Abstract:
A toy projectile and method of making the toy projectile is provided herein. The toy projectile having: an elongated dart body secured to a tip assembly, the tip assembly comprising: a tip insert secured to a forward end of the elongated dart body and a tip secured to the tip insert, wherein the tip comprises a styrene ethylene butylene styrene copolymer (SEBS rubber) tip.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. patent application Ser. No. 13/838,900 filed Mar. 15, 2013, the entire contents of which are incorporated herein by reference thereto. 
     
    
     BACKGROUND 
       [0002]    Various embodiments of the present invention relate to a toy projectile or dart and a method of making the toy projectile or dart. 
         [0003]    Darts or toy projectiles have been used in toy guns or other toys to provide an enhanced play factor to the toy guns or toys. As with any toy projectile, it is desirable to provide the same with a blunt soft end as well as certain characteristics that allow for durability and continued use. 
         [0004]    Accordingly, it is desirable to provide a toy dart or toy projectile that is easy to manufacture and have robust characteristics as well as providing for the aforementioned safety factures. 
       SUMMARY OF THE INVENTION 
       [0005]    In one embodiment, a toy projectile is provided, the toy projectile having: an elongated dart body secured to a tip assembly, the tip assembly comprising: a tip insert secured to a forward end of the elongated dart body and a tip secured to the tip insert, wherein the tip comprises a styrene ethylene butylene styrene copolymer (SEBS rubber) tip. 
         [0006]    In another embodiment, a toy projectile is provided, the toy projectile having: an elongated dart body; a tip assembly, secured to the forward end of the elongated dart body, the tip assembly comprising: a tip insert and a tip portion molded thereto, the tip insert having a plurality of annular features extending from an exterior surface of the tip insert, wherein at least one of the plurality of annular features is covered by the tip portion when the tip portion is molded onto the tip insert and wherein at least one other of the plurality of annular features is only covered by a forward portion of the elongated dart body when it is secured to tip assembly. In one embodiment, the tip portion can be co-molded with the tip insert. In another embodiment, the tip portion can be insert molded with the tip insert. 
         [0007]    In yet another embodiment, a method of securing a SEBS rubber tip to an extruded dart body is provided. The method including the steps of: forming a tip assembly by inserting a tip insert into a die of an injection molding machine, wherein the tip insert has a central opening extending therethrough and a plurality of features extending from an exterior surface of the tip insert; insert molding a SEBS rubber material wherein the die of the injection molding machine is configured to allow a portion of the SEBS rubber material to extend into a portion of the central opening and cover some of the plurality of features extending from the exterior surface of the tip insert; removing the tip assembly from the injection molding machine; and securing a forward end of an extruded dart body to at least one of the plurality of features of the tip insert that is not covered by the SEBS rubber material. 
         [0008]    In yet another embodiment, a method of securing a SEBS rubber tip to an extruded dart body is provided. The method including the steps of: forming a tip assembly, wherein the tip insert has a central opening extending therethrough and a plurality of features extending from an exterior surface of the tip insert; co-molding a SEBS rubber material with the tip insert wherein the SEBS rubber material covers some of the plurality of features extending from the exterior surface of the tip insert; and securing a forward end of an extruded dart body to at least one of the plurality of features of the tip insert that is not covered by the SEBS rubber material. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    These and/or other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: 
           [0010]      FIG. 1  is a view of a dart or projectile in accordance with an exemplary embodiment of the present invention; 
           [0011]      FIG. 2  is a cross-sectional view of the dart or projectile along the lines  2 - 2  of  FIG. 1 ; 
           [0012]      FIG. 2A  is a cross-sectional view of the dart or projectile along the lines  2 A- 2 A of  FIG. 1 ; 
           [0013]      FIG. 2B  is an enlarged portion of  FIG. 2 ; 
           [0014]      FIGS. 3A and 3B  are front and rear perspective views of the dart or projectile illustrated in  FIG. 1  in accordance with an exemplary embodiment of the present invention; 
           [0015]      FIGS. 4 and 5  are side views of the dart or projectile in accordance with an exemplary embodiment of the present invention; 
           [0016]      FIG. 4A  is a view along lines  4 A- 4 A of  FIG. 4  or a rear view of the dart or projectile of  FIG. 1  in accordance with an exemplary embodiment of the present invention; 
           [0017]      FIG. 4B  is a view along lines  4 B- 4 B of  FIG. 4  or a front view of the dart or projectile of  FIG. 1  in accordance with an exemplary embodiment of the present invention; 
           [0018]      FIG. 6  is a view of a tip assembly constructed in accordance with one non-limiting exemplary embodiment of the present invention; 
           [0019]      FIG. 7  is a cross-sectional view of an insert constructed in accordance with one non-limiting exemplary embodiment of the present invention; 
           [0020]      FIG. 8  is a cross-sectional view a tip assembly constructed in accordance with one non-limiting exemplary embodiment of the present invention; 
           [0021]      FIG. 9  is a flowchart illustrating a method or process for forming a forming a dart or projectile in accordance with one non-limiting exemplary embodiment of the present invention; 
           [0022]      FIG. 9A  is a flowchart illustrating an alternative method or process for forming a dart or projectile in according with another embodiment of the present invention; 
           [0023]      FIGS. 10 and 11  illustrate an apparatus for trimming a tail or rearward end of the dart or projectile; 
           [0024]      FIG. 12  illustrates an apparatus for securing an extruded dart body to a tip assembly; 
           [0025]      FIG. 13  illustrates a dart or projectile formed in accordance with an alternative exemplary embodiment of the present invention; and 
           [0026]      FIGS. 13A-13D  illustrate portions of the dart or projectile illustrated in  FIG. 13 . 
       
    
    
       [0027]    Although the drawings represent varied embodiments and features of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to illustrate and explain exemplary embodiments the present invention. The exemplification set forth herein illustrates several aspects of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner. 
       DETAILED DESCRIPTION 
       [0028]    Referring now to the FIGS. and in particular  FIGS. 1-5 , a dart or projectile  10  constructed in accordance with an exemplary embodiment of the present invention is illustrated. Dart or projectile  10  has an elongated tubular body portion  12  which has a forward end or front end  14  and a rearward or rear end  16 . Rearward or rear end  16  has an opening  17  (see  FIG. 2B ) that extends into an opening or cavity  19  of the elongated tubular body portion  12 . Referring back to  FIG. 1 , secured to the forward end  14  is a tip assembly  18 . Tip assembly  18  has a tip portion  20  and a tip insert  22 . The tip portion  20  is secured to a first portion of the tip insert  22  and a second portion of the tip insert  22  is secured to the forward end  14  of the elongated tubular body portion  12 . 
         [0029]    Accordingly, tip insert  22  provides a means for securing the tip portion  20  to the forward end  14  of the elongated tubular body portion  12 . In one exemplary embodiment, tip insert  22  is configured to have an inner opening  24  extending therethrough. In addition, an exterior surface  26  of the tip insert  22  is configured to have a plurality of features or annular rings  28  extending away from the exterior surface  26  of the tip insert  22 . In one embodiment, the plurality of features or annular rings  28  provides securement features to which the tip  20  and the forward end  14  are secured thereto. Still further, the plurality of features or annular rings also provide a plurality of grooves  30  located between the annular rings. The features or annular rings  28  as well as the grooves  30  located therebetween provide a mechanism for rigidly securing the forward end  14  to the tip assembly  18 . In one implementation and as the material of forward end  14  is pushed between annular rings  28  and then cooled, an interlock of the tip assembly  18  and the tubular body portion  12  is formed. 
         [0030]      FIG. 6  illustrates a tip assembly  18  formed in accordance with one non-limiting exemplary embodiment of the present invention.  FIG. 7  is a cross-sectional view of the tip insert  22  formed in accordance with one non-limiting exemplary embodiment of the present invention while  FIG. 8  is a cross-sectional view of the tip insert  22  with the tip  20  secured thereto. As illustrated, the plurality of features or annular rings  28  provides securement features to which the tip  20  and the forward end  14  are secured thereto. Still further, the plurality of features or annular rings  28  also provide a plurality of grooves  30  located between the annular rings. In accordance with one embodiment, the height or distance of the annular rings  28  may vary. In addition, a rearward end  32  of the tip insert  22  maybe formed with a flange portion  34  which provides additional rigidity to the tip insert and/or tip assembly and in particular to the area that is secured to the forward end  14  of the elongated dart body  12 . 
         [0031]    In accordance with one non-limiting exemplary embodiment, the tip insert  22  is formed from the following material TPR Thermoflex ME1385 via an injection molding process. Of course, other equivalent materials for forming the tip insert are considered to be within the scope of exemplary embodiments of the present invention. In one non-limiting exemplary embodiment, the core part or tip insert  22 , was shot at a temp of 225° C. and the shot pressure was 65 bar for a cycle time of 40 seconds. Of course, other temperatures, times and pressures greater and less than the aforementioned values are considered to be within the scope of various embodiments of the present invention. 
         [0032]    In accordance with one non-limiting exemplary embodiment, the tip  20  is formed from a styrene ethylene butylene styrene copolymer (SEBS rubber) or more particularly the following material TPR Thermoflex ME1927 via an injection molding process. Of course, other equivalent materials for forming the tip are considered to be within the scope of exemplary embodiments of the present invention. In one non-limiting exemplary embodiment, the tip part was shot at a temp of 225° C. and the shot pressure was 50 bar for a cycle time of 60 seconds. Of course, other temperatures, times and pressures greater and less than the aforementioned values are considered to be within the scope of various embodiments of the present invention. 
         [0033]    In accordance with one non-limiting exemplary embodiment, the elongated tubular body portion  12  is formed from an extrusion process wherein the tubular body portion is formed from a polyethylene which in one embodiment comprises 60% LDPE and 40% HDPE. Of course, other equivalent materials and combinations thereof are considered to be within the scope of exemplary embodiments of the present invention. 
         [0034]    Referring now to  FIG. 9 , a flowchart  40  illustrating one non-limiting method for forming the dart or projectiles  10  is provided. At box  42  at least one or a plurality of tip inserts  22  are formed by the aforementioned injection molding process. Simultaneously, previously or afterwards at least one or a plurality of elongated tubular dart body portion  12  are formed by an extrusion process at step  44 . During this step or process the tubular body portion  12  is formed from an extrusion machine wherein an elongated member is extruded from the aforementioned materials and once cooled, the extruded member is cut into the desired lengths for use as tubular body portion  12 . 
         [0035]    At step  46 , the rear end or tail end  16  of the elongated tubular dart body portion proximate to opening  17  is trimmed to have a curved or rounded surface  48  (see at least  FIG. 1 ). Once trimmed, the elongated tubular body portion  12  is ready to be secured to the tip assembly  18 . In an alternative embodiment step  46  may be eliminated. 
         [0036]    At a step  50 , the molded tip insert  22  is inserted into an injection molding machine wherein the tip portion  20  is insert molded onto a portion of the tip insert  22  as described above and illustrated in the attached FIGS. Once this process is complete, the tip assembly  18  is now formed. 
         [0037]    After conclusion of the process at step  50 , the form tip assemblies  18  are now secured to the elongated body portions  12  via a heat treating process which occurs at step  52 . 
         [0038]    Referring to  FIG. 9A , a flowchart illustrating another method  100  for forming a dart or projectile according to the present invention is illustrated. As shown, the method  100  includes several steps that are performed. In step  102 , the tip insert for the dart is injection molded. Subsequently, in step  104 , a SEBS tip for the dart is co-molded with the tip insert. In one implementation of this process, the mold in which the tip insert is injection molded is rotated to reposition it so that the SEBS material can be inserted into the mold to be co-molded with the tip insert. In one exemplary process, the mold is rotated 180 degrees between step  102  and step  104 . 
         [0039]    In step  106 , the body of the dart is formed. In this process, the dart body is extruded in a substantially cylindrical form with an opening or channel therethrough. In step  108 , the extruded body of the dart is cut by a machine in an automated process. The dart body has a desired length and any excess material beyond that length is trimmed In step  110 , the end  17  of the dart body is rolled to form a slightly curved or curled end as shown in the drawings. 
         [0040]    In step  112 , the tip insert is engaged with the dart body. In particular, the tip insert has a first end to which SEBS material has been co-molded and a second end opposite the first end. The second end of the tip insert is inserted into an open end of the dart body. The tip insert is inserted so that a few of the grooves on the tip insert are located inside the dart body. In step  114 , the dart body is coupled to the tip insert via a heat rolling process. In this process, heat and pressure are applied to the dart body via a tool, such as a pair of rollers, that is aligned with some of the grooves of the tip insert. The dart body is rotated about its longitudinal axis so that the tool remains in contact with the dart body as it rotates, thereby causing the dart body to conform to the profile of the tip insert and be pushed into the grooves of the tip insert. When the dart body has been coupled to the tip insert via this process, the forming of the dart is complete. 
         [0041]    Referring now to  FIGS. 10 and 11 , apparatus for use in one embodiment of a dart body forming process according to the invention are illustrated. As shown, an apparatus  54  for use in the trimming step  46  is illustrated. Apparatus  54  has a plunger  56  onto which the extruded elongated body  12  is placed and an end portion  58  of plunger  56  has corresponding rounded ends which form the rounded ends or end  48  of the elongated body portion  12  when plunger  56  is moved towards a copper plate or other of material  70  which is heated in order to manipulate or trim the extruded elongated body  12  to have a trimmed end or rounded surface  48 . 
         [0042]      FIG. 12  illustrates an apparatus  72  for use in step  52  wherein the elongated body  12  with the tip insert inserted into a forward end  14  of the elongated body  12  is placed between a pair of rollers  74  which rotate the same. A heated copper roller assembly or other equivalent material  76  applies heat and pressure to the forward end  14  of the elongated body such that portions of the same are now pushed into the grooves  30  of tip insert  22  so that the elongated body  12  is now secured to the tip assembly  18  and the dart or projectile  10  is formed. 
         [0043]    Referring now to the  FIGS. 13-13D  an alternative exemplary embodiment of the present invention is illustrated. Here the tip insert  22 A and the tip portion  20 A have alternative configurations. In this embodiment, after the insert molding process the tip  20 A or material used to form tip  20 A extends completely through the central opening  24 A of the tip insert  22 A and is received within the central opening of the elongated tubular body  12 A. In addition and in this embodiment, the forward end  14 A of the elongated body  12 A is formed onto features  28 A and groove  30 A as well as a portion of tip portion  20 A. Of course, numerous other configurations are considered to be within the scope of exemplary embodiments of the present invention and the above embodiments are merely examples of various embodiments of the present invention. 
         [0044]    As discussed above, the insert molding process of forming the tip and the tip insert is only one process used in the forming of a dart according to the present invention. A dart may be formed using the injection molding and co-molding processes described above as well. The heat rolling process is used to couple the tip insert to the dart body as described above as well. 
         [0045]    As used herein, the terms “first,” “second,” and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another, and the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. In addition, it is noted that the terms “bottom” and “top” are used herein, unless otherwise noted, merely for convenience of description, and are not limited to any one position or spatial orientation. 
         [0046]    The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., includes the degree of error associated with measurement of the particular quantity). 
         [0047]    While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.