEVEN, MA, HUNG WAI
Application year: 1991
Main classification: A63H29
IPC codes: A63H5, H01M2, A63H3