Patent Publication Number: US-7591704-B2

Title: Cloth doll head and a method for making same

Description:
FIELD OF THE INVENTION 
   This invention relates to a cloth doll&#39;s head and a method for manufacturing the same. 
   BACKGROUND OF THE INVENTION 
   The cloth stuffed doll has been a favorite toy of children. Toy manufacturers seek inexpensive ways of producing a cloth stuffed doll that is safe for the child. Many dolls are undesirable because they utilize hard or removable head features that may be pulled or torn from the doll and pose a choking hazard to the child. Removable features, such as hair and plastic eyes are particularly hazardous for younger children. 
   One of the challenges manufacturers face in producing safe cloth stuffed dolls is ensuring the doll has features that are distinctive and attractive to children. One of the most attractive and distinctive features of the stuffed doll is the head. Children identify with the distinctive human features of the dolls head and may be particularly attracted to the doll&#39;s eyes and hair. Therefore, a toy manufacturer strives to produce cloth stuffed dolls with distinctive facial features and realistic but bright, thick, and long hair. At the same time, the toy manufacturer desires to produce a stuffed doll whose facial features and hair are secure and will not be broken or torn away from the dolls head portion. 
   One attractive and inexpensive partial solution is to produce a stuffed cloth doll with embroidered or sewn facial features that are bright and distinctive. Embroidered or sewn facial features provide texture and allow the manufacturer to produce dolls that vary in the color and design of the facial features simply and inexpensively. A child will be drawn to the textured and bright facial features, but there will be no attendant risk that these features will become dislodged from the head and pose a threat to the child. 
   While embroidering or sewing the facial features of the stuffed doll can be accomplished easily and inexpensively, producing a doll with desirable hair characteristics in such a manner to securely and effectively cover the head portion, however, has been difficult. Many stuffed dolls utilize a hard scalp portion because this makes it easier for the manufacturer to attach the hair to the doll&#39;s head while at the same time providing an opportunity for even and full hair coverage on the doll&#39;s head. Manufacturers often secure the hair to the hard scalp portion by gluing, bonding, or utilizing a root or plug style process of affixing the hair to the head. Incorporating a hard plastic scalp portion and the present method of affixing hair to the head, however, increases manufacturing costs and has the safety disadvantages previously discussed. 
   Manufacturers have also found it difficult to produce natural looking hair. Hair materials currently in use are often difficult to curl, have a tendency to tangle, are not easily combed, or do not possess sheen emulating natural hair. Therefore, it is desirable to produce a doll with distinctive embroidered or sewn facial features and hair that is directly sewn onto a soft cloth scalp portion of the doll providing attractive full and natural looking scalp coverage that is safe for a child. 
   SUMMARY OF THE INVENTION 
   It is an object of the present invention to provide a method for producing the head portion of a cloth stuffed doll with distinctive sewn or embroidered facial features and attractive hair that is sewn onto a soft cloth scalp portion in a manner so as to provide full and natural looking scalp coverage. 
   Accordingly, the foregoing objectives are provided for where a doll&#39;s head is assembled from soft cloth material. The cloth material is cut in a predetermined pattern and includes a face plate. Selected human features are imprinted on the outer surface of the face plate. The imprinted features cannot be pulled or torn from the doll and pose no choking hazard for a child. Once the face plate has been formed, cloth jaw portions are sewn to the face plate to form a face portion. 
   A scalp cap is formed by sewing together right, left, and center scalp portions. Thereafter, a linear hair segment is sewn to the scalp portion in an outwardly spiraling pattern with a crown of the scalp cap forming the center of the concentric rings. The linear hair segment that is sewn to the scalp cap is formed from individual hair fibers that have been assembled into hair bundles. The hair fibers of the hair bundles are comprised of a material that is amenable to holding a curl and has softness and pliability characteristics mimicking natural human hair. The hair bundles are then sewn together in such a way so as to firmly secure individual hair bundles to adjacent bundles. The linear hair segment formed in this manner is stitched securely to the scalp cap to prevent the hair from being pulled or torn from the doll. 
   The scalp cap is sewn to the face portion after the hair has been attached. Once the scalp cap and the face portion have been assembled, the fully assembled doll&#39;s head is turned right-side-out. The doll&#39;s head is then used to form a soft cloth doll. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Further objects of the invention, together with additional features contributing thereto and advantages occurring therefrom, will be apparent from the following description of the invention when read in conjunction with the accompanying drawings; wherein: 
       FIG. 1  depicts a block diagram indicating a manufacturing process according to one embodiment of the subject invention; 
       FIG. 2  depicts the raw hair material in appropriate length and weight; 
       FIG. 3  depicts a section of hair following sewing operation and prior to curling; 
       FIG. 4  depicts a section of hair after the curling process; 
       FIG. 5  depicts individual cloth scalp portions prior to combination; 
       FIG. 6  depicts selected views of the assembled cloth scalp portions; 
       FIG. 7  depicts the sewing pattern and an example of the assembled hair portions early in the sewing state; 
       FIG. 8  depicts the embroidered and sewn face portions; 
       FIG. 9  depicts the final assembled face after final sewing and once it&#39;s turned right-side-out. 
       FIG. 10  depicts a sewing apparatus that can be used to sew the hair bundles into a linear hair segment. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   A brief description of a preferred method for producing a cloth doll&#39;s head according to the invention is provided in the block diagram of  FIG. 1 : 
   Synthetic hair is selected and prepared  4  by cutting and weighing hair fibers to an appropriate length and weight. The hair is then separated into a plurality of hair bundles and the hair bundles are then sewn and glued  6  into a linear hair segment. The linear hair segment is placed on a cylindrical roller and curled  8  by heating to a temperature and for a period of time appropriate for the hair material. Concurrently, or thereafter, a plurality of fabric scalp segments are cut in a predetermined pattern and sewn  2  forming side portions, a top portion, a back portion, and a crown. Once the linear hair segment has been formed and curled and the fabric scalp portions assembled, the linear hair segment is sewn in concentric rings onto the scalp portion  10  beginning in a circle around the crown and then sweeping in an outward spiral down. 
   Concurrently or thereafter, a fabric face plate is cut in a predetermined pattern and embroidered  12  to provide colorful and distinctive facial features likely to be attractive to a child. Left and right cloth head portions are cut according to a predetermined pattern and an assembled face portion is formed by sewing these head portions to the face plate  14  so as to give form and smoothness to the side and chin portions of the face plate. The assembled face portion is then sewn to the scalp portion  16  and turned right-side-out to form the fully assembled head of the cloth doll. Thereafter, the cloth doll&#39;s head can be attached to the body portion of the doll and filled with appropriate filling material. 
   A more detailed description of at least one embodiment of the method for producing the doll&#39;s head according to the invention is now provided: 
   Referring to  FIG. 2  a quantity of synthetic doll&#39;s hair  13  is selected according to desired color and texture characteristics. In one embodiment of the invention, the hair is comprised of strands of dyed poly vinyl chloride (PVC). The advantages of manufacturing hair fibers of PVC and a method of doing the same are described in the registered Korean Patent No. 10-0529004 filed on Sep. 23, 2003 and titled Poly-Vinyl Chloride Fibers and Its Manufacturing Method. Briefly, the advantages of PVC fibers are that they possess excellent malleability characteristics, possess softness and pliability profiles similar to natural human hair, and can easily be manipulated to produce long lasting curls. These fibers can be produced, for example, by a manufacturing method which utilizes in parts by weight out of 100 parts: 2.5-3.0 organotin heat stabilizer; 0.5-1.0 lubricant; and 1.5-2.0 processing aid. These are combined to produce the dry blend (powder) which is then compounded in a screw extruder with a compression ratio of 1.9-2.1 to produce the pellets (granules). The resulting pellets or granules are extruded from the screw with a compression ratio of 2.0-2.2. While PVC fibers are preferred, it will be apparent to one skilled in the art that other synthetic and organic hair fibers may be used consistent with the scope of the present invention. 
   Once the hair material has been selected, the hair is cut to a desired length. The amount of hair required for any given application will vary. The circumference of the doll&#39;s head, scalp coverage, and the desired hair follicle density are important considerations when determining the required weight of hair material. In a preferred method of manufacturing a doll&#39;s head according to the invention synthetic dyed PVC hair strands are cut to a length approximating 17 centimeters and weighed to provide approximately 30 grams of the synthetic hair material. This selection will result in complete scalp coverage and follicle density that is attractive for a doll&#39;s head with a circumference approximating 6.4 to 7.6 centimeters. 
   Referring now to  FIG. 3  and  FIG. 10 , in a preferred method according to the present invention the hair is separated into discrete hair bundles  11  approximating anywhere from 5 to 50 strands. The hair bundles  11  are sewn into a linear hair segment  20  using a 3-step sewing process. First, the hair bundles are fed into a high speed  2  needle lock stitch machine  50  and stitched  1  to allow for an approximate 2 centimeter top portion  9  above the stitch  1 . The resulting hair segment is next fed into a one needle lock stitch machine  52 . The top portion  9  is first folded over the first stitch  1  and a second stitch  3  is run the length of the segment. Finally, an additional one needle lock stitch machine  54  is used to run a final stitch  5  the length of the segment. In one embodiment of the invention, once stitches  1 ,  3 , and  5  have been completed, the sewn portion of the resulting segment is glued or slightly melted and fused to secure the stitches  1 ,  3 , and  5  and the hair bundles  11  together so they do not become disassembled later. The resulting linear hair segment  20  is depicted in  FIG. 3   a . Consistent with the scope of the present invention, alternative stitching means may be utilized that result in a linear hair segment that can be subsequently sewn to a cloth scalp cap of a doll&#39;s head as described below. 
   Referring now to  FIG. 3  and  FIG. 4 , the linear hair segment  20  may be curled to provide for a more distinctive and attractive doll. In one method according to the invention, a dyed PVC linear hair segment  20  is heated in an YVERI M/C heat machine. The linear hair segment  20  is wrapped onto a roller and inserted into the heat machine. In a preferred embodiment of the invention, the roller is approximately 25 millimeters in diameter. The linear hair segment is heated at a temperature ranging from 65 to 70 centigrade for approximately 25 minutes. 
   In alternative embodiments of the invention, the temperature and heating time may be varied to produce a curl that is more or less extreme. The curling method and process may also be varied, for example, to take advantage of the unique characteristics of the material selected for the hair fibers. A temperature and time should be selected that results in adequate softening of the hair material to allow it to curl around the roller. The roller diameter may also be changed to produce more or less severe curling of the linear hair segment  20 . Once the linear hair segment  20  has been heated and then cooled, the linear hair segment is in a curled condition  15  and ready to be sewn to a cloth scalp cap of a doll&#39;s head. In an alternative method consistent with the present invention, the curling step may be omitted entirely to produce a doll with straight hair. 
   Referring now to  FIG. 5 , a scalp cap is comprised of a right scalp portion  32 , a left scalp portion  29 , and a center scalp portion  33 . The right, left, and center scalp portions  32 ,  29 , and  33  have an inner and outer side. In one embodiment of the invention, the inner and outer sides of the plurality of scalp portions have different textures such that the inner sides are rough to the touch while the outer side that will be exposed to the child in the finished product has a soft and pleasant feel. 
   The scalp portions may be comprised of a soft cloth material such as Nylex®, treated cotton, nylon, polyester or any soft material that is preferably fire resistant and safe for children. Preferably, a cloth material is selected to allow for expansion and stretching when filling matter is placed inside the assembled doll&#39;s head. In a preferred embodiment of the invention, the cloth material is Nylex®, a tightly woven fabric that will prevent material sewn to the cloth scalp from being pulled out by a child. 
   Referring briefly to  FIG. 9 , the right scalp portion  32  will be positioned on the right side of the doll&#39;s head when it is in a fully assembled state. The left scalp portion  29  will be positioned on the left side of the doll&#39;s head when it is in a fully assembled state. The center scalp portion will form the top and back of the head as shown. 
   Returning to  FIG. 5  the right and left scalp portions  32 ,  28  are cut to approach a hemispherical shape  17 ,  19  at the side where the scalp portions are to be sewn on either side of the center scalp portion  33 . Opposite the substantially hemispherical cuts  17 ,  19  of the right and left scalp portion  32 ,  28  there are upper cut portions  25 , 27 , center cut portions  29 ,  31 , and lower cut portions  21 ,  23 . The upper and lower cut portions  25 ,  27  and  21 ,  23  are slightly curved while the center cut portions  29 ,  31  are substantially flat. 
   The center scalp portion has an upper cut portion  39 , a lower cut portion  41 , and right and left cut portions  38 ,  40 . At the centermost region of the lower cut portion  41  of the center scalp portion  33  a triangular notch  43  is cut. 
   Referring now to  FIG. 5  and  FIG. 6 , the right scalp portion  32  is sewn to the center scalp portion  33 . The pieces are sewn such that the hemispherical cut portion  17  of the right scalp portion  32  is sewn to the right cut portion  38  of the center scalp portion  33 . The stitching  49  should be placed at an appropriate distance from the cut edge of the right  32  and center  33  scalp portions to ensure proper mating and engagement of the scalp pieces. In a preferred embodiment of the invention, the stitch  49  is at least 0.3 centimeters from the cut edges. 
   The left scalp portion  29  is sewn to the center scalp portion  33  as described above. Briefly, the left scalp portion  29  is sewn to the center scalp portion  33  such that the hemispherical cut portion  19  is sewn to the left cut portion  40 . The stitch  47  is placed at an appropriate distance from the cut edge to ensure proper mating and engagement of the scalp pieces. In a preferred embodiment, the stitch is placed at least 0.3 centimeters from the cut edges. 
   Referring now to  FIG. 6 , the scalp cap formed by sewing the right and left scalp portions  32 ,  29  to the center scalp portion  33  is depicted. The assembled scalp cap has top  53 , back  51 , and crown  46 , portions. The center scalp portion notch  43  is located at the lowermost edge of the back portion  51 . The right and left scalp portions  32 ,  29  in conjunction with the center scalp portion proscribe a cavity. The cut sides  17 ,  19 ,  38 ,  40  of the scalp portions and the stitches  49 ,  47  are exposed on the inner surface of the cavity. The outer surface of the cavity includes smooth seams where the scalp portions have been sewn together. The outer surface of the cavity includes smooth seams where the scalp portions have been sewn together. The outer surface of the cavity constitutes the outer surface of the scalp cap of the assembled doll&#39;s head. The assembled scalp cap proscribes a substantially hemispherical profile when viewed on the right and left faces of the scalp cap. 
   Referring now to  FIG. 7 , the linear hair segment  20  is sewn to the outer surface of the scalp cap so as to provide natural looking scalp coverage and to strengthen and secure the assembled scalp cap. A preferred sewing pattern is shown at  55 . Beginning a small distance from the crown  46 , the linear hair segment  20  is sewn in an outwardly spiraling fashion with the crown  46 , at the center. In one embodiment of the invention, the outwardly spiraling pattern  55  is originally confined to the center scalp portion  33  and thereafter broadened to incorporate the right and left scalp portions  32 ,  39  so as to strengthen and secure the scalp cap. In one embodiment, the linear hair segment  20  is stitched at the upper portion  9  utilizing a high speed Post Bed Single Needle Lock Stitch machine. The stitching continues in the outwardly spiraling fashion until the entire linear hair segment  20  has been attached to the scalp cap. The density of the hair can be manipulated by sewing in a tighter or looser spiral pattern. In a preferred embodiment, sewing a linear hair segment in an outwardly spiraling pattern whereby the hair segment has previously been curled will allow the hair. 
   Referring now to  FIG. 8 , a face plate  79  is cut in a predetermined pattern from a soft cloth such as Nylex®, treated cotton, nylon, polyester or any soft material that is preferably fire resistant and safe for children. In a preferred embodiment of the invention, the material is Nylex®. The face plate has on inner and outer surface. In one embodiment of the invention, the inner and outer surfaces have different textures such that the inner surface is rough to the touch while the outer surface that will be exposed to the child in the finished product has a soft and pleasant feel. The face plate has a top cut portion  59 , right and left cut portions  63  and  61 , and a chin portion  57 . 
   Selected features of a human face are formed on the outer surface of the face plate. Preferably, the pattern includes bright colors and is done in a manner that is distinctive and likely to be exciting to a child or collector. In a preferred embodiment of the invention, the human facial features are embroidered onto the outer surface of the face plate. In an alternative embodiment of the invention, the human facial features are sewn or painted onto the surface of the cloth. It will be apparent to one skilled in the art that other methods of producing a face on the face plate may be substituted and are within the scope of the invention. 
   Right and left jaw portions  67 ,  65  are cut from the same or similar fabric as the face plate. Preferably the fabric is semi-elastic to allow for expansion when filling material is introduced into the doll on assembly. In a preferred embodiment of the invention, the fabric is Nylex®. 
   The right and left jaw portions  67 ,  65  have an outer cut portion  83 ,  85 , top cut portions  87 ,  89  bottom cut portions  91 ,  93 , and inner cut portions  95 ,  97 . At the uppermost region of the inner cut portions  95 , 97  tabs extend outwardly  71 ,  69 . The jaw portions  67 ,  65  have inner and outer surfaces and, the inner and outer surfaces may have different textures such that the inner surfaces are rough to the touch while the outer surfaces that are to be exposed to the child in the finished product have a soft and pleasant feel. 
   The right and left jaw portions  67 ,  65  are sewn onto the face plate  79  as shown in  FIG. 8 . The top cut portions  87 ,  89  are sewn to the right and left cut portions  63 ,  61  of the face plate from the periphery between the top  59  and right and left cut portions  63 , 61  of the face plate down to the chin section  57 . When the right and left jaw portions  67 ,  65  have been sewn to the face plate  79  as described the tabs  71 ,  69  meet at the chin section  57  of the face plate. The innermost tab portions are sewn together  73  to fully assemble the face portion. The stitches  77 ,  75 ,  73  of the assembled face portion are exposed on an inner surface of the face portion. The outer face portion bearing the selected human facial features constitutes the portion of the doll that is assessable to the child on the finished doll product and includes smooth seams corresponding to the area where the various jaw portions have been attached to the face plate. 
   Referring now to  FIG. 9 , the face portion and the scalp cap are sewn to fully assemble the doll&#39;s head. The scalp cap is sewn to the face portion so that the outer cut portions  83 ,  85  of the right and left jaw portions  65 ,  67  and the top cut portion  59  of the face plate  79  are sewn continuously from one side of the notch  43  at the back of the scalp portion, around the surfaces of the right and left scalp portions  29 ,  31  and ending the at the opposite side of the notch  43 . When fully sewn, the doll&#39;s head is inside out, such that the stitching is visible on the outside of the doll&#39;s head. Turning the doll right-side-out completes the assembly of the doll&#39;s head as shown in  FIG. 9 . The doll&#39;s head may now be assembled on a body portion of a cloth doll and filled with material to give it substance and form. 
   A specific embodiment of a cloth doll head manufactured according to the present invention has been described for the purpose of illustrating the manner in which the invention is made and used. It should be understood that the implementation of other variations and modifications of the invention and its various aspects will be apparent to one skilled in the art, and that the invention is not limited by the specific embodiments described. Therefore, it is contemplated to cover the present invention and any and all modifications, variations, or equivalents that fall within the true spirit and scope of the basic underlying principles disclosed and claimed herein.