Abstract:
Toys and other fabric coated articles that glow in the dark. The present invention is preferably directed to a variety of articles, especially stuffed toys, that exhibit luminescence in the dark following light exposure. The toys may be any variety of animal, plant or specific form, including but not limited to mammals, reptiles, birds and insects. Methods of manufacture are described that use fabric coated with luminescent material on one side that is used as casings with the rough coating side facing inwardly for toys and other items.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to various coated fabric articles of manufacture that glow in the dark. More specifically, the invention preferably relates to coated fabric toys and similar articles, especially stuffed animal or other figure toys, that have specific general body luminescence or anatomic parts that void or attenuate general luminescence and emit visible light in low light or in the dark. The invention describes toys of various sizes, shapes and designs. In a most preferred embodiment, the invention provides stuffed fabric toys. 
         [0003]    2. Description of the Prior Art 
         [0004]    Toys and various articles of manufacture that have light emitting elements from external natural or artificial light sources are known in the art. Also, toys and articles that selectively phosphoresce and/or, fluoresce have been described. Various human and animal toys that glow or emit light, and gloves that glow are described in U.S. Pat. Nos. 5,374,192, 6,360,693, 4,655,721 and 5,580,154. 
         [0005]    What is needed are toys or other items that are capable of storing light energy when struck by light and selectively emitting visible light over extended periods in low light or in the dark. Preferably, what is needed are various coated fabric toys, including but not limited to stuffed animals and the like, that glow in the dark and selectively emit light so as to delineate recognizable overall form and/or selected body parts. The present invention is directed toward solving this need. 
         [0006]    By way of background, luminescence is a general term applied to all forms of cool light (i.e., light that is usually occurs at low temperatures in contrast to incandescent light emitted by hot incandescent bulbs or the like). There are several kinds of luminescence: chemoluminescence (including bioluminescence from living organisms such as sea plankton, fireflies, glowworms, certain fungi etc.; produced by chemical reactions, primarily oxidations, at low temperatures), crystalloluminescence; electroluminescence (i.e.,cathodoluminescence; produced by electric discharges that occur when silk or fur is stroked, when adhesive surfaces are separated, etc.); photoluminescence (i.e., phosophorescence; fluorescence); radioluminescence; sonoluminescence; thermoluminescence (i.e., produced by crushing crystals); and triboluminescence. Luminescence can be caused by chemical or biochemical changes, electrical energy, subatomic motions, various reactions in crystals, or by stimulation of an atomic system. Although phosphorescence is a specific type of photoluminescence related to fluorescence, they are sometimes confused. Also, the term phosphorescence is often incorrectly used synonymously with luminescence. The process of coating dials, fabric, signs, aviation and navigations instruments, etc. with luminescent materials is known as luminising. 
         [0007]    A wide variety of non-radioactive photoluminescent products that glow in the dark are known, including luminescent powders, paints, waxes, gels, polishes, inks, plastics, yarns, signs, sheets, and the like. A wide variety of organic and inorganic compositions are known to effect luminescence. Zinc sulfide based material has been commonly used to produce glow in the dark items and paints. However, zinc sulfide based compositions and related materials have limited glow in the dark characteristics after exposure to natural or artificial light, typically glowing for only an hour or so after exposure to light. More recently, a new generation of luminescent materials containing rare earth metals has been developed that provide extended glow in the dark luminescent after exposure to light. Such rare earth metal compositions (i.e., containing Europium etc.) provide bright and long lasting luminescence (i.e., sometimes glowing in the dark for 12 hours or more after being exposed to light). 
         [0008]    A major limitation of the use of rare earth metal composition coating on fabric is that luminising provides a surface coating exposed to the light that is rough or coarse to the touch. Hence, items with fabrics that are coated with these compositions that touch the skin of the user have a texture that is unacceptable. Luminescent coating are generally applied to the surface of articles that re exposed to light sot that maximum light exposure will be provided to the coating material for maximal generation of luminescence 
         [0009]    Accordingly, it is an object of the present invention to provide improved luminescent fabric having glow in the dark capability; 
         [0010]    Another object of the present invention is to provide luminescent fabric coated glow in the dark toys; 
         [0011]    Yet another object of the present invention is to provide glow in the dark luminescent fabric coated articles that do not have a coarse texture. 
       SUMMARY OF THE INVENTION 
       [0012]    The present invention provides a system and method for articles of manufacture that have luminescent or glow in the dark features. Preferred embodiments are fabric-coated toys, sports equipment, household items, clothing, and the like, that absorb daylight or artificial light and emit light in the dark. Articles that may be coated with luminescent-coated fabric of the invention include but are not limited to: animal and character slippers; animal and character and decorative pillows; key chains; squishy pillows; character animal pens; plush cars, trains boats, bats, ball and beds; glow fabric picture frames; glow fabric picture frames with characters/animals; purses; coin purses; books; puzzles; notepad covers; Halloween costume accessories, tails, masks, ears; Halloween fabric trick or treat bags; fabric coated buttons; Christmas ornaments; shoe laces; shoes; scarves; hats; visor hats; fabric books; fabric rattles; puppets; magnets with plus toy attached or in plus toy; backpacks; barrettes; hair pony tails; ribbon; bibs; belts; socks; cell phone holders; and ear muffs. Luminescent capability is preferably provided by coating fabric with doped or rare earth metal activated photo-luminescent materials (i.e., Strontium Aluminates, Sr:Al:Eu, and related products). Organic as well as inorganic luminescent compositions may be applied to fabric. Luminescent material is applied to only one side of the fabric. 
         [0013]    The present invention is directed to fabric-coated articles, preferably toys that glow in the dark, including especially stuffed toys that exhibit luminescence in the dark after exposure to natural or artificial light. The toys may be any variety of animal or plant or specific form of any object. Toys that are animal variants are preferred, including mammals, reptiles, birds and insects. The toys exhibit glow patterns in the dark that generally show the entire glowing form of the toy with distinguishable, generally lower or non-glowing intensity of specific organs, body parts and the like giving life-like appearance to the toy. Toys and other fabric-coated items that luminesce are preferred, but toys and other fabric-coated items that phosphoresce or fluoresce are also within the scope of the invention. 
         [0014]    Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. Although any methods, materials, and devices similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, the preferred methods, materials, and devices are now described. All publications mentioned herein are incorporated by reference. Nothing herein is to be construed as an admission that the invention is not entitled to antedate such disclosure by virtue of prior invention. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods and examples are illustrative only and not intended to be limiting. 
         [0015]    Other features and advantages of the invention will be apparent from the following description and from the claims. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The accompanying drawings, which are incorporated in and form a part of the specification, illustrate embodiments of the present invention and, together with the description serve to explain the principles of the invention. The embodiments illustrated in the drawing should not be read to constitute limiting requirements, but instead are intended to assist the reader in understanding the invention. 
           [0017]      FIG. 1  is a photograph of four stuffed toys with luminescent fabric and embroidered eyes, nose, ears, fingers, and toes. 
           [0018]      FIG. 2  is diagrammatic cross sectional view of a stuffed doll member having luminescent coated fabric. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0019]    The present invention includes any and all fabric coated articles, including in a preferred embodiment toy stuffed animals, mammals, reptiles, birds, insects preferably made to glow in the dark with fluorescent coated fabric. Preferably, the fabric of the invention is coated on one side with luminescent material doped with Europium and other rare earth elements. Any fabric that has some natural porosity, including cotton, polyester and other synthetic fibers, wool, and combinations thereof to which luminescent coating adheres may be used. Multiple layer fabrics or very tightly woven fabrics may not be suitable materials. In the fabrication of stuffed toys and other fabric coated articles, the coated side that has a rough texture is faced inward with the untreated side of the fabric facing outward. By placing the untreated side of the casing fabric outward, the toy or other fabric coated article has a natural feel to the touch while still providing luminescent properties. Normally the treated side of fabric would be faced outward to maximize light absorption and luminesce. It was surprising to learn that the luminescent glow in the dark capabilities were retained when the treated side of the fabric was turned “inside-out” away from the light. Optionally, toys or other articles may have embroidered or embroidered features (i.e., eyes, nose, mouth, nails, ears, paws, claws and other markings) with untreated fabric, threads, or fiber. With such embroidered or other features on the base luminescent fabric, the glow in the dark or luminescent characteristics of the base fabric are negated thereby leaving the features without any glow in the dark capability emphasizing the features. Alternatively, if eyes, nose, mouth or other feature markings are made with treated fabric, threads, or fibers, the features will luminesce along with the base fabric. 
         [0020]    The glow patterns of the articles and toys of the invention may preferably be obtained by use of by coating one side of the chosen casing fabric with rare earth doped luminescent material or other luminescent material that will still provide glow in the dark capability. Alternatively, luminescent coating may be added to the stuffing of the article or toy as the case may be. For example, pellets that are luminescent, preferably super high intensity glow pellets, may be used as toy stuffing or placed in a layer underneath casing fabric of toys or other articles. With luminescent stuffing (pellets, etc.) it is preferred that the casing fabric be loosely woven fabric so as to permit light penetration. Thus, the toy will show the same glow pattern as if one-side-luminescent-material-treated fabric used inside-out were used. A stuffed bear toy was prepared using loosely woven fabric and stuffed with high intensity glo pellets. This stuffed bear glowed successfully in the dark. Glo stuffing should be directly underneath the outer casing or fabric. 
         [0021]    The articles of the invention, preferably stuffed toys with luminescent one-side-coated casing fabric with the coated side facing inward, will take on the appearance, touch and feel of a traditionally stuffed toy but when exposed to darkness will glow in the dark creating a ghost like image of the stuffed toy. Stuffed toys of the invention are preferably fabric coated and in the case of stuffed animals, preferably have fur or fur-like fabric. However, toys may alternatively be made of solid material. 
         [0022]    Referring now to  FIG. 1 , shown are four stuffed dolls of the invention. The dolls have a polyester fabric casing  101  that is treated on one side with Europium doped luminescent material with the treated (coarse textured) side facing inward. The dolls have embroidered facial features (eyes, nose, mouth, cheeks, whiskers, ears) that use untreated thread or fabric Eye  102  is shown. 
         [0023]    Referring now to  FIG. 2 , shown is a diagrammatic cross section of a member of a doll of  FIG. 1 . The diagram shows a schematic cross section of a representative member of a doll (i.e., head, arm, leg, etc.) to show the interior location of the luminescent coating on the casing fabric of the doll. Shown is the casing fabric  201  with the untreated side facing outward, the luminescent material on the inward side of the casing  202 , and stuffing of the doll  203 . 
         [0024]    Stuffed toys of the invention may be manufactured by coating one side of any traditional casing fabric with luminescent material, preferably doped with Europium and other rare earth elements. Any luminescent coating that is able to provide glow in the dark capability after exposure to light may be used, but material comprising Europium is preferred. The casing fabric may be spray coated, brush coated, or otherwise applied to one side of the fabric by methodology known in the art. In addition most animal toys of the invention will be accented with features and markings with fibers or other material that may or may not be luminescent treated. For example, add-on features may use untreated materials. 
         [0025]    The present invention comprises the treating of one side of fabric with luminescent material and use of the treated fabric for covering or casing of various articles of manufacture, preferably stuffed toys, to provide nighttime or glow in the dark luminescence when articles are placed in the dark after exposure to natural or artificial light. Various ornamental features may optionally be applied to the fabric casing of the doll or other articles using standard luminescent threads or materials or untreated threads or materials. Optionally, in addition to whole body luminescence provided by use of treated casing fabric, dolls or other articles may use one-side-treated fabric similarly placed (“inside out”) for just certain portions of the items placed on untreated casing. For example, in the case of dolls, just the eyes, nose, mouth, ears or other features may use the treated fabric thereby providing nighttime luminescent to just the features after exposure to light. With use of rare earth doped luminescent material, the dolls or other articles will glow in the dark for extended periods of time. Children will be comforted in the night by luminescent dolls of the invention. 
         [0026]    In the manufacture of stuffed toys of the invention, glow in the dark dolls, or dolls with just luminescent features and/or markings will provide a ghost-like image when exposed to darkness. The invention is novel and will provide the child with a traditional cuddle toy with a special effect. The invention provides novel stuffed toys and luminescent products. 
         [0027]    There are a number materials that can be mixed or melted with paint, waxes, plastics, gels etc. to provide luminescence. For example, newly developed Europium-based materials, or older Zinc Sulfide based materials, are available. The Europium-based materials are sometimes known as phosphorescent powders, but function as luminescent products. These phosphorescent powders come in blue or green colors. Europium-based paints and powders are available commercially. Luminescent or phosphorescent glow is produced after exposure to sunlight, artificial light (incandescent or fluorescent), or ultra violet light. Also, photo-luminescent (glow-in-the-dark) yarns and films are available commercially having luminescent materials consisting mainly of crystals of Strontium Aluminates (Sr:Al:Eu). Strontium Aluminates provide luminescent glow that lasts several times longer than traditional crystals of Zinc Sulphide and are used in a wide variety of products (i.e., photo-luminescent pigments, PVC film, paints, signs, etc.). Strontium Aluminates or Europium-based materials are preferred for coating the fabrics of the invention. 
         [0028]    Photo-luminescent self-adhesive films and tapes containing Strontium Aluminates may be cut into various shapes and applied to surfaces (walls, ceilings, etc.) or used on sporting goods, stationary, telephones, electronic equipment, indoor and outdoor emergency lines and signs, and the like. In such applications, it is desirable to have maximum light exposure provided to the luminescent material. Generally with luminescent films and paints a film thickness in the range of 100-150 μm is provided. 
         [0029]    With photo-luminescent glow-in-the-dark articles of the invention, any convenient natural or synthetic fabric that may be coated on one side with luminescent material, preferably coated with Europium based material, may be used. Cotton, polyester, nylon, rayon, wool, etc. or any combinations of natural and/or synthetic fabric may be used. Acceptable glow-in-the-dark functionality is optimally provided by light colored fabrics (i.e., white, yellow, beige, etc.) that have acceptable weaves. Acceptable weaves of fabric is interpreted to mean fabrics wherein sufficient light can penetrate the fabric when light is exposed to the untreated side to activate the luminescent coating on the treated side of the chosen fabric. Dark colors (i.e., black) are not preferred and seem to absorb luminescent light and produce attenuated glow-in-the-dark functionality. Very thick or tightly woven fabrics may not work optimally or work poorly. Coating and testing samples of desirable fabrics can conveniently enable evaluation of the suitability of various fabrics. 
         [0030]    Preferred luminescent materials are Strontium Aluminates (Sr;Al;Eu) or rare earth activated silicate aluminates (strontium aluminates-silicates). These materials may contain addition materials such as rare earth elements or metals (i.e., Europium Oxide; Dysprosium Oxide, Aluminum Oxide). Zinc sulfide-based luminescent materials may be used but are not preferred. Any photo-luminescent coating that can produced acceptable luminescence when applied to fabric on one side and used inside-out (coated side inside; light exposed to the untreated side of the fabric) to avoid coarse feel of the coating to the touch may be used. 
       EXAMPLE 
     Fabrication of Glow-In-The-Dark Stuffed Toys 
       [0031]    Various stuffed animals shown in  FIG. 1  were fabricated. The casing of the dolls is white polyester fabric that was coated with photo-luminescent rare earth-based material on one side by Jiang Su Guo Da Group, Jiangsu Province, China. The coating material, that has a green color, contained SrAl 2 O 4 :Eu (45%); Al 2 O 3  (42%); Eu 2 O 3  (8%); and Dy 2 O 3 . The dolls are approximately 8½ inches in length and have non-luminescent embroidered features. Non-luminescent material (i.e., thread or fabric), was sewn on to provide certain dress or anatomical features (i.e., inner ear; belts; boots, gloves, eyes, nose, mouth). The treated side of the casing fabric was on the inside surface with the natural fabric side on the outside. The filling of the dolls is polyester. Antennae are constructed with foil coated wire stiffeners. Following exposure to light, the dolls all provide a long-lasting green glow pattern. Black polyester fibers were sewn to mark the eyes, nose and paw markings. 
         [0032]    Although the present invention describes in detail certain embodiments, it is understood that variations and modifications exist known to those skilled in the art that are within the invention. Accordingly, the present invention is intended to encompass all such alternatives, modification and variations that are within the scope of the invention as set forth in the following claims.