Patent Publication Number: US-7223150-B2

Title: Illuminated elastomeric flying disc and its method of manufacture

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   In general, the present invention relates to flying-disc projectile toys. More particularly, the present invention relates to flying-disc projectile toys that are made from elastomeric material and flying disc toys that are illuminated. 
   2. Description of Related Art 
   Flying disc toys, such as the Frisbee™, have been popular in the toy marketplace for decades. In this period of time, there have been many variations to the design and structure of toy flying discs. Toy flying discs have been made from metal, wood and plastic. Furthermore, a variety of different electronic light modules have been attached to flying disc toys so that the flying discs will appear illuminated during low light conditions. 
   Within the past few years, advancements have occurred in the field of polymer science that have enabled highly elastic gel materials to be produced. These elastic gels are also very resistant to tearing. These elastomeric gels are produced by mixing oils with various tri-block copolymers. Since such gel materials are soft, they have been adapted for use in the field of projectile toys, in order to make the projectile toys safer. 
   Elastomeric gels have been used in the manufacture of flying discs. This was done to make the disc easier to store, easier to hold, easier to catch and less inclined to cause impact damage. Prior art flying discs made from elastomeric gels are exemplified by U.S. Pat. No. 5,324,222 to Chen, entitled Ultra-Soft, Ultra-Elastic Airfoils. 
   A problem associated with fabricating a flying disc from an elastomeric gel is that there exists no rigid structure to mount a light module or other electronic module. Of course, a rigid electronic module can be glued to the flexible flying disc, but this would make the body of the disc rigid, thereby eliminating the benefits of making the flying disc from an elastomeric gel. 
   A need therefore exists for a way to connect electronic components to a flexible elastomeric body in a manner that does not make the elastomeric body rigid. This need is met by the present invention as described and claimed below. 
   SUMMARY OF THE INVENTION 
   The present invention is an internally illuminated toy. The toy has a flexible body that is made from an elastomeric gel. The flexible body defines an internal chamber that is accessible through a small access opening. An electronics module is provided that contains a light source and a battery needed to power the light source. The electronics module is inserted into the internal chamber of the flexible body by hyper-extending the access opening to a size that enables the electronics module to pass. Once inside the internal chamber, the access opening elastically contracts and the electronics module is trapped within the flexible body. Since the electronics module is not attached to the flexible body, the electronics module does not prevent the flexible body from being stretched in any direction. 
   When activated, the electronics module illuminates, thereby internally illuminating the flexible body of the toy. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a better understanding of the present invention, reference is made to the following description of exemplary embodiments thereof, considered in conjunction with the accompanying drawings, in which: 
       FIG. 1  is a perspective view of an exemplary embodiment of the present invention toy; 
       FIG. 2  is a cross-sectional view of the embodiment of  FIG. 1 ; 
       FIG. 3  is a cross-sectional view of the embodiment of  FIG. 1  shown in a stretched condition; 
       FIG. 4  is a method schematic for the manufacture of the embodiment of the present invention shown in  FIG. 1 ; 
       FIG. 5  is a selectively cross-sectioned view of an alternate embodiment of the present invention toy 
   

   DETAILED DESCRIPTION OF THE DRAWINGS 
   Although the present invention can be utilized in many different types of toy projectiles, such as balls, footballs and the like, the present invention is particularly well suited for use in the fabrication of flying discs. Accordingly, the exemplary embodiment of the present invention is illustrated and described as a flying disc. This is done to set forth the best mode contemplated for the present invention. However, such an exemplary embodiment should not be considered a limitation to the application of the present invention to other thrown toy projectiles. 
   Referring to  FIG. 1 , a first exemplary embodiment of the present invention is shown. The shown embodiment is a flying disc  10 . The flying disc  10  has a molded body  12  that is fabricated from an elastomeric gel. An appropriate elastomeric gel is described in co-pending patent application Ser. No. 10/641,795, filed Aug. 15, 2003, entitled Elastic Non-Sticky Surface Gel Material, which is incorporated into this specification by reference. 
   The flying disc  10  has a flexible body  12  that is shaped like a circular disc. Because the flexible body  12  is molded from an elastomeric gel, the flexible body of the flying disc is both soft and highly elastic. A cavity  14  is formed in the geometric center of the flexible body  12 . As will later be explained in more detail, the central cavity  14  is created by placing a removable form in the mold when the flexible body  12  is molded from elastomeric gel. 
   An electronics module  20  is placed within the central cavity  14  of the flexible body  12 . The electronics module  20  is a self-contained unit having a rigid housing  22  that surrounds an internal light source, power supply and control button  24 . The electronics module  20  is sized to fit securely within the central cavity  14  of the flexible body  12 . However, the control button  24  of the electronics module  20  can be manually manipulated through the material of the flexible body  12 . Consequently, the electronics module  20  can be selectively turned on and off. 
   The elastomeric gel used to create the flexible body  12  is preferably translucent. Consequently, light produced by the electronics module  20  passes through the material of the elastic body  12  and the flying disk  10  glows from internal illumination. 
   Referring to  FIG. 2 , it can be seen that a small access hole  26  is formed in the flexible body  12  that leads to the central cavity  14 . The access hole  26  is needed to remove the molding form that is used to create the central cavity  14  during molding. The access hole  26  has a diameter that is far smaller than the diameter of the electronics module  20 . However, due to the physical properties of the elastomeric gel that forms the flexible body  12 , the access hole  26  can be temporarily stretched open to a diameter that will enable the electronics module  20  to pass through the access hole  26  and into the central cavity  14 . The moment the electronics module  20  passes through the access hole  26 , it elastically contracts back to its normal size, thereby trapping the electronics module  20  within the central cavity  14 . 
   If the electronics module  20  ever needs to be removed from the central cavity  14  for repair or battery replacement, the electronics module  20  can be pressed against the access hole  26 . If pushed with enough force, the electronics module  20  will hyper-extend the access hole  26  until it opens wide enough for the electronics module  20  to pass. 
   The electronics module  20  has a translucent protective housing  22 . Contained within the housing  22  is at least one light emitting diode (LED)  28  and a battery  30  to power the LED  28 . The activation of the LED  28  is controlled by a manual control switch  24  that is present on the exterior of the protective housing  22 . In addition to the LED(s)  28 , the protective housing  22  also contains a small circuit board  32  with circuitry that causes the LED(s)  28  to flash in a predetermined sequence. 
   The electronics module  20  may also contain a noise generator and speaker so that the electronics module can produce sound in addition to light. 
   The housing  22  of the electronics module  20  physically protects the various electronic components from damage and contamination with water and dirt. The housing  22  retains the electronics components in place, thereby making the electronic components highly resistant to shock damage, which is important with a thrown projectile toy. The housing  22  also protects the electronic components from being damaged, should the flying disc  10  ever be stepped upon or otherwise crushed. 
   Referring now to  FIG. 3 , it can be seen that since the flexible body  12  of the flying disc  10  is made from an elastomeric gel, the flexible body  12  can be stretched. When the flexible body  12  is stretched, it elongates. As the flexible body  12  elongates, so does the central cavity  14 . It can be seen that the central cavity  14  retains the electronics module  20  but is not bonded to the electronics module  20 . Consequently, the electronics module  20  is free to move within the central cavity  14  as the central cavity  14  elongates indifferent directions. The stretching force, therefore, never acts directly upon the electronics module  20  and the flying disc  10  can be stretched without concern of damaging the electronics module  20 . 
   Referring to  FIG. 4 , an exemplary method of manufacture is shown for the fabrication of the flying disc  10 . As is indicated by Step  1 , the shape of a projectile toy is formed by injection molding an elastomeric gel in a mold  40 . The elastomeric gel  46  is molded around an insert  42  that forms the central cavity  14  in the molded flexible body  12 . The insert  42  is supported in the mold  40  by a support shaft  44 . The elastomeric gel  46  forms around the support shaft  44 . 
   As is indicated by Step  2 , the flexible body  12  is removed from the mold  40 . The flexible body  12  has a central cavity  14  created by the molding insert  42 . An access hole  26  is present that leads to the central cavity  14 . The access hole  26  is created by the support shaft  44  that held the insert  42  in place during molding. To remove the flexible body  12  from the insert  42 , the flexible body  12  is pulled off the insert  42 . The access hole  26  hyper-extends and passes around the insert  42 . 
   Referring to Step  3  in  FIG. 4 , it can be seen that an electronics module  20  is provided. The electronics module  20  is sized to fit within the central cavity  14  of the flexible body  12 . Lastly, as is indicated by Step  4 , the electronics module  20  is inserted into the central cavity  14  by again hyper-extending the access hole  26 . 
   In the embodiment of the present invention shown to this point, the flexible body  12  has only one central cavity  14  and only one electronics module  20  that fits within that central cavity  14 . Referring to  FIG. 5 , an alternate embodiment of the present invention device is shown. In the embodiment of  FIG. 5 , a flying disc  50  is shown having a flexible body  52 . Contained within the flexible body  52  are a plurality of cavities  54 . A plurality of electronics modules  56  are provided that fit within the different cavities. The electronics modules  56  can be different sizes and have different functions. For instance, each of the electronics modules  56  can produce light of a different color. Alternatively, some of the electronics modules  56  may produce light while others produce sound. The electronics modules  56  are preferably symmetrically disposed around the center of the flying disc  50  so that the flying disc  50  is balanced while spinning during flight. 
   It will be understood that a person skilled in the art can make many variations to the present invention using functionally equivalent parts to the parts that are illustrated. For instance, the electronics modules need not be round, they can be oval, disc shaped or can have any other body shape. A rounded shape is preferred due to its lack of salient points that may wear against the material of the flexible body. Furthermore, the flexible body itself can be formed into many different geometric shapes. Additionally, the function of the electronics modules can be varied in many ways. The electronics modules can be made to flash in any pattern and/or play any selection of music or sounds. All such variations, modifications and alternate embodiments are intended to be included within the scope of the present invention as described and claimed below.