Abstract:
A water toy is disclosed herein. In one aspect, the water toy is comprised of a non-rigid material which has an injection molded main body and flap. This flap is integral with the main body and connected via a living hinge. The flap can be either in an open or closed position. When the flap is in the closed position, an inner chamber is defined and it is capable of containing enough air to enable the toy to float. When the flap is in the open position, access is provided to the inner chamber for cleaning or drying. Teething portions may also be provided in features of the water toy.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims priority and benefit to U.S. Provisional Patent Application 61/270,990 filed Jul. 16, 2009 entitled “Process for generating safe toys—bug bites, duck”, which is hereby incorporated by reference as if set forth in full in this application for all purposes. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    Toys are frequently used by children during play. The variety of designs is virtually limitless as are the materials used in manufacturing. It is common in the art to have electronics designed into the toy for light, sound or motion powered by batteries. A panel, flap or hatch may provide access to the battery compartment. This panel, flap or hatch may be permanently attached in one area, for example, hinged, or may be removable and attached by external fasteners. Some plastic toys may also have a living hinge connecting two members that close unto one another. These members may be a flap and main body, or simply, two members that mate in a clamshell manner. A secured, closed position may be achieved by various means such as snap fit, latching mechanisms or external fasteners. It is also known in the art that plastic toys may have a built-in internal structure, for example, ribs, braces or reinforcements, for strengthening and rigidity. 
         [0003]    Water toys are common items used by children during, for example, bathing or swimming. These water toys may be designed to float while others may be designed to sink. Floating water toys have been designed in many configurations over the years to provide interesting new forms of amusement. These toys often resemble animals and common themes include frogs, dolphins and bears but none of these are as iconic as the rubber duck. While the appearance and physical size of floating water toys may vary substantially, most floating water toys are constructed of a soft, vinyl material such as polyvinyl chloride, commonly known as PVC. 
         [0004]    PVC is used extensively in toys because it is rotomoldable, inexpensive, durable and easy to assemble. In order to soften and permit flexibility of the PVC material, additional chemicals (plasticizers) are added to the PVC to change the chemical consistency of the product, however these additives do not bond well to PVC. PVC products are known to have human and environmental health risks associated with the use and manufacturing. It is known that these plasticizers can leach out of the product thus having significant health risks associated with using the product, especially if the product is in a child&#39;s mouth and chewed on. Also, during the manufacture of PVC, dioxin and other pollutants are emitted into the air, water and land, which present both acute and chronic health hazards as well as pollution. 
         [0005]    There are many methods for manufacturing plastic toys. For example, blow molding may be used for bowling pins, figurines or balls. Injection molding is a common method for making slot cars, toddler ride-on toys and game pieces. Hollow plastic toys, such as doll heads or outdoor playsets are often manufactured by using a rotation molding (rotomolding) process. 
         [0006]    It is known in the art that most plastic toys are manufactured outside of the United States of America (USA) then imported to the USA. In the last few years, the amount of toys being recalled in the USA by the Consumer Product Safety Commission has greatly increased. Many of these recalls involve high levels of lead exposure found in either the paint or plastic of the toy. Paint containing lead was banned in the USA in 1978 but it is still widely used in other countries and therefore can be found on imported toys. As mentioned previously, additional chemicals added to plastic may leach out. Because of the amount of recalls, consumers are concerned about toys manufactured outside of the USA and are seeking safer, non-toxic toys manufactured in the USA. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    A water toy is disclosed herein. In one aspect, the water toy is comprised of a non-rigid material which has an injection molded main body and flap. This flap is integral with the main body and connected via a living hinge. The flap can be either in an open or closed position. When the flap is in the closed position, an inner chamber is defined and is capable of containing enough air to enable the toy to float. When the flap is in the open position, access is provided to the inner chamber for cleaning or drying. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
           [0009]      FIG. 1  provides a perspective view of a water toy according to the present invention; 
           [0010]      FIG. 2  shows a side view of a water toy with the flap in the closed position; 
           [0011]      FIG. 3  depicts a side view of a water toy with the flap in the open position; 
           [0012]      FIG. 4  details a rear view of the water toy with the flap in the closed position; 
           [0013]      FIG. 5A  is a top view of a water toy with the flap in the open position; 
           [0014]      FIG. 5B  is a top view of a water toy with the flap in the open position illustrating another embodiment of the living hinge; 
           [0015]      FIGS. 6A  provides a bottom view of a water toy with the flap in the open position revealing an inner chamber with an inner structure; 
           [0016]      FIG. 6B  is a bottom view of a water toy with the flap in the open position revealing an inner chamber illustrating a further embodiment of the inner structure; and 
           [0017]      FIG. 7  is section D-D of  FIG. 1  and depicts a cutaway view of a water toy with the flap in the closed position further detailing the inner chamber. 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0018]    The water toy of the present invention provides significant health and safety advantages for the user who is typically a young child that may place the water toy in their mouth for extended periods of time. The material used in the construction of the water toy is safe and non-toxic avoiding the issue of dangerous chemicals leaching into the child&#39;s mouth with no known adverse health conditions to the user. Next, the product design is fundamentally different than other water toys currently available in that the design accommodates manufacturability of a safe, non-toxic material which cannot be effectively fastened or sealed via bonding agents. Additionally, designed in safety features remove the risk of the user swallowing, choking or suffocating when using this product. Also, the risk of mold developing and accumulating inside the toy is eliminated because of a unique flap feature which allows water to be drained. The flap facilitates cleaning and drying for the inside of the water toy, which prevents mold. Mold is extremely dangerous for children and is often found in currently available water toys. Lastly, this product may be completely made in the USA. These unique features will be evident and readily appreciated as embodiments according to the present invention are described in more detail in reference to the accompanying figures. 
         [0019]    An embodiment according to the present invention is depicted as a water toy  100  in  FIG. 1 . Water toy  100  has a main body  110  that includes head  112 , beak  114 , tail  116 , wings  118  (symmetrical), hair tuft  120  and eyes  122  (symmetrical). A living hinge  124  connects flap  128 , which is located under the bottom portion of water toy  100 . Note that water toy  100  is depicted in the form of a duck only by example. Water toy  100  may also take the form of other shapes such as a frog, a star or an automobile. 
         [0020]    The water toy may be made from many different materials. For example, a non-PVC thermoplastic elastomer (TPE), in particular, Medalist® MD-155 marketed by Teknor Apex Company may be used. This material is FDA compliant Medical Grade and tests conducted by an independent laboratory found the lead content less than 10 parts per million (ppm). The exact lead level is unknown because presently, the test equipment cannot test to any lower limit. The current federal restriction for consumer products intended for children 12 and under states that the product cannot have more than 300 ppm of lead content in any accessible part and the American Academy of Pediatrics recommends no more than 40 ppm of lead contamination. In other embodiments, any non-toxic material may be used, for example, a thermoplastic polyurethane (TPU), a low density polyethylene (LDPE), a linear low density polyethylene (LLDPE), silicone, or other thermoset materials. These safer, non-toxic materials are needed to improve consumer health and the environment. The present invention may be manufactured solely in the USA and is in full compliance with all International, European Union and USA mandatory and voluntary toy safety standards as well as the Environmental Protection Agency (EPA). 
         [0021]    Currently, viable safe, non-toxic materials are not commonly used in manufacturing hollow parts of water toys. Because of the limitations of rotational molding for this material and design, the process of injection molding is used. In injection molding, an extractable tool with drafts cores out the toy cavity resulting in a hollow product, or a toy with an inner chamber. As mentioned above, the present invention includes flap  128  attached to main body  110  via living hinge  124 . When flap  128  is in a closed position, flap  128  closes the inner chamber inside main body  110  and allows the water toy to float. It is known in the art that an adhesive will not bond well to non-toxic material, i.e. flap  128  cannot be effectively fastened via bonding agents when using the safer materials. 
         [0022]      FIG. 2  shows a side view of the water toy  100  with flap  128  in the closed position. When flap  128  is in this closed position, enough air is entrapped in the inner chamber within main body  110  to enable water toy  100  to float. 
         [0023]      FIG. 3  depicts the side view of water toy  100  with flap  128  in the open position. Flap  128  can be opened by placing the thumb on one wing  118  and index finger on other wing  118  and gently squeezing inward, or by inserting a fingernail or other object between flap  128  and inner surface of the main body  110 . When flap  128  is in the open position, inner chamber  670  is revealed (refer to  FIG. 6A ). 
         [0024]    It is common for mold to form when stagnant water is encased in an area without drainage. It is known in the art that water toys may become a repository for mold because water may become trapped inside the toy with no opportunity to drain or dry this confined water. It is also known in the art that regular exposure to mold can result in an array of health concerns such as headaches, respiratory infections, congestion, skin irritation and death. The present invention water toy  100 , has flap  128  that may be opened and closed. This is a significant aspect of the design because when flap  128  is in the open position, access is allowed to the interior of water toy  100  for draining, cleaning and drying any trapped water droplets or other materials located in the inner chamber, thus eliminating the risk of mold developing and accumulating inside the toy. In one embodiment, water toy  100  is dishwasher safe. 
         [0025]    Beak  114 , tail  116 , wings  118  and eyes  122  will now be discussed. In one embodiment, all of these features are integral with main body  110  thus eliminating the need for additional operational steps, such as paint and assembling. These additional operational steps could add potentially hazardous materials to the invention. Streamlining the manufacturing process by taking out additional operational steps also saves production costs. In one embodiment of the invention, beak  114  extends forward from main body  110  and tail  116  extends rearward of main body  110 . Both of these extremities may provide a teething surface. In other embodiments of the invention, these extremities could be depicted as other features of the toy, such as legs, a triangle or a wheel. Wings  118  are raised decorative panels with varying wall thickness. In other embodiments, there may not be wings or wings  118  could be in any other shape. Eyes  122  in this embodiment are circular-shaped with a cutout. In other embodiments, eyes  122  could be shaped differently, for example, triangular, rectangular or octagonal. 
         [0026]      FIG. 4  details the rear view of water toy  100  with flap  128  in the closed position. In this view, hair tuft  120  is shown as being integral to main body  110 . In this embodiment, hair tuft  120  is a raised enhancing feature. In other embodiments, there may not be hair tuft  120  or hair tuft  120  could be in any other shape. Again, because in this embodiment, this feature is integral with main body  110 , the need for additional operational steps, such as paint and assembling, are eliminated. 
         [0027]      FIG. 5A  is a top view of water toy  100  with flap  128  in the open position. In this embodiment, a narrow groove  560  extends perpendicular along the width of living hinge  124 . Groove  560  assists with the operation of living hinge  124  so material on living hinge  124  does not impede the function of opening and closing hinge  124 . In a second embodiment,  FIG. 5B  illustrates no groove on living hinge  124 . In further embodiments, the groove may be narrower or wider or in a different shape. 
         [0028]      FIG. 6A  provides a bottom view of water toy  100  with flap  128  in the open position, revealing a hollow cavity, also referred to as inner chamber  670 , located inside main body  110 . Contained within inner chamber  670 , an inner structure  672  integral to main body  110  may exist. The purpose of inner structure  672  may be threefold. First, inner structure  672  may reinforce main body  110  providing rigidity and additional structure, thus water toy  110  cannot collapse upon itself. Second, because of the dimensions of inner structure  672 , the risk of the user swallowing the toy, choking on the toy or suffocation while using the toy is minimized. The present invention conforms to all Consumer Product Safety Commission (CPSC) small parts regulations, specifically ASTM F973, and Consumer Product Safety Improvement Act of 2008 (CPSIA). Lastly, inner structure  672  may assist with maintaining flap  128  in the closed position, preventing flap  128  from opening during various tests. In this embodiment, flap  128  is closed by inserting it into inner chamber  670  where it is seated by ribs  674 , shown in  FIG. 7 . Flap  128  then fits tightly to inner chamber  670  and to the inner surface of main body  110 . In other embodiments, flap  128  could be held closed by various means, for example, snap fit designs, latching mechanisms or external fasteners. 
         [0029]    In this embodiment, inner structure  672  is integral to main body  110  and consists of brace  676 , spokes  678  and optionally, ribs  674 . Brace  676  may be circular with a diameter not less than 1.25 inches and may be 1.5 inches located in the center of the lower portion of inner chamber  670 , approximately 5/32 inches upward from the bottom surface of inner chamber  670 . The material of brace  676  extends upward toward head  112  and connects to main body  110 . Brace  676  may be further connected to main body  110  by spokes  678 . In this embodiment, there may be six spokes  678  extending radially outward from brace  676  to the inner surface of main body  110 . Ribs  674  may be approximately ⅝ inches in length, extending perpendicular to main body  110  and evenly spaced around the perimeter of inner chamber  670 , as shown in  FIG. 7 . 
         [0030]      FIG. 6B  is a second embodiment for the configuration of inner structure  672 . In this embodiment, inner structure  672  may again be integral to main body  110  and may consist of plate  682  and optionally, ribs  674 . In this embodiment, plate  682  is a flat member with a circular cutout. The diameter of the cutout is not less than 1.25 inches and may be 1.5 inches. Plate  682  is attached to the inner surface of main body  110  and located in the lower portion of inner chamber  670 , approximately 5/32 inches upward from the bottom surface of inner chamber  670 . If ribs  674  are utilized, they may be approximately ⅝ inches in length, extending perpendicular to main body  110  and evenly spaced around the perimeter of inner chamber  670 . In additional embodiments, inner structure  672  could consist of continuous reinforcements located across inner chamber  670  or any variation thereof that adds stability to main body  110 , provides safety from choking and/or assists with maintaining flap  128  in the closed position. 
         [0031]      FIG. 7  is section D-D of  FIG. 1  and depicts a cutaway view of water toy  100  with flap  128  in the closed position further detailing inner chamber  670 . Here, flap  128  is shown in relation to optional ribs  674  and optional ribs  674  are fully detailed. Also, varying wall thickness of main body  110  is illustrated. In other embodiments, the wall thickness may vary differently or not at all. 
         [0032]    While the specification has been described in detail with respect to specific embodiments of the invention, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily conceive of alterations to, variations of, and equivalents to these embodiments. These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention. Thus, it is intended that the present subject matter covers such modifications and variations as come within the scope of the appended claims and their equivalents.