Abstract:
An improved posable figure, having extended life and resistance to failure, and being repeatedly posable in a realistic fashion. The posable figure includes an inner armature constructed of a plurality of strands of wire, and an outer molded body covering constructed of a flexible substance such as a thermoplastic material, commonly a soft polyvinyl chloride material. The armature includes a plurality of junctures, which may be spot welded, connecting the strands of wire to form an articulated structure.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]    The present application claims priority from U.S. Provisional Patent Application Serial No. 60/385,255, filed May 31, 2002, incorporated herein by reference in its entirety for all purposes. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present disclosure relates generally to flexible doll toys and action figure toys. More particularly, it includes dolls and action figures in which the outer surface of the toy is a soft, flesh-like material, and an inner skeleton includes a bendable armature.  
         BACKGROUND OF THE INVENTION  
         [0003]    Many different varieties of flexible dolls and action figures have been developed over the years, mainly for the purposes of entertainment and display. Creation of a flexible or posable figure generally requires creation of a movable articulated body and limbs, ideally configured to retain whatever pose the figure is placed into. Furthermore, it is desirable that the figure be posable a large number of times without failure of the structure.  
           [0004]    One class of posable figures includes an inner armature or skeleton including joints to recreate the articulation of a human skeleton, and a molded outer covering or body constructed of a flexible material that surrounds and is bonded or otherwise anchored to the inner armature. Examples of such toys are found in U.S. Pat. Nos. 280,986, 1,189,585, 1,551,250, 1,590,898, 2,017,023, 2,073,723, 2,109,422, 2,392,024, 2,601,740, 2,684,503, 3,325,939, 3,284,947, 3,395,484, 3,624,691, 3,955,309, 4,123,872, 4,136,484, 4,233,775, 4,932,919, 4,954,118, 4,964,836, 5,516,314, 5,630,745, 5,762,531, 5,800,242, 6,155,904, and 6,217,406, and in publications JP49-18954, JP49-18955, JP60-97067, JP61-94090, JP61-94091, JP61-94092, JP62-53686, JP62-164092, JP63-103685, JP11-221369, WO0067869, and WO0010665. Other examples of flexible doll toys and action figure toys are found in U.S. Pat. Nos. 3,277,601, 3,716,942, 4,470,784, 4,932,919, 5,017,173, and 6,074,270, and in publication WO0108776. The disclosures of all of these patents and publications are incorporated herein by reference.  
         SUMMARY OF THE INVENTION  
         [0005]    An improved posable figure is provided, having extended life and resistance to failure, and being repeatedly posable in a realistic fashion. The posable figure includes an inner armature constructed of a bendable material such as a plurality of strands of wire, and an outer molded body covering constructed of a flexible substance such as an elastomer material, commonly a thermoplastic elastomer such as a soft polyvinyl chloride material. The armature includes a plurality of junctures between the strands of wire, which may be spot welded, connecting the strands of wire to form an articulated structure.  
           [0006]    The advantages of the posable figure provided will be understood more readily after a consideration of the Drawings and the Detailed Description of the Preferred Embodiment. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]    [0007]FIG. 1 is a front elevation view of an armature for a posable figure, according to an embodiment of the invention.  
         [0008]    [0008]FIG. 2 is a magnified view of a portion of the armature of FIG. 1, showing details of the twisted wire structure of the armature.  
         [0009]    [0009]FIG. 3 is a front view of a head portion of an armature for a posable figure, according to another embodiment of the invention.  
         [0010]    [0010]FIG. 4A is a front elevation view of a partially formed posable figure, after one step of insert molding.  
         [0011]    [0011]FIG. 4B is a rear elevation view of the partially formed posable figure of FIG. 4A.  
         [0012]    [0012]FIG. 5A is a magnified view of a portion of the partially formed posable figure of FIGS. 4A and 4B, showing details of upper arm locating pegs.  
         [0013]    [0013]FIG. 5B is a magnified view of a portion of the partially formed posable figure of FIGS. 4A and 4B, showing details of upper leg locating pegs.  
         [0014]    [0014]FIG. 5C is a magnified view of a portion of the partially formed posable figure of FIGS. 4A and 4B, showing details of lower leg locating pegs.  
         [0015]    [0015]FIG. 6A is a front elevation view of a posable figure after two steps of insert molding, according to an embodiment of the invention.  
         [0016]    [0016]FIG. 6B is a real elevation view of the posable figure of FIG. 6A.  
         [0017]    [0017]FIG. 7 is a semi-transparent front elevation view of the posable figure of FIGS. 6A and 6B, showing an armature and a molded body enclosing the armature.  
         [0018]    [0018]FIG. 8 is a semi-transparent side elevational view of the posable figure of FIG. 7.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0019]    Referring to FIG. 1, an armature  10  for a posable figure is shown. Although it is anticipated that armature  10  will eventually be enclosed by and bonded to an outer covering, such as an injection-molded body of a posable figure, FIG. 1 shows the inner core of the armature in isolation for clarity. Armature  10  may include a plurality of twisted strands of wire  12 , best seen in FIG. 2, which may be joined together to form an articulated structure. As depicted in FIG. 2, strands  12  may be constructed from three pliable metal wires twisted together, although other suitable numbers of wires and/or materials may be used to construct the inner armature of the invention.  
         [0020]    As depicted in FIG. 1, armature  10  may include a lower strand  14 , a middle strand  16 , and an upper strand  18 . Lower strand  14  may extend from a first foot portion  20   a  to a second foot portion  20   b , and middle strand  16  may extend from a first hand portion  22   a  to a second hand portion  22   b . Upper strand  18  may extend from an upper portion  24  of the lower strand, to a head portion  26 .  
         [0021]    The strands of wire in the armature may be connected at junctures  28  and  30  to form a unitary structure. As indicated, juncture  28  may connect lower strand  14  to upper strand  18  at a point at or near a lower end of the upper strand, so that the upper strand may not extend appreciably below its intersection with the lower strand at juncture  28 . Juncture  30  may connect the middle strand to the upper strand at a point between juncture  28  and head portion  26 . Junctures  28  and  30  may be formed, for example, by spot welding, although other forms of adhesion such as gluing, crimping, or the like may also be suitable for forming connections between the strands of wire.  
         [0022]    As depicted in FIG. 1, armature  10  may be formed into an articulating structure that includes lower leg portions  32   a  and  32   b , upper leg portions  34   a  and  34   b , lower arm portions  36   a  and  36   b , upper arm portions  38   a  and  38   b , and a neck portion  40 . For simplicity, symmetric pairs of parts such as the leg and arm portions, among numerous others, may hereinafter be referred to by a single reference number. Thus, “lower leg portions  32 ” will be understood to mean lower leg portions  32   a  and  32   b , and so forth.  
         [0023]    The strands of wire may be chosen to have any diameter that permits a desired amount of flexibility in the various regions of the armature. For example, lower strand  14  and upper strand  18  may be formed from twisted wires that are approximately 0.030-inches in diameter, and middle strand  16  may be formed from a twisted wire that is approximately 0.025-inches in diameter. However, it will be appreciated that wires of other diameters may be equally suitable or more suitable for various designs, depending on the overall size of the posable figure and its intended use.  
         [0024]    In the embodiment depicted in FIG. 1, a distal end of upper strand  18  forms head portion  26  in the shape of a substantially circular loop  42  that is spot welded to neck portion  40  at an upper juncture  44 . However, it should be appreciated that the head portion may be suitably formed in various other ways. For example, FIG. 3 shows an embodiment in which a head portion  126  is formed in the shape of a curved hook or semi-loop  46 .  
         [0025]    In FIGS.  1 - 3 , the various wire strands  14 ,  16 , and  18  that are included in armature  10  are shown before any injection molding steps involving the toy figure have been performed. Such injection molding may typically be performed in a two-step process. In the first injection molding step, a plurality of structures may be injection molded around the inner wire, to form a more rigid and substantial inner skeleton. In the second injection molding step, a flesh-like outer covering may be molded around the skeleton to form a surrounding body, which may enclose both the inner wire armature and portions of rigid structures that were added in the first step. These two injection molding steps are described below in greater detail.  
         [0026]    [0026]FIGS. 4A and 4B show front and rear elevation views, respectively, of a partially formed posable FIG. 110, after a first injection molding step has been performed. After the first injection molding step, partially formed FIG. 110 may include wire armature  10  as described above, as well as a plurality of support members. These support members may include surrounding members  48 ,  50 , and  52 , end caps  54  and  56 , and sprues  58 ,  60 , and  62 , among others. The support members may extend outward from the strands of wire, adding structure and stability to armature  10 . As described below, some of the support members may also allow partially formed FIG. 110 to be located accurately and conveniently in a mold, prior to a second injection molding step.  
         [0027]    The support members may be constructed from any suitable material, such as a resin material that may be conveniently molded around wire armature  10  in molten form. The support member material may, for example, be a relatively flexible polymer material such as polypropylene, or it may be a more rigid polymer such as polyethylene. The support member material may also be a thermoplastic elastomer material such as polyvinylchloride (PVC), or a styrene-based elastomer such as a Kraton material manufactured by Kraton Polymers of Houston, Tex. In some embodiments, this material may be chosen to bond and/or be otherwise compatible with a material used for the outer covering of the toy figure.  
         [0028]    Surrounding members  48 ,  50 , and  52  each may be configured to surround a portion of the wire of armature  10 , and each may include a plurality of locating pegs extending substantially radially outward from the wire. For example, surrounding member  48  may include upper arm pegs  64  and  66 , surrounding member  50  may include upper leg pegs  68  and  70 , and surrounding member  52  may include lower leg pegs  72 ,  74 , and  76 . The locating pegs may be substantially cylindrical as depicted in FIGS. 4 and 5, or they may have any other suitable shape. For example, the locating pegs may be substantially conical or frustoconical. The locating pegs may also have rounded ends.  
         [0029]    [0029]FIG. 5 shows details of the structure of surrounding members  48 ,  50 , and  52 , and their associated locating pegs. The locating pegs may be configured to assist in locating partially formed FIG. 110 in a mold, in preparation for a second injection molding step. As indicated, upper arm pegs  64 , upper leg pegs  68 , and lower leg pegs  72  may extend forward and away from the armature, upper arm pegs  66  and upper leg pegs  70  may extend backward and away from the armature, lower leg pegs  74  may extend laterally and away from the armature, and lower leg pegs  76  may extend medially and away from the armature.  
         [0030]    Providing locating pegs of the type just described may help to position partially formed FIG. 110 in a desired location within a mold. For example, a particular locating peg may be configured to substantially span a radius of the mold, thereby holding a wire strand of the armature spaced away from the walls of the mold. This may allow material to be injected into the mold to form a continuous molded body, encasing and bonded to the armature, with the wires of the armature spaced away from the surface of the body.  
         [0031]    As depicted in FIGS. 4A and 4B, end caps  54  and  56  may be disposed to cover free ends of lower strand  14  and/or middle strand  16 . In other words, the end caps may be disposed to cover foot portions  20  and/or hand portions  22  of the inner wire armature. End caps  54  and  56  may hold loose ends of the wires together, and may reduce the chances that an end of one of the wires will break through the body of the toy.  
         [0032]    Sprues  58 ,  60 , and  62 , which may be substantially cylindrical, may serve to further locate partially formed FIG. 110 in a mold during a second injection molding step. For example, the sprues may be placed in corresponding cylindrical depressions or recesses in the mold, to hold the armature in position while a surrounding body is injection molded around partially formed FIG. 110.  
         [0033]    As depicted in FIGS. 4A and 4B, sprues  58  and  60  may be disposed near end caps  54 , and attached to the end caps by connecting shafts  78 . In addition, sprues  60  may be attached to surrounding members  80  by shafts  82 , and surrounding members  80  may be attached to each other by a connecting shaft  84 . In this manner, sprues  58  and  60 , connecting shafts  82  and  84 , and surrounding members  80  all form a substantially continuous structure for locating the partially formed figure in a mold, and supporting it there during a second injection molding step. Similarly, sprues  62  may be connected to end caps  56  by connecting shafts  86 , and end caps  56  may be connected to each other by a connecting shaft  88 , as indicated.  
         [0034]    Aside from the aforementioned structures, a molded head portion  90  may also be added during the first injection molding step. Molded head portion  90  may include a rear section  92  extending in slight relief from the remainder of the molded head portion. Rear section  92  may include a substantially rectangular aperture  94 , and two smaller circular apertures  96 . Apertures  94  and/or  96  may be used for additional secure positioning of partially formed FIG. 110 in a second mold, for instance using shafts, pins, or the like to extend from the mold into the apertures.  
         [0035]    A chest portion  98  may also be added during the first injection molding step. Furthermore, portions of the inner wires may be covered with a relatively thin coating of material, generally indicated at  100 . The additional structure of chest portion  98  and wire coating  100  may serve to selectively increase the rigidity of portions of the toy figure, and to provide greater stability to the partially formed figure prior to a second injection molding step.  
         [0036]    FIGS.  6 - 8  show a toy figure, generally indicated at  210 , after two steps of injection molding. As is best seen in FIGS.  7 - 8 , toy FIG. 210 may include partially formed FIG. 110 (including armature  10 ), and also a surrounding and continuously molded body  212 . Body  212  may be constructed from any resilient, flexible material, such as a highly elastic thermoplastic material such as a soft polyvinyl chloride (PVC) material having a Shore hardness of approximately 65. The body material may be colored to match the desired finished color of the posable figure, but the body material is depicted as transparent in FIGS.  7 - 8 , so that partially formed FIG. 110 may be seen disposed within it.  
         [0037]    Although in general, any suitable material may be used to construct the body of the toy figure, in some embodiments the body material may be chosen to bond to and/or be otherwise compatible with the material used for the support members of the armature of the toy figure. For example, the body material and the support member material may both be constructed from styrene-based elastomers such as a Kraton material, with either similar or different Shore hardnesses. Such similar elastomers may tend to bond particularly securely to each other during injection molding of the body around the armature.  
         [0038]    [0038]FIGS. 6A and 6B show front and rear views, respectively, of toy FIG. 210 after a second step of injection molding but before final finishing of the toy figure is complete. Sprues  58 ,  60 , and  62  may still be attached externally to FIG. 210 after the second molding step. Similarly, portions of connecting shafts  78 ,  82 ,  86 , and/or  88  may remain outside of body  212  after the second molding step. The protruding sprues and/or shafts, if any, may be cut or broken off of toy FIG. 210 as part of final finishing steps.  
         [0039]    [0039]FIG. 7 shows a front view of toy FIG. 210 after some final finishing steps, with the material of molded body  212  depicted as transparent so that armature  10  may be seen within the figure. As depicted in FIG. 7, locating pegs  74  and  76  may extend to lateral and medial surfaces  214  and  216  of the body, respectively. Also as depicted in FIG. 7, various finishing steps may be applied to the toy figure after the second injection molding step. For example, sprues and/or connecting shafts that remain external to molded body  212  may be removed, possibly leaving portions of shafts  82  extending to surfaces of the body. Facial features, generally indicated at  218 , may be added by, for example, etching and/or painting. Hair  220  may be attached to the figure by, for example, heat sealing or gluing. In some embodiments, clothing and/or other accessories may be added to the figure.  
         [0040]    [0040]FIG. 8 shows a right side view of toy FIG. 210, with the material of molded body  212  depicted as transparent as in FIG. 7. As depicted in FIG. 8, locating pegs  64 ,  68 , and  72  may extend to an anterior surface  222  of the body, and locating pegs  66  and  70  may extend to a posterior surface  224  of the body. End portions of the various locating pegs extending to surfaces of the body may be sanded or otherwise smoothed as desired, as a final finishing step.  
         [0041]    While the present description has been provided with reference to the foregoing embodiments, those skilled in the art will understand that many variations may be made therein without departing from the spirit and scope defined in the following claims. The description should be understood to include all novel and non-obvious combinations of elements described herein, and claims may be presented in this or a later application to any novel and non-obvious combination of these elements. The foregoing embodiments are illustrative, and no single feature or element is essential to all possible combinations that may be claimed in this or a later application. Where the claims recite “a” or “a first” element or the equivalent thereof, such claims should be understood to include incorporation of one or more such elements, neither requiring, nor excluding, two or more such elements.