Patent Publication Number: US-8967130-B2

Title: Toy projectile launcher apparatus

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to a toy projectile launcher apparatus, and, more particularly, to a toy projectile launcher apparatus that discharges a covered circular disc or toy projectile having a soft exterior and somewhat robust interior with good flight characteristics and distance. 
     BACKGROUND OF THE INVENTION 
     Toys and other devices that discharge disc-like objects have been designed in the past with various housing and internal elements. These devices are often difficult to use or dangerous for children, or are too expensive, complicated or insufficiently robust. 
     Launching devices, toy and otherwise, are well known and are disclosed in several existing patents. By way of example, Napier patented a launching device in 1920 and 1921, U.S. Pat. No. 1,353,663 for a “Target Throwing Device” and U.S. Pat. No. 1,374,757 for a “Catapult.” These patents purport to disclose a launching device for clay pigeon targets and include a slanted platform with a guideway in the platform, a guide rail to one side of the platform and a roller for accelerating the clay pigeon. Friction material is added to the guide rail and to the roller to “give it (the missile-clay pigeon) the desired action as it leaves said platform.” U.S. Pat. No. 4,016,854 for a “Spring Type Bottle Cap Pistol” issued in early 1977 to Lehman and purports to disclose a pistol to propel and spin a bottle cap by positioning a spring connected to a plunger in a lower longitudinally directed chamber, attaching a hammer to the plunger, the hammer extending through a slot in a upper longitudinally directed chamber where the bottle cap is loaded. The hammer is located off-center from the bottle cap so that when a trigger is rotated, the plunger is released to accelerate the hammer and bottle cap along the upper chamber discharge the bottle cap while also inducing a spin in the cap. A restraining pin extends through a slot to abut an interior surface wall of the bottle cap to prevent the bottle cap from moving along the upper chamber until the trigger is depressed at which time the pin moves out of the way. Loading of a bottle cap is from above the pistol through a sliding cover. Another patent issued to Lehman later in 1977, U.S. Pat. No. 4,059,089 for a “Flying Saucer Launching Pistol” purports to disclose a pistol very similar to that disclosed in his earlier patent but with a pair of ramps in the firing chamber tapered so as to center different diameter discs when each is loaded. U.S. Pat. No. 4,170,215 for a “Disk Toy And Launcher” issued in 1979 to Kettlestrings, purports to disclose a mechanical launcher for a toy disk that has a recess for engaging and bending a leaf spring when loaded. After bending the spring, the disk is received by tabs of catch members in the launcher. When a plunger dislodges the tabs the spring propels the disk away from the launcher. 
     Another U.S. Pat. No. 4,248,202 for a “Disc Launcher” issued in 1981 to Jaworski and Breslow, and purports to disclose a mechanical launcher having a circular casing, a disc magazine for feeding discs by gravity, an actuating arm movable between a loading position and a firing position, a spring and a rubber band biased trigger. In the loading position the actuating arm receives a soft round disc in front of curved edge portion. A user rotates the actuating arm and the edge portion to a firing position, the actuating arm preventing any more discs falling from the magazine, while moving a free arm of the spring loads the spring. All the while a launching slot is blocked. The user then returns the actuating arm to the loading position. When the user pulls the trigger, the free arm of the loaded spring contacts the outer peripheral portion of the disc to eccentrically propel the disc through the launching slot and away from the launcher. 
     U.S. Pat. No. 4,659,320 for a “Toy Vehicle With Disc Launching Apparatus And Disks” issued in 1987 to Rich et al, and purports to disclose a toy vehicle carrying an inclined track for storing multiple disks and a spring biased catapult lever. When a user moves the catapult lever to load the spring and then releases the catapult lever, a peripheral edge of the lever engages a spindle of a disk causing the disk to spin and eject from the vehicle. The disk moves away from the vehicle along the surface on which the vehicle is positioned. (It is noted that the spellings used for “disc” and “disk” are adopted from spellings used by the referenced patents, and in the case of U.S. Pat. No. 4,659,320 both spellings are used.) U.S. Pat. Nos. 5,471,967 and 5,611,322 issue to Matsuzaki in 1995 and 1997, respectively, for a “Disc Discharging Toy” purports to disclose motor operated spinning wheels for imparting energy to a discharging disc. U.S. Pat. No. 5,996,564 for a “Disc Discharge Device” issued in 1999 to Kotowski, and purports to disclose a disc-discharging toy having a magazine for stacking resilient discs and a motor driven roller mounted in a position such that the roller&#39;s axis of rotation is perpendicular to the axis of rotation of a discharging disc. When the motor is activated and a disc is moved forward to the spinning roller, a bumper places the disc in position to make correct contact between the disc and the roller prior to the disc being discharged. In 2001, U.S. Pat. No. 6,224,457 for a “Knockdown Style Safety Disk-Shooting Toy” issued to Wu, and purports to be another example of a motor driven disk-discharging toy, although this device included light and sound effects. 
     In 2004, U.S. Pat. No. 6,733,356 for a “Flying-Object Launching Toy Gun” issued to Lee, and purports to disclose a toy gun for launching a propeller-like device from the gun using springs to provide launch energy and a rack and pinion to cause the propeller-like device to spin as it is launched. Lastly, U.S. Pat. No. 7,673,624 issued in 2010 for a “Disk Shooting Toy” issued in 2010 to Rosella Jr., and purports to disclose a toy for shooting disks using a spring plunger and a spin member, the distal end of a curved resilient arm. 
     These patents and devices are of some interest, however, they do not disclose or illustrate a superior marketable toy item. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, an advantageous method and apparatus are provided in the form of a toy projectile launcher apparatus that discharges a soft foam circular projectile. The toy launcher is easily operated, even by young children, and requires a slide to be moved rearward to cock a launch spring, a projectile to be inserted and a lever to be pivoted. Pivoting the lever causes the slide and a projectile receptacle to snap forward in response to another spring such that the projectile is properly located to be contacted by a rotating launch arm once a trigger is pulled. The launcher apparatus also has the advantages of being relatively simple, easy to operate, fun to use, safe, relatively inexpensive, compact and yet, structurally robust. 
     Briefly summarized, the invention relates to a toy launcher apparatus for discharging circular projectiles including a housing assembly, a platform assembly mounted to the housing assembly, the platform assembly including a panel with a slot positioned to be spaced away from alignment with a center point of a loaded circular projectile, a cocking assembly connected to the platform assembly, the cocking assembly including a launch spring, a launch arm connected to the launch spring, a sliding structure, and a catch structure, the launch arm rotating in the slot when passing between a first uncocked position and a second cocked position and when the launch arm makes contact with a projectile disposed on the panel as the launch arm moves from the second position to the first position, the sliding structure being connected to the launch arm for moving the launch arm from the first position to the second position, and the catch structure engaging and maintaining the launch arm in the second position, and a trigger mounted to the housing assembly and connected to the catch structure to enable the catch structure to release the launch arm. 
     The invention also relates to a method for manufacturing the toy launcher apparatus including the steps of providing a housing assembly, attaching a platform assembly to the housing assembly, the platform assembly including a panel with a longitudinally directed slot positioned to be spaced away from alignment with a center point of a loaded circular projectile, attaching a cocking assembly to the platform assembly, providing a launch spring and a launch arm connected to the launch spring with the cocking assembly, rotating the launch arm in the slot when the launch arm passes between a first position and a second position, mounting a sliding structure for moving the launch arm from the first position to the second position, attaching a catch structure for engaging and maintaining the launch arm in the second position, and connecting a trigger to the catch structure to enable the catch structure to release the launch arm. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For the purpose of facilitating an understanding of the invention, the accompanying drawings and detailed description illustrate preferred embodiments thereof, from which the invention, its structures, its construction and operation, its processes, and many related advantages may be readily understood and appreciated. 
         FIG. 1  is a downward looking isometric view of a preferred embodiment of the present invention in the form of a toy projectile launcher apparatus. 
         FIG. 2  is a right side elevation view of the toy projectile launcher apparatus shown in  FIG. 1 . 
         FIG. 3  is a left side elevation view of the toy projectile launcher apparatus shown in  FIGS. 1 and 2 . 
         FIG. 4  is a front elevation view of the toy projectile launcher apparatus shown in  FIGS. 1-3 . 
         FIG. 5  is a top plan view, partially broken away, of the toy projectile launcher apparatus shown in  FIGS. 1-4 . 
         FIG. 6  is an upward looking isometric view of a toy projectile of the type that may be discharged by the toy launcher apparatus shown in  FIGS. 1-5 . 
         FIG. 7  is a downward looking isometric view of the toy projectile shown in  FIG. 6 . 
         FIG. 8  is a reduced downward looking isometric view of the toy projectile launcher apparatus illustrated in  FIGS. 1-5 , but in a cocked position. 
         FIG. 9  is a downward looking isometric view of the toy projectile launcher apparatus illustrated in  FIG. 8 , but with a toy projectile in a loaded position. 
         FIG. 10  is a downward looking isometric view of the toy projectile launcher apparatus, partially broken away, as illustrated in  FIGS. 8 and 9 , but with the toy projectile in position for discharge. 
         FIG. 11  is an enlarged, partial diagrammatic elevation view, similar to the view shown in  FIG. 2 , but with a launch arm moving between an uncocked position and a cocked position. 
         FIG. 12  is an enlarged, partial diagrammatic top plan view, similar to the view shown in  FIG. 5 , but illustrating force components acting on a toy projectile caused by impact of the launch arm. 
         FIG. 13  is a flow diagram for a method of manufacturing the toy projectile launcher apparatus illustrated in  FIGS. 1-5 . 
         FIG. 14  is a right side elevation of another preferred embodiment of the present invention illustrating a different outer configuration from that shown in  FIGS. 1-5 . 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The following description is provided to enable those skilled in the art to make and use the described embodiments set forth in the best mode contemplated for carrying out the invention. Various modifications, equivalents, variations, and alternatives, however, will remain readily apparent to those skilled in the art. Any and all such modifications, variations, equivalents, and alternatives are intended to fall within the spirit and scope of the present invention. 
     Referring now to  FIGS. 1-5 , there is shown an embodiment of the invention in the form of a toy projectile launcher apparatus  10  for discharging circular projectiles provided in the form of an aerodynamic flying disc or a toy projectile having a soft exterior and a more robust interior, somewhat similar to discs commonly referred to as Frisbees, one such projectile  12  being shown in  FIGS. 6 ,  7  and  9 - 12 . The toy projectile is structured to be discharged from a toy launcher apparatus with discharge energy imparted to the toy projectile through a brief, but sharp impact at a relatively small contact area at the toy projectile generating good flight characteristics and distance. The toy launcher apparatus includes a housing assembly  14 , a platform assembly  16 , a cocking assembly  18 , a trigger  20  and side support panels  22 ,  24 . The platform assembly, part of the cocking assembly and the support panels as formed of clear plastic to better illustrate internal mechanisms of the launcher apparatus  10 . In the alternative, non-clear plastic and different shapes may be used if found desirable as exemplified by the embodiment shown in  FIG. 14 . 
     The housing assembly  14  includes a gun-like grip  30  to enable a user to hold the toy projectile launcher apparatus while easily cocking the apparatus, and loading, positioning and discharging the projectile. The housing assembly  14  acts as a base for the platform assembly  16 , the cocking assembly  18 , the trigger  20  and the side support panels  22  and  24 . The trigger  20  is located in the conventional location for ease of use. 
     The platform assembly  16  includes a horizontally disposed lower panel or launch deck  40  having a top surface  42 , and an upper panel or disc ceiling  44  positioned parallel to, but spaced from the lower panel  40  at a predetermined distance approximately equal to the height of the projectile  12 , and having a bottom surface  46 . The platform assembly also includes a longitudinal guide wall  50  mounted to the launch deck  40 , a positioning wheel or limit structure  52  also mounted to the launch deck  40 , and support rollers  54 ,  56 ,  58  connected to the support panels  22 ,  24  for supporting part of the cocking assembly. Connected to and depending from the launch deck  40  are the side support panels  22 ,  24 . The launch deck  40  includes a longitudinal slot  60 , running parallel to the guide wall  50 , with the longitudinal slot  60  being positioned in the launch deck out of alignment with a center point of the projectile  12  as will be explained in more detail below. The bottom surface  46  of the upper panel  44  and the top surface  42  of the launch deck  40  each include friction reducing guide rails, a pair of guide rails  70 ,  72 ,  FIG. 4 , on the bottom surface  46  and three guide rails  74 ,  76 ,  78  on the top surface  42 . The rails provide low friction guides for a positioning and discharging projectile and the rails prevent the projectile from moving upward in response to a discharge force. 
     The circular projectile  12 ,  FIGS. 6 and 7 , has a circular plan view configuration, with a center point  82 ,  FIG. 7 , an outer covering  84  of soft material, such as that sold under the brand NERF™, and an inner core  86  of a more robust material, all as disclosed in a companion patent application (attorney docket 1-360). The outer covering  84  is generally donut shaped with an open center and the inner core  86  is generally cup shaped and positioned in the open center so that the top of the projectile is closed, as shown in  FIG. 7 , and the bottom is opened, as shown in  FIG. 6 . Bordering the open bottom is an annular inner wall  88  of the inner core  86 . Aerodynamically the projectile  12  acts similarly to a Frisbee in that the projectile has, when launched, a direction of flight or travel as well as a rotational spin. As will be explained in more detail below, when launched, the “off center” location of the launcher slot  60  relative to the center point  82  of the projectile allows the projectile to be engaged by a launch arm so such that a component of force is directed parallel to the slot in the direction of projectile travel, and a component force acts perpendicular to the slot to enable a spin to be engendered when the projectile is launched. 
     The cocking assembly  18  includes a launch arm  100 ,  FIGS. 2 ,  3  and  11 , that is connected to the side panels  22 ,  24  at a pivot  102  so that the launch arm is rotatable about the pivot  102  between two positions, a first or uncocked forward position shown in  FIGS. 2 and 11  adjacent a cushioned bumper  104 , and designated  100   a , in  FIG. 11 , and a second or cocked rearward position also shown in  FIG. 11 , in dotted line and designated  100   b , where the launch arm is captured by a catch structure  106 . An intermediate position of the launch arm is also shown in dotted line in  FIG. 11 , and designated  100   c , between the forward and rearward positions. The cocking assembly  18  also includes a torsion spring  108  mounted to the pivot  102  and to the support panels  22 ,  24  for causing the launch arm  100  to snap from the rearward cocked position to the forward position when the user squeezes the trigger  20 . One arm  110  of the spring is connected to the launch arm  100  and is movable with the launch arm, and a second arm  112  of the spring is fixed to the support panels. When the launch arm  100  is moved rearward to the cocked position, the torsion spring  108  is loaded, and when released, provides a launching force or energy to the launch arm, and from the launch arm to the projectile, to cause discharge of the projectile. 
     The cocking assembly includes, in addition, a sliding structure or cocking slide  120  mounted beneath the lower panel or launch deck  40  and connected to the launch arm  100 . The cocking slide  120  may be moved by the user from a first, at rest position shown in  FIGS. 1-3  and  5 , and a second, cocking position shown in  FIG. 8 . Attached to the cocking slide  120  is one end  122  of a slide spring  124  with the other end  126  connected to one or both of the side panels  22 ,  24 . Movable with the cocking slide is a projectile carriage  127  that includes a projectile receptacle  128  to receive a projectile as shown in  FIG. 9 . Pulling the cocking slide  120  to the second position causes the slide spring  124  to stretch and create a biasing force to return the cocking slide and a loaded projectile carriage to a predetermined projectile discharge position, as shown in  FIG. 10 , when the slide and the carriage are released by the user. In the second position the cocking slide engages a ramp that captures and maintains the cocking slide in the rearward position until the user causes release. Simultaneously, when the cocking slide  120  is pulled rearward to the cocked position, the connected launch arm  100  is rotated to its second, cocked position where the catch structure  106  captures the launch arm  100 , as shown in  FIG. 11 , until released by a user squeezing the trigger  20 . 
     In addition to the launch arm  100 , the catch structure  106 , the cocking slide  120 , the projectile carriage  127 , and the slide spring  124 , the cocking assembly includes release levers  130 ,  131 , one lever on each side of the launcher apparatus as shown in  FIGS. 2 and 3 . The cocking slide  120  is connected to the release levers  130 ,  131  so that when either lever is activated, the projectile carriage  127  with the loaded projectile  12  and the slide  120  are caused to snap forward to the discharge position where the projectile is positioned against the guide wall  50  and the positioning wheel  52 , as shown in  FIG. 10 . 
     The launch arm  100  includes a distal or extended end portion  140 ,  FIG. 11 , shaped like a rounded hammer, which is movable in an arc  142  shown in dotted lines as the launch arm travels between the uncocked forward position shown in solid lines and labeled  100   a , and the cocked rearward position of the launch arm shown in phantom lines and labeled  100   b , where the launch arm  100  is captured by the catch structure  106 . An intermediate position of the launch arm  100  is shown in  FIG. 11  and labeled  100   c , between the forward and rearward positions. The vertical position of the launch arm  100   c  represents the most extended position of the launch arm above the top surface  42  of the bottom panel or launch deck  40 . The movement of the launch arm end portion  140  is located in the slot  60  of the launch deck  40  and is represented by the arc  142 . The arm end portion  140  extends below the top surface  42  of the launch deck  40  at opposite end portions of the arc when the launch arm is in the uncocked and cocked positions as represented by the launch arms designated  100   a  and  100   b , such that no intersection with the projectile is possible. In the middle portion of the arc (exemplified by the intermediate position of the launch arm  100   c ) the launch arm is above the top surface  42  of the launch deck  40  and contact with the projectile will take place. 
     When the launch arm end portion  140  moves rapidly above the top surface  42  of the launch deck  40 , engagement is made between the launch arm  100  and the toy projectile annular inner wall  88  and energy is transferred from the launch arm  100  to the toy projectile  12  to accelerate the toy projectile between the rails  70 ,  72 ,  74 ,  76 ,  78  in the upper and lower panels  40 ,  44 . Because the slot  60  in the launch deck  40  is misaligned relative to the center point  82  of the toy projectile (shown off center in an exaggerated fashion in  FIG. 12 ), the impact force of the launch arm includes a main component of force  150 ,  FIG. 12 , directed parallel to the direction of travel of the projectile along the longitudinal axis of the toy launcher apparatus and parallel to the guide wall  50  and the slot  60 , and a secondary component of force  152  directed normal to the direction of travel. 
     Referring now to  FIGS. 8-10 , cocking, loading and positioning of the toy projectile is illustrated. In  FIG. 8 , the cocking slide  120  is illustrated after being pulled rearward by the user to tension the torsion spring  108  and the slide spring  124 . In  FIG. 9 , the toy projectile  12  has been loaded in the projectile receptacle  128 . After the release lever  130  is activated, the slide spring  124  rapidly moves the cocking slide  120 , the carriage  127  and the loaded toy projectile into a discharge position illustrated in  FIG. 10 . In the discharge position the toy projectile  12  has moved forward and bears against the guide wall  50  on one side and against the positioning wheel  52  on the opposite side, as illustrated in  FIGS. 4 ,  10  and  12 . A combination of the toy projectile bearing against the guide wall  50  caused by the force component  152  and the position of the wheel  52 , creates a friction force and causes, upon discharge, the projectile to spin and thereby improve flight characteristics. It is noted that at the start of discharge the toy projectile must “squeeze” past the wheel  52 . The squeeze insures that the projectile  12  will bear against the guide wall  50  inducing friction and causing the desired spin. 
     It is noted that throughout this disclosure, words such as “forward”, “rearward”, “upper”, “lower”, “top”, “bottom”, “front”, “rear”, “above” and “below”, as well as like terms, refer to portions of the toy launcher apparatus as they are viewed in the drawings relative to other portions or in relationship to the positions of the apparatus as it will typically be held and moved during play when operated by a user. 
     The trigger  20  is mounted to the housing assembly  12 , is spring loaded, and is connected to the catch structure  106 . When pulled by the user after the user has cocked the toy launcher apparatus, the trigger moves the catch structure sufficiently to cause the launch arm  100  to be released, allowing the launch arm to rotate rapidly under the influence of the torsion spring  108  and impact upon the toy projectile as best illustrated in  FIG. 11 . 
     The toy launcher apparatus may include, in the alternative, a projectile magazine, a cartridge, a cassette or a canister loaded with multiple projectiles to load projectiles into the receptacle. Also in the alternative, the launch arm may have a peripheral notch that a pivoting catch structure may engage to capture the launch arm in a cocked position. Another alternative may dispense with the cocking slide moving the launch arm. Instead, a cocking lever may be used or a user may directly retract the launch arm with his/her hand to its cocked position. The housing assembly may have a different design and the platform assembly may be covered or modeled after a real weapon and/or have indicia of a popular merchandising concept. One such variation toy launcher apparatus  154  is shown in  FIG. 14 . Also, it should be noted that the various structures described above which have been grouped as part of assemblies, may be treated individually without regard to an “assembly”, or the structures may be grouped in smaller assemblies or subassemblies. The use of assemblies here is strictly for convenience and clarity. 
     In operation, the toy projectile launcher apparatus is held by one hand of a user using the pistol grip. The cocking slide is gripped with the other hand and pulled rearward until both the launch arm and the cocking slide are captured in their rearward positions. At the same time the carriage with the projectile receptacle, being connected to the cocking slide, is also moved rearward to expose the receptacle and allow a user to insert a circular projectile. Thereafter, one of the release levers may be moved downward to release the slide and the carriage so as to have them move forward under the influence of the stretched slide spring. This forward movement properly locates the loaded projectile in a forward position against both the positioning wheel and the guide wall, and places the projectile in position to be engaged by the launch arm once the user pulls the trigger. Once the launch arm is released and moves along the arc, the loaded projectile is impacted to cause the projectile to be discharged with a spin. 
     The present invention also includes a method for manufacturing a toy launcher apparatus capable of discharging circular projectiles, the steps including forming  160 ,  FIG. 13 , a housing assembly, attaching  162  a platform assembly to the housing assembly, the platform assembly including a panel with a slot positioned to be spaced away from alignment with a center point of a loaded circular projectile, attaching  164  a cocking assembly to the platform assembly, the cocking assembly including a launching spring, a launch arm, and a carriage, the launch arm being connected to the torsion spring, the launch arm being movable in the slot when passing between first uncocked position and second cocked positions, mounting  166  a sliding structure and a slide spring, the sliding structure being connected to the launch arm for moving the launch arm from the first uncocked position to the second cocked position, and the carriage and slide spring for moving a loaded projectile to a predetermined discharge position, mounting  168  a catch structure and a release lever, the catch structure for engaging the launch arm to maintain the launch arm in the cocked position, and the release lever being connected to the sliding structure for causing the sliding structure and the carriage to return to an uncocked position, and attaching  170  a trigger to the housing assembly, the trigger being connected to the catch structure to enable the catch structure to release the launch arm allowing the launch arm to snap back to the first uncocked position. 
     The toy launcher apparatus disclosed in detail above has great play value, is fun to use and easy to operate in a safe manner, even for young children, and yet the launcher apparatus has a robust, but simple structure, that may be produced at a reasonable cost. 
     From the foregoing, it can be seen that there has been provided features for an improved toy launcher apparatus and a disclosure for the method of the making the toy. While a particular embodiment of the present invention have been shown and described in detail, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim is to cover all such changes and modifications as fall within the true spirit and scope of the invention. The matters set forth in the foregoing description and accompanying drawings are offered by way of illustrations only and not as limitations. The actual scope of the invention is to be defined by the subsequent claims when viewed in their proper perspective based on the prior art.