Abstract:
A toy including stand up flexible pouch or other flexible type pouch affixed to a rollable mechanical base and method of making the toy. When assembled, the toy may be manually or remotely controlled to roll or move about in a predetermined direction or fashion. The flexible pouch is shaped and printed to resemble a desired character while still maintaining its ability to contain a product. The base apparatus includes rolling members, e.g., wheels, to allow the base to be rolled or otherwise moved across a surface. The pouch and base are joined together, for example, by heat sealing, ultrasonic sealing, adhesives, etc. The rollable base may include a battery or other power source and/or electronics allowing for remote controllability of the assembled toy. The flexible pouch may contain a separate food or other product and a fitment, snap closure or other type of reclosure as desired.

Description:
FIELD OF THE INVENTION 
     This invention relates to toys, and more particularly, to toys (e.g., robots, animated characters) that may be readily created and modified by changing the die cut shape of flexible packages for holding products (e.g., food stuffs) in a hermetically sealed condition (e.g., isolated from the ambient atmosphere). 
     BACKGROUND OF THE INVENTION 
     Toy manufacturers are inherently concerned with production expenses. Often in preparing plastic toys for mass production, a manufacturer goes through a lengthy mold making process. Injection molding is a primary process for manufacturing plastic parts for toys. Injection molding involves taking plastic of your choice in the form of pellets or granules and heating the plastic until a melt is obtained. Then the melt is placed into a split-die chamber/mold where it is allowed to cool and harden into the desired shape. The mold is then opened and the part is ejected, at which time the cycle may be repeated. While the cost per part is fairly low, the tooling is expensive. 
     Thermoforming is a technology that produces a three-dimensional structure from a two-dimensional thermoplastic sheet. The three-dimensional structure is formed by heating a thermoplastic sheet and then pulling it down onto a mold surface to shape the sheet. The structure is formed to the shape of the mold surface by vacuum forming. Then the structure is cooled and released from the mold. 
     A significant contributing factor to the costs of toy making is the speed of machining. Once a designer has conceived an approved design, it is imperative to convert the design concept into a prototype mold quickly since selling seasons are short. The life cycles of many toys are so short that the designers often work on very tight time schedules. Therefore, it would be beneficial to manufacture toys using a more economical solution. 
     Children today reap the benefits of the number of toys in the marketplace, with many children having thousands of toys to choose from at a store and hundreds of toys at their house. Despite the many available toys, a child generally has only a couple favorite toys. The other toys are either put into storage or sit around waiting for the child&#39;s attention, which is often fleeting. While many parents have ample space for their children&#39;s toys, there are some environments where space is limited. For example, children have limited space for playing with their toys in confined environments (e.g., a car), especially when space in the cramped environment is also needed to store luggage or groceries. For example, there may not always be ample space in a car for the car to hold groceries or luggage, and also to have space for many toys for the child to play with. Accordingly, it would be beneficial to provide toys that children can play with that can be used for holding a product. 
     SUMMARY OF THE INVENTION 
     These and other objects of this invention are achieved by providing a toy having an interior for holding a product (e.g., candy, coffee, cookies, foodstuff, etc.) therein. The toy is formed of a flexible material suitable for being hermetically sealed with the product located within its interior. The toy comprises a base having a bottom section arranged for moving against a surface (e.g., floor, wall, table top), and a stand-up sealable package that opens to define the interior. Preferably, the bottom section includes wheels or a transporting mechanism that rotates to roll or otherwise move the base in a predetermined manner. The base also includes an upper section having a predetermined circumference. The sealable package includes a bag or pouch having a front panel and a rear panel sealed to each other along their side edges. Each of the panels includes a lower lip having an outside surface and an inside surface. The inside surface is open to form a lower mouth therebetween. The toy is formed upon coupling the lower mouth about the circumference of the upper section of the base. 
     In a preferred embodiment, the package also comprises a flexible floor panel sealed to the pouch along the lower lip. The floor panel extends between the base and the interior of the package to close off and isolate the interior of the pouch from the base. In another preferred embodiment, the lower lips of the pouch are directly sealed to the base, preferably about the peripheral sides of the base. The pouch may also include a sealable upper section that opens to provide access to the interior of the pouch. The sealable section is arranged for closing and sealing the product in the interior of the package upon closure of the section. The sealable section may also include a fitment secured to the pouch. The fitment  40  preferably includes a connector (e.g., spout, valve) and a cap. The connector is hermetically sealed to the pouch and provides a conduit for access to the interior of the package. The cap securely attaches to the connector to seal the interior and disconnects from the connector to expose the interior for access therein. 
     The base preferably includes a motor that turns the wheels as desired to move the base against the surface. The base may also include a steering mechanism to control the direction and speed of rotation of the wheels. The steering mechanism can be adapted to control the wheels based on a signal received from a remote controller. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will be described in conjunction with the following drawings in which like-referenced numerals designate like elements and wherein: 
     FIG. 1 is an isometric view of one exemplary embodiment of a flexible toy in accordance with a first preferred aspect of the invention; 
     FIG. 2 is an exploded isometric view of the flexible toy of FIG. 1; 
     FIG. 3 is a partial isometric view of the bottom of the pouch shown in FIG. 1; 
     FIG. 4 is a side elevational view partially in section of the flexible toy taken along line  4 — 4  of FIG. 1; 
     FIG. 5 is a partial side elevational view of the flexible toy of FIG. 1; 
     FIG. 6 is a longitudinal view of the base of the flexible toy shown in FIG. 1; 
     FIG. 7 is a side elevational view of a flexible pouch in accordance with a second exemplary preferred embodiment of the invention; 
     FIG. 8 is a side elevational view of a flexible pouch in accordance with a third exemplary preferred embodiment of the invention; 
     FIG. 9 is a sectional view of a snap closure of the pouch taken along line  9 — 9  of FIG. 8; 
     FIG. 10 is a side elevational view of a flexible pouch  16  having the shape of a toy in accordance with a fourth exemplary preferred embodiment of the invention; and 
     FIG. 11 is a side elevational view of another flexible pouch having the shape of a toy in accordance with a fifth exemplary preferred embodiment of the invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIGS. 1-3 there is shown at  10  a toy constructed in accordance with a first preferred embodiment of the invention. The toy  10  basically comprises a flexible package  12  (e.g., container) and a base  14 . The package  12  is arranged to hold any particular material (e.g., candy, snack food, coffee, foodstuffs) and is suitable for packaging small amounts of such materials or for holding large amounts of such materials. 
     The package  12  includes a pouch  16  (e.g., bag) formed of a web of any conventional, flexible material, such as a laminated film. The pouch  16  basically includes a front panel  18 , a rear panel  20 , a sealable upper section  22  and a lower section  24 . The sealable upper section  22  of the pouch  16  terminates in a top marginal edge  26 . The lower section  24  of the pouch  16  terminates in a bottom marginal edge  28 . Preferably the pouch  16  is die cut to form its shape, as will be described below. 
     As illustrated at FIGS. 1 and 2, the front and rear panels  18 ,  20  of the pouch  16  are coupled together at outer sides of the panels. The panels  18 ,  20  are coupled by any conventional sealing method, for example, heat sealing, ultrasonic sealing, adhesive (e.g., epoxy sealing, etc.). The coupling of the front and rear panels  18 ,  20  forms outer flanges or fins  30 . Preferably the fin  30  extends longitudinally along the sides of the pouch  16  from the top marginal edge  26  to the bottom marginal edge  28 . The fin  30  is formed by portions of the web material contiguous with the side vertical edges of the front and rear panels  18 ,  20  which are brought into engagement with each other and are secured to one another via the conventional sealing technique. In addition to providing a hermetic seal between the panels, the fins  30  increase the stability of the pouch  16 , especially along portions of the pouch  16  closest to the fins  30 . 
     The pouch  16  is shown in FIGS. 1 and 2 in an open configuration illustrating the hollow interior  32 . The pouch  16  is flexible so that it can be economically formed and stored in a flattened configuration, with both the front and rear panels  18 ,  20  abutting each other to consume a minimal amount of space. When the pouch  16  is in its open configuration, the lower section  24  can bend as desired to conform to the shape of the base  14  to fit and seal the pouch  16  to the base  14  as will be described below. As shown in FIGS. 1 and 2, the sealable upper section  22  of the flexible pouch  16  is arranged to permit ingress to the product in the interior  32  of the package  12  and to seal the product from the ambient atmosphere. When the pouch  16  is formed as described above by coupling the front and rear panels  18 ,  20 , the top marginal edge  26  forms an upper mouth  34 . The upper mouth  34  includes an inner wall  36  along the inner circumference of the upper mouth  34 , and an outer wall  38  along the outer circumference of the upper mouth  34 . 
     As an example of a sealable upper section  22 , FIGS. 1 and 2 show a fitment  40  comprising a connector  42  and a removable cap  44 . As best shown in FIG. 2, the connector  42  includes an upper rim  46 , a dome-shaped intermediate section  48  and a lower rim  50 . The upper rim  46  forms a first opening and the lower rim  50  forms a second opening. The lower rim  50  is coupled at its circumference to the top marginal edge  26  of the pouch  16  to form a hermetic seal therebetween. The lower rim  50  is shown having a circumference slightly less than the circumference of the top marginal edge  26 . This enables the lower rim  50  to fit snugly about the inner wall  36  of the upper mouth  34 . It is also within the scope of this invention to provide a lower rim  50  that fits about the outer wall  38  of the upper mouth  34  or to provide a lower rim  50  that abuts the top of the upper mouth  34 , as long as the connector  42  and the pouch  16  are hermetically sealed. 
     In this embodiment, the connector  42  is formed of any conventional lightweight material (e.g., plastic) and is semi-rigid having a dome-like shape. The intermediate section  48  extends from the lower rim  50  to the upper rim  46 , and has a circumference that decreases toward the upper rim  46 . The connector&#39;s upper rim  46  is basically cylindrical in shape and has a circumference less than the circumference of the lower rim  50 . Coupling the connector  42  to the upper mouth  34  of the pouch  16  increases the stability of the pouch  16  towards the upper section  22  of the pouch  16 . In other words, the upper section  22  of the flexible pouch  16  becomes more sturdy when it is attached to the semi-rigid connector  42  as is readily understood by a person skilled in the art. This increased stability enables the package  12  to stand and retain its shape for better use as a toy  10 . 
     The removable cap  44  is arranged to seal the interior  32  of the package  12  from the atmosphere external to the package  12 . As can best be seen in FIG. 2, the exemplary cap  44  has a flat disc-like top  43  and a cylindrical shaped flange  45  longitudinally extending from the underside of the top adjacent its outer rim. The cylindrical flange  45  is constructed to frictionally engage the upper rim  46  of the connector  42 . For example, as shown in FIGS. 1 and 2, the cylindrical flange  45  couples about the upper rim  46  of the connector  42  when the cap  44  is placed upon the connector  42 . The cap  44  connects to the connector  42  using any conventional method (e.g., screw or push on). This exemplary cap  44  is a push on lid with a flange  45  having an inner circumference about equal to the outer circumference of the upper rim  46  of the connector  42  such that the flange  45  frictionally extends about the outer circumference of the upper rim  46  to secure the cap  44  to the connector  42 . The cap  44  can be placed on and taken off of the connector  42  as desired to access the contents of the interior  32  of the flexible pouch  16 . 
     For safety purposes, the fitment  40  may also include a removable safety cover that forms a tamper-proof seal. This cover is placed over the first opening defined by the upper rim  46  of the connector  42  and provides a one-time seal notwithstanding the seal provided by the cap  44  placed over the upper rim  46  of the connector  42 . The safety cover is preferably placed over the upper rim  46  after the package  12  is initially filled with a product and is removed by the user after purchase. Prior to its removal, the cover can be inspected to ensure that the package  12  was not tampered with by another prior to purchase. 
     As can be seen in FIGS. 3 and 4, the package  12  also includes a flexible floor panel  52  for sealing the lower section  24  of the package  12 . The floor panel  52  is preferably formed of the same material as the front and rear panels  18 ,  20  (e.g., laminated film). The floor panel  52  is sized to extend across the interior  36  and abut the inner wall  36  of the front and rear panels  18 , 20 . The floor panel  52  is secured to the inner wall  36  of the lower section  24  using any conventional sealing technique (e.g., heat sealing, welding, adhesive, etc.) to form a hermetic seal between the entire perimeter of the floor panel  52  and the lower section  24 . 
     When the package  12  is flat, the floor panel  52  folds along a crease  54  and is substantially flat. When the package  12  is open, as shown in FIGS. 3 and 4, the floor panel  52  unfolds and forms a cup-like shaped layer having a vertically extending wall  68  sealed along the inner wall  36  of the lower section  24 . In this manner, the floor panel  52  provides a layer between the interior  32  of the package  12  and the atmosphere external to the package  12  to seal the product in the package  12 . 
     As can be seen clearly in FIGS. 4-6 the base  14  preferably has a cylinder-like shape and is rounded off of its bottom edge  56 . The base  14  includes an upper region  58 , a lower region  60 , wheels  62 , a motor  64  and a battery  66 . As shown in FIGS. 4 and 5, the upper region  58  is fitted and secured within the inner wall  36  of the package  12 . In FIG. 4, the upper region  58  is secured to the vertically extending wall  68  of the floor panel  52 . In FIG. 5, the upper region  58  is sealed directly to the inner wall  36  of the lower section  24 . While the upper region  58  can be sealed to the package  12  using any conventional method as discussed above for securing the panels together, the exemplary bases shown in FIGS. 4 and 5 are sealed to the package  12  with a layer of epoxy cement  74  between the radial peripheral side of the upper region  58  and the adjoining inner wall  36  of the floor panel  52  (FIG. 4) or lower section  24  (FIG.  5 ). 
     The wheels  62  of the base  14  rotate for rolling the toy  10  against a surface (e.g., floor, wall, table top). The battery  66  communicates with the motor  64  and provides power to the motor  64  for driving at least one of the wheels  62 . The driving wheels  62  are attached to the motor  64  via axles  70  extending between the attached wheels  62  and the motor  64 . The axles  70  rotate based on the motor  64  and turn the driving wheels  62 . The base  14  may also include a steering mechanism  72  for turning the toy. The exemplary base  14  shows the steering mechanism  72  integrated with the motor  64 . It is also within the scope of this invention to provide the steering mechanism  72  separate from the motor  64  and communicating with at least one of the wheels  62  to turn the toy as it moves along a surface. The motor  64  may also operate based on input from a remote controller as known to a skilled artesian for operating the movement of the toy. 
     As discussed above in FIG. 5, the pouch  16  is sealed directly to the base  14  to create a hermetic seal. The inner wall  36  of the lower section  24  surrounding the package  12  is preferably permanently sealed to the base  14  along a seam line formed between the periphery of the base  14  and the lower section  24  as described above and shown in FIG.  5 . This approach provides the benefit of a hermetic seal formed along the bottom marginal edge  28  of the package  12  without the floor panel  52  shown in FIGS. 3 and 4. 
     FIG. 6 is a longitudinal view of the lower region  60  of the base  14 . The lower region  60  includes a base floor  76 , which supports the motor  64  and includes openings  77  through which each of the wheels  62  extend. In this example, the driving wheels  62  are connected to the axles  70  inside of the base  14  and extend through the openings  77  in the base floor  76  where they can roll along a surface. The free wheels  62  are rotatably coupled to the base  14 , preferably at the base floor  76 . 
     FIG. 7 shows a second exemplary preferred embodiment of the flexible pouch  16  In FIG. 7, the pouch  16   a  is formed by the front and rear panels  18 ,  20  of web material sealed along the peripheral sides and a lower section  24 . The lower section  24  is sealed at the bottom marginal edge  28  along a curved seam line (FIG. 7) such that when the pouch  16   a  is opened, the lower section  24  rotates under the pouch  16   a  and forms a somewhat bowl-like configuration. Using this configuration, the pouch  16   a  preferably attaches to the top surface of the base  14  or within upwardly extending outer peripheral walls of the base  14 . It is understood that the pouch  16   a  is securely sealed to the base  14  to prevent any unwanted separation during handling of the toy. 
     Another example of a flexible pouch is shown at FIG.  8 . The pouch  16   b  basically comprises a front panel  18 , a rear panel  20  and a gusseted floor panel  52 . The front and rear panels  18 ,  20  have side edges  78 , a top end portion  79  and a bottom end portion  81 . The top end portions of the front and rear panels  18 ,  20  terminate in a top marginal edge  26 . The bottom end portion of the front and rear panels  18 ,  20  terminate in a bottom marginal edge  28 . The side edges  78  are hermetically sealed and form fins  30  using any conventional sealing technique as discussed above. As shown, side edges  78  of the front and rear panels  18 , 20  are sealed from the top marginal edge  26  to the bottom end portion  81 . 
     The gusseted floor panel  52  of the flexible pouch  16   b  is an integral portion of a single sheet or web of the flexible material, of single or multiple ply or layers. The floor panel  52  has a width terminating at side edges  78 . The width is substantially equal to the width of the front and rear panels  18 ,  20 . The floor panel  52  also includes bottom edges that extend approximately to the bottom marginal edge  28  of the pouch  16   b.  The floor panel  52  is folded and seamed to form a floor layer having a crease  54  similar to the floor layer shown in FIG.  3 . The floor panel  52  extends from the crease  54  to the bottom edges. 
     In this exemplary pouch  16   b,  the floor panel  52  is hermetically sealed to both the front panel  18  and the rear panel  20  along the side edges  78  and bottom marginal edge  28 , thereby forming a gusseted bottom. An unfolded floor panel  52  forms a flattened floor layer similar to the floor layer shown in FIGS. 3 and 4. In this position, the pouch  16   b  becomes cylindrical at its bottom end portion  81 , and the bottom marginal edge  28  of the front and rear panels  18 ,  20  is sufficiently planar so the pouch  16   b  can stand on its bottom marginal edge  28 . In other words, when the pouch is opened, the gusseted bottom separates about its crease  54  to form a floor layer and vertically extending wall  68  as can be seen in FIG.  3 . The flexible pouch  16   a  shown in FIG. 7 is an exemplary non-gusseted stand up package  12 , and the flexible pouch  16   b  shown in FIG. 8 is an exemplary gusseted type stand up package  12 . 
     FIG. 9 illustrates an exemplary integrated snap closure  80  for reclosing and resealing the pouch  16  of FIG. 8 after the pouch  16  has been opened. As can be seen in FIGS. 8 and 9, the front and rear panels  18 ,  20  include an upper section  22 , which between the panels  18 ,  20  define an opening  82  in the pouch  16 . The snap closure  80  is provided within this opening  82 . The snap closure  80  basically comprises a pair of snap strip members  84 ,  86  secured to respective portions of the front and rear panels  18 ,  20 . Each of the strips  84 ,  86  is formed of a flexible material (e.g., a plastic material, such as high or low density polyethylene or polypropylene or some other material) which is slightly flexible to enable it to be bent out of its original shape by the application of force thereto, but returns to its original shape after removal of that force. Each strip  84 ,  86  extends the width of the panel  18 ,  20  to which it is secured. Each strip  84 ,  86  is arranged to be fixedly secured, e.g., welded or permanently adhesively secured to the inner surface of the upper section  22  of the respective panel  18 ,  20  adjacent the top marginal edge  26  and across the full width of the strip  84 ,  86 . 
     The strip  84  basically consists of an elongated tongue-shaped member  88 . In particular, this strip  84  includes an elongated planner upper flange section  90 , an elongated planner lower flange section  92  and an intermediate projecting tongue section  94 . The tongue section projects perpendicularly upward from respective planner flange sections  90 ,  92  and has a transversely cylindrical shape that appears bulbous in its cross section (FIG.  9 ). 
     The strip  86  basically consists of an elongated channel or recess-shaped member  96 . In particular, the strip  86  includes an elongated planner upper flange section  98 , an elongated planner lower flange section  100  and a generally C-shaped intermediate section  102  defining a groove or recess  104  therein. 
     The material forming the strips  84 ,  86  is somewhat elastic and/or flexible to enable the tongue  88  of the strip  84  to snap fit into the groove or recess  104  of the strip  86 , and to be locked therein against accidental disconnection, yet which enable the tongue  88  to exit that recess  104  when the strips  84 ,  86  are pulled apart. It must be pointed out that the strips  84  and  86  can be mounted and secured to the rear panel  20  and front panel  18 , respectively, instead of to the front panel  18  and rear panel  20 , respectively. It must also be pointed out that the strips  84 ,  86  can be mounted and secured to the front and rear panels  18 ,  20  of the flexible pouch  16   a  shown in FIG.  7 . Thus, the embodiments of FIGS. 7 and 8 are merely exemplary. 
     Notwithstanding their slight elasticity, the strips  84 ,  86  are substantially rigid so that when they are snapped together, the strips  84 ,  86  serve to hold the upper section  22  of the front panel  18  tightly against the top portion of the rear panel  20 . The recess  104  of strip  86  tends to reinforce the strips  84 ,  86  and keep them linear to further insure that the opening  82  of the package  12  is sealed closed when the strips  84 ,  86  are snap connected to each other. Thus when the strips  84 ,  86  are snapped together, the contents of the pouch  16  are effectively isolated from the ambient surroundings so that it can be kept fresh over an extended period of time. 
     Other exemplary embodiments of the toys constructed in accordance with this invention are shown in FIGS. 10 and 11. The toy  110  shown in FIG. 10 is cut in the shape of an animal and includes a pouch  16   c  constructed in a substantially similar manner to that of the pouches and packages shown at FIGS. 1,  2 ,  7  and  8 , and described heretofore. The shape of the pouches are defined by the shape of the die. The toy  120  shown in FIG. 11 is formed in the shape of an angel and includes a pouch  16   d  constructed in a substantially similar manner to that of the pouches and packages described heretofore. The pouches shown in FIGS. 10 and 11 are provided as examples of alternative toy figures that provide playful pleasure to a child. Both pouches can be filled with a product (e.g., candy, foodstuffs) and fixed to the base  14  as described above as a combination toy with food package  12 . By providing a combination toy and food package  12  in one product, a child can play with the toy without taking up extra space for the product stored in the pouch  16 . Accordingly, space is used more efficiently, because the same space is occupied as both a food package  12  and a toy. 
     It should be apparent from the aforementioned description and attached drawings that the concept of the present application may be readily applied to a variety of preferred embodiments, including those disclosed herein. Thus, as will be appreciated by those skilled in the art, the closures of this invention, the shapes of the package  12  and features of the toy  10  can be modified insofar as its construction and/or material composition is concerned in order to accommodate the preferred uses of the toy  10 . For example, the package  12  can also have the shape of a robot or a vehicle (e.g., car, truck, airplane, train, etc.). In addition, the base can include other types of rolling members (e.g., one wheel, ball bearings, rollers, tractor treads, spoked hubs, etc.). The rolling member could also be placed horizontally (with a vertical axis) and rotate the toy about the axis. Moreover, the package need not be hermetically sealed. In fact other resealable approaches could be used in addition to the fitment and snap closure described herein. For example, the package could be provided with an easy opening top or tab. Further, the package could have a seal separate from the fitment such that the fitment is used after the package is initially opened by the user. 
     Without further elaboration the foregoing will so fully illustrate our invention that others may, by applying current or future knowledge, adopt the same for use under various conditions of service.