Abstract:
An apparatus and kit for stuffing plush toys and a method of stuffing using the device. The apparatus including a stuffing hopper with an inlet for receiving stuffing, an auger housing located below and in communication with the stuffing hopper, a device located in the stuffing hopper for feeding stuffing from the stuffing hopper into the auger housing and a rotatable auger located within the auger housing to feed stuffing out of the apparatus and into a plush toy casing.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims benefit from U.S. Provisional Patent Application Ser. No. 61/519,988, filed Jun. 3, 2011, the contents of which are hereby incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention is directed to the field of stuffed toys, in particular, a method, apparatus and kit for stuffing plush toys. 
     2. Description of the Related Art 
     Retail shops at which customers can make customized stuffed toys such as teddy bears are extremely popular. Such toys are also known in the toy trade as “plush.” At such retail shops customers choose from a variety of pre-made animal or character “skins,” which are the outer fabric casings of the plush toy comprised of fabric panels sewn together into the form of the animal or character and act as the container, which is formed into the full shape of the animal or character by being stuffed full of a soft, fluffy stuffing material. In essence, the skin is the plush toy absent the stuffing and decorative detailing. The customer also selects from a variety of facial features to be attached to the skin in the appropriate location after the skin is stuffed and choose from a variety of clothing and other accessories to complete the plush toy. 
     The focal point of the in-store manufacturing process is the stuffing machine. It is a large piece of heavy equipment that typically measures several feet in length, width, and height, and weighs hundreds of pounds. It is powered by a/c current that runs large motors, blowers and air compressors which, together, generate and direct significant air velocity and pressure needed to feed the stuffing from the machine, through an injection tube, and into the skin through a hole in the fabric of the skin. Once filled with stuffing, the skin is removed from the injection tube and the store employee closes the skin fill hole by tying shut laces around the hole, or by some other method of closure, which requires the skill of the store employees. 
     Due to the size and costs of the machine required for this method of stuffing a plush toy, it is too dangerous to be handled by customers, especially young children. Therefore, the customer merely passively watches, while the employee performs the entire manufacturing process. 
     Attempts have been made to reduce the size and cost of these stuffing machines to make them more portable and more suitable for the mass market, but the degree to which they can be reduced is restricted by the requirements of the large motors and compressors needed to generate sufficient pressure to fill the skins. Such machines also require skill and dexterity not possessed by young children. 
     There remained a need for a toy stuffing apparatus to be reduced to a size, price, and level of skill and safety that would allow them to be used at home by small children as an activity toy, or craft kit. The inventors&#39; prior U.S. Pat. No. 7,377,841, the contents of which are hereby incorporated by reference, sets forth a mechanical apparatus for stuffing plush toys which can be used at home. This patent includes an apparatus having a top drum within which arms and paddles are rotated to fluff the plush toy stuffing and push the stuffing down into a chamber in which a simultaneously rotated auger, transports the stuffing along the auger shaft and out to an exit, and, in turn into the plush toy casing. 
     However, this apparatus has numerous parts and their configuration requires a certain size and internal volume to operate properly. Accordingly, there remained a need to have a simpler mechanical toy stuffing apparatus which has less parts and is smaller than the prior art apparatus and, therefore, easier and less expensive to manufacture. There also remained a need to have a mechanical toy stuffing apparatus that was simpler and easier to operate and eliminated the need to hold the plush casing onto the fill nozzle. 
     The prior art discloses different types of stuffing apparatus. However, so far as is known, none of the prior art devices resolve all of these problems in a simple, effective and yet highly advantageous manner as in the present invention discussed herein. 
     SUMMARY OF THE INVENTION 
     It is therefore an object of the invention to provide a novel toy stuffing apparatus. 
     It is also an object of the invention to provide a toy stuffing apparatus which is simpler and easier to use. 
     It is a further object of the invention to provide a toy stuffing apparatus wherein the user does not have to hold the stuffed toy casing on the end thereof, when stuffing. 
     It is yet another object of the invention to provide a toy stuffing apparatus which is simple, easy and inexpensive to manufacture and is comprised of fewer parts than the prior art devices. 
     Certain of the foregoing and related objects are readily attained according to the present invention by the provision of an apparatus for inserting stuffing into a casing, comprising a stuffing hopper defining an interior chamber therein, having an inlet for receiving stuffing and an outlet for discharging stuffing; an auger housing located below said stuffing hopper and defining an interior chamber therein, which is in communication with said interior chamber of said stuffing hopper, said auger housing having an inlet located adjacent to and in communication with said outlet of said stuffing hopper, and a discharge outlet to discharge the stuffing from said apparatus; means for feeding stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing, which means are located within said stuffing hopper; a rotatable auger located within said interior chamber of said auger housing to drive the stuffing in said interior chamber of said auger housing towards and to said discharge outlet thereof, where it, in turn, exits said auger housing into the casing; and drive means for rotating said auger. 
     Preferably, the apparatus further comprises an externally threaded nozzle connected to said auger housing adjacent said discharge outlet. In a preferred embodiment, said means for feeding stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing is a resilient bellows movable between a compressed configuration and an expanded configuration, received within said interior chamber of said stuffing hopper. It is also preferable that at least one of said stuffing hopper and said auger housing includes a transparent portion. In one embodiment, said stuffing hopper is transparent. Advantageously, the apparatus further comprises at least one transparent window in said auger housing. 
     It is preferred that the apparatus further comprises a removable lid receivable over said inlet of said stuffing hopper. Advantageously, said drive means is a manually-operable handle. 
     Certain of the foregoing and related objects are also readily attained according to the present invention by the provision of a kit for making a stuffed toy at home, comprising a casing having an opening therein; stuffing to be inserted into said casing; closure means for closing said opening in said casing; and an apparatus for inserting stuffing into said casing, comprising a stuffing hopper defining an interior chamber therein, having an inlet for receiving said stuffing and an outlet for discharging said stuffing; an auger housing located below said stuffing hopper and defining an interior chamber therein, which is in communication with said interior chamber of said stuffing hopper, said auger housing having an inlet located adjacent to and in communication with said outlet of said stuffing hopper, and a discharge outlet to discharge said stuffing from said apparatus; means for feeding said stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing, which means are located within said stuffing hopper; a rotatable auger located within said interior chamber of said auger housing to drive said stuffing in said interior chamber of said auger housing towards and to said discharge outlet thereof, where it in turn, exits said auger housing into said casing and drive means for rotating said auger. 
     Preferably, the apparatus further comprises an externally threaded nozzle connected to said auger housing adjacent said discharge outlet. Advantageously, said means for feeding stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing is a resilient bellows movable between a compressed configuration and an expanded configuration, received within said interior chamber of said stuffing hopper. It is preferable that at least one of said stuffing hopper and said auger housing includes a transparent portion. It is also preferred that a removable lid is receivable over said inlet of said stuffing hopper. Desirably, said drive means is a manually-operable handle. 
     In addition, certain of the foregoing and related objects are also readily attained according to the present invention by the provision of a method for making a stuffed toy comprising a casing having an opening therein, stuffing to be inserted into said casing, closure means for closing said opening in said casing and an apparatus for inserting stuffing into said casing, comprising a stuffing hopper defining an interior chamber therein, having with an inlet for receiving said stuffing and an outlet for discharging said stuffing; an auger housing located below said stuffing hopper and defining an interior chamber therein, which is in communication with said interior chamber of said stuffing hopper, said auger housing having an inlet located adjacent to and in communication with said outlet of said stuffing hopper, and a discharge outlet to discharge said stuffing from said apparatus; means for feeding said stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing, which means are located within said stuffing hopper; a rotatable auger located within said interior chamber of said auger housing to drive said stuffing in said interior chamber of said auger housing towards and to said discharge outlet, thereof, where it in turn, exits said auger housing into said casing; and drive means for rotating said auger; removing said means for feeding said stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing, from said stuffing hopper; inserting said stuffing into said interior chamber of said stuffing hopper; placing said means for feeding said stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing into said stuffing housing; affixing said opening of casing onto said discharge outlet of said auger housing; rotating said drive means to, in turn, rotate said auger, to feed said stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing and towards and out of said discharge outlet of said auger housing and into said casing; removing said casing from said apparatus; and closing said opening of said casing via said closure means. 
     It is preferred that the apparatus include an externally threaded nozzle connected to said auger housing adjacent said discharge outlet. It is also preferable that said means for feeding stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing is a resilient bellows movable between a compressed configuration and an expanded configuration, received within said interior chamber of said stuffing hopper. Desirably, the apparatus further comprises a removable lid receivable over said inlet of said stuffing hopper. It is also advantageous that said drive means is a manually-operable handle. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other objects and features of the present invention will become apparent from the detailed description considered in connection with the accompanying drawings, which disclose several embodiments of the invention. It is to be understood that the drawings are to be used for the purpose of illustration only and not as a definition of the limits of the invention. 
         FIG. 1  is a perspective view of the toy stuffing apparatus, according to the present invention; 
         FIG. 2  is a rear elevational view thereof; 
         FIG. 3  is a front elevational view thereof; 
         FIG. 4  is a right side elevational view thereof; 
         FIG. 5  is a left side elevational view thereof; 
         FIG. 6  is a top plan view thereof; 
         FIG. 7  is a bottom plan view thereof; 
         FIG. 8A  is a left side elevational view of the toy stuffing apparatus, comparable to  FIG. 5 , but with a stuffed toy casing on the end thereof and with the bellows removed and stuffing being placed in the interior chamber of the stuffing hopper; 
         FIG. 8B  is a left side elevational view comparable to  FIG. 8A , but showing the bellows being placed in the interior chamber of the stuffing hopper atop the stuffing; and 
         FIG. 8C  is a left side elevational view comparable to  FIG. 8B , but showing a user cranking the handle to rotate the auger and, in turn, stuff the plush toy casing. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Turning now to  FIG. 1 , therein illustrated is the toy stuffing apparatus  10 , according to the present invention. As seen in  FIGS. 1 through 7 , toy stuffing apparatus  10  comprises a housing consisting of an upper stuffing hopper  14 , a middle auger housing  16 , and a lower base  18 , used to stuff plush toy casing  100 . 
     As can be seen in  FIG. 8A , stuffing hopper  14  defines an interior chamber therein for receipt of stuffing  200  to subsequently be stuffed into plush toy casing  100 . As seen in  FIGS. 1-6  and  8 A, stuffing hopper  14  has a cylindrical-shaped interior chamber and a stuffing inlet  36  on its open top end, through which the stuffing  200  is inserted. Stuffing hopper  14  also has a lower discharge outlet  32  opposite from the inlet  36 , to allow stuffing  200  to exit stuffing hopper  14  into auger housing  16 . 
     As also seen in  FIGS. 1-6 , a removable lid  38  is attachable to inlet  36  of stuffing hopper  14 . A compressible, resilient bellows  40  is mounted on the underside of lid  38  and is removably receivable within the interior chamber of stuffing hopper  14 . Bellows  40  is compressible into a non-expanded configuration (See,  FIG. 8B ) and expandable into an open and expanded configuration (See,  FIG. 8A ). Particularly, bellows  40  is made of a resilient material which biases the bellows  40  to its open and expanded configuration. Preferably, bellows  40  includes a plunger  42  on its lower end thereof. As seen in  FIG. 8A , lid  38 , bellows  40  and plunger  42  can be removed from stuffing hopper  14  to provide access to the hollow interior chamber of stuffing hopper  14 . This allows stuffing  200  to be placed within stuffing hopper  14  via the inlet  36 . 
     It is preferred that bellows  40  has a diameter slightly less than the diameter of the cylindrically-shaped interior chamber of stuffing hopper  14 , to allow for it to expand downwardly to its open and expanded configuration due to its resilient nature and, conversely, be resiliently compressed when in contact with stuffing  200 . It is also preferred that plunger  42  has a diameter which is less than the diameter of bellows  40  and is tapered on its lower end thereof, to feed stuffing  200  downwardly in the interior chamber of stuffing hopper  14  and subsequently into auger housing  16 . 
     Lid  38  is removably affixed to inlet  36  of stuffing hopper  14 , such as by corresponding screw threads (not shown). However, other means to affix cap  38  can be utilized such as by a snap or press fit. As an alternative to the preferred embodiment, bellows  40  and lid  38  are separate unattached components. 
     As seen in  FIG. 8B , after stuffing  200  is placed within the interior chamber of stuffing hopper  14 , bellows  40  and plunger  42  can then be placed within the interior chamber of stuffing hopper  14 , on top of stuffing  200 . Bellows  40  is compressed due to stuffing  200  within stuffing hopper  14  and biasely exerts a downward pressure on stuffing  200  via plunger  42 , as a result of its resiliency, to force stuffing  200  into auger housing  16 . Preferably, stuffing hopper  14  is made of a transparent material, such as clear plastic so that bellows  40 , plunger  42  and stuffing  200  are visible through stuffing hopper  14 . This provides added visual interest to the users, and in particular, children, who can view stuffing  200  through stuffing hopper  14 . 
     As can also be seen in  FIGS. 1-6 , auger housing  16  is located beneath stuffing hopper  14 . Auger housing  16  also defines an interior chamber therein which is in communication with the interior chamber of stuffing hopper  14 . Particularly, the interior chamber of auger housing  16  has an inlet located adjacent to outlet  32  of stuffing hopper  14 , and a discharge outlet  26 . In use, stuffing  200  is fed downwardly from outlet  32  of stuffing hopper  14 , into the inlet of auger housing  16  through pressure exerted from bellows  40  via plunger  42  (see,  FIGS. 8B and 8C ). Preferably, the inlet of the interior chamber of auger housing  16  has a funnel-shaped, downwardly-tapered configuration (not shown), which is not too steep to feed the stuffing  200  from discharge outlet  32  of stuffing hopper  14  too quickly but not too shallow to cause the stuffing  200  to bind or collect in the interior chamber of auger housing  16 . 
     Auger housing  16  also encloses a corkscrew-like, rotatable auger  24 . Auger  24  is centrally positioned within the interior chamber of auger housing  16  in order to, when rotated, move stuffing  200  in the interior chamber of auger housing  16 , towards discharge outlet  26  and, subsequently, into toy casing  100 , as shown in  FIG. 8C . 
     Auger  24  is attached to drive means for rotating auger  24 . As seen in  FIGS. 1-6 , the drive means is a handle  22  which can be manually rotated. Preferably, the end of handle  22  has a knob  23 , so that handle  22  is easier to grip by the user, and in particular children. As handle  22  is turned, auger  24  is also rotated. As seen in  FIG. 8C , the rotation of auger  24  allows for stuffing  200  to be moved through the interior chamber of auger housing  16  towards discharge outlet  26 . It will be understood, however, that alternate drive means for rotating auger  24  will be obvious to one skilled in the art, such as by a motor and the necessary electronic circuitry to connect the motor to the power source and operating controls. 
     In the preferred embodiment, auger housing  16  also includes a nozzle  28 , as seen in FIGS.  1  and  3 - 6 . Nozzle  28  is preferably tapered on its outer end and has external screw threads  29 . However, other suitable nozzle configurations and shapes can be utilized, such as one having an arrow shape or one having a larger-sized outer end and a narrower inner neck portion, to allow the casing  100  to be placed over the larger end and held to the narrower neck in order to prevent the casing from easily coming off during stuffing. 
     As can be seen in  FIGS. 8A-8C , plush toy casing  100  is removably affixed to nozzle  28  to allow for casing  100  to be filled by stuffing  200  exiting apparatus  10 . The optional provision of external threads  29  on the outside of nozzle  28  allows for the user to screw casing  100 , here in the shape of a rabbit, onto nozzle  28  so that it can be securely, yet removably, affixed thereto and does not have to be held in place by the user. This allows the user to have both hands free while using apparatus  10  to stuff casing  100 . This is beneficial when the device is used by small children who can hold the apparatus  10  with one hand and turn handle  22  with the other hand. Alternatively, other means to manually secure casing  100  to nozzle  28  can be utilized. 
     As seen best in  FIGS. 4-5  and  8 A- 8 C, it is also preferable that auger housing  16  include windows  44 , which are made of a transparent material such as clear plastic. This allows the user to view auger  24  and stuffing  200  through windows  44  and provides added visual interest since the user can see the auger  24  being turned and stuffing  200  moving towards the stuffing exit  26 . The location, number and size of windows  44  can vary. 
     Other elements of the main embodiment can be seen in  FIGS. 1 through 7 . Base  18  can include a storage compartment  50  in which decorative accessories may be stored. Additionally, apparatus  10  may further comprise a battery housing (not shown) which contains circuitry and batteries (not shown), which powers elements, such as lights, for example, LED&#39;s or a sound chip (not shown), to provide further entertainment. The electronic circuitry necessary to connect these elements to the power source would be well known to a person having ordinary skill in the art. 
     Therefore in use, as seen in  FIGS. 8A-8C , plush toy casing  100 , here in the shape of a rabbit having an opening  102 , is placed over and mounted on nozzle  28 . Particularly, opening  102  is placed over the outermost thread  29  and casing  100  is turned onto external threads  29  of nozzle  28  so that it is securely yet removably affixed thereto and so that a portion of nozzle  28  is received within casing  100 . As shown in  FIG. 8A , lid  38  and, in turn, bellows  40  and plunger  42  are removed from the interior chamber of stuffing hopper  14 . Stuffing  200  is placed via inlet  36  into the interior chamber of stuffing hopper  14 . As seen in  FIG. 8B , bellows  40  and plunger  42  are then placed back into the interior chamber of stuffing hopper  14 , atop the stuffing  200 , and bellows  40  are compressed due to the stuffing  200  now within stuffing housing  14 . The cap  38  is then screwed onto stuffing hopper  14  to seal inlet  36  of stuffing hopper  14 . 
     As can be seen in  FIGS. 8B-8C , bellows  40 , due to its resiliency, continuously forces stuffing  200  downwardly in the interior chamber of stuffing hopper  14  toward the stuffing outlet  32  of stuffing hopper  14  and, subsequently, into auger housing  16 . As shown in  FIG. 8C , handle  22  is turned, rotating auger  24 . Auger  24  drives stuffing  200  through auger housing  16 , and out of outlet  26 , and in turn, into casing  100 . Once fully stuffed, stuffing casing  100  is removed from nozzle  28  and opening  102  is closed via means for fastening such as by stitching, buttons, zipper, laces, etc. (not shown). 
     While there have been shown and described novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the method steps described, the devices illustrated, and the operation thereof, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto. 
     Particularly, while the stuffed toy casing has been illustrated in the shape of a rabbit, it can assume any other shape such as, for example a teddy bear or dog. Moreover, although the window and stuffing hopper have been illustrated as being transparent, they can be fully or partially transparent or opaque. Additionally, the number and location of the windows can be altered. Furthermore, the shape of the nozzle can be modified and the device may include other mechanical means for securing the casing to the nozzle.