Patent Description:
There is a continuing desire to provide toys that interact with a user, and for the toys to reward the user based on the interaction. For example, some robotic pets will show simulated love if their owner pats their head several times. While such robotic pets are enjoyed by their owners, there is a continuing desire for new and innovative types of toys and particularly toy characters that interact with their owner. Examples known in the art include <CIT>, which discloses an interactive hatching egg.

The present invention is as set out in independent claim <NUM>. Optional features are as disclosed in dependent claims <NUM> to <NUM>.

For a better understanding of the various embodiments described herein and to show more clearly how they may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings in which:.

Reference is made to <FIG>, which show a toy assembly <NUM> in accordance with an embodiment of the present disclosure. The toy assembly <NUM> includes a housing <NUM> and a toy character <NUM> that is positioned in the housing <NUM>. For the purposes of showing the toy character <NUM> inside the housing <NUM>, parts of the housing <NUM> are shown as transparent in <FIG>, however the housing <NUM> may, in the physical assembly, be opaque in the sense that, under typical ambient lighting conditions, the toy character <NUM> would be not visible to a user through the housing <NUM>. In the embodiment shown, the housing <NUM> is in the form of an egg shell and the toy character <NUM> inside the housing <NUM> is in the form of a bird. However, the housing <NUM> and toy character <NUM> may have any other suitable shapes. For manufacturing purposes, the housing <NUM> may be formed from a plurality of housing members, individual shown as a first housing member 12a, a second housing member 12b and a third housing member 12c, which are fixedly joined together so as to substantially enclose the toy character <NUM>. In some embodiments the housing <NUM> could alternatively only partially enclose the toy character <NUM> so that the toy character could be visible from some angles even when it is inside the housing <NUM>.

The toy character <NUM> is configured to break the housing <NUM> from within the housing <NUM>, as to expose the toy character <NUM>. In embodiments in which the housing <NUM> is in the form of an egg, the act of breaking the housing <NUM> will appear to the user as if the toy character <NUM> is hatching from the egg, particular in embodiments in which the toy character <NUM> is in the form of a bird, or some other animal that normally hatches from an egg, such as a turtle, a lizard, a dinosaur, or some other animal.

Referring to the transparent view in <FIG>, the housing <NUM> may include a plurality of irregular fracture paths <NUM> formed therein. As a result, when the toy character <NUM> breaks the housing <NUM> it appears to the user that the housing <NUM> has been broken randomly by the toy character <NUM>, to impart realism to the process of breaking the housing. The irregular fracture paths <NUM> may have any suitable shape. For example, the fracture paths <NUM> may be generally arcuate, so as to inhibit the presence of sharp corners in the housing <NUM> during breakage of the housing <NUM> by the toy character <NUM>. The irregular fracture paths <NUM> may be formed in any suitable way. For example, the fracture paths may be molded directly into one or more of the housing members 12a-12c. In the example shown, the fracture paths <NUM> are provided on the inside face (shown at <NUM>) of the housing <NUM> so as to not be visible to the user prior to breakage of the housing <NUM>. As a result of the fracture paths <NUM>, the housing <NUM> is configured to fracture along at least one of the fracture paths <NUM> when subjected to a sufficient force.

The housing <NUM> may be formed of any suitable natural or synthetic polymer composition, depending on the desired performance (i.e., breakage) properties. When presented in the form of an egg shell, as shown for example in <FIG>, the polymer composition may be selected so as to exhibit a realistic breakage behavior upon impact from the breakout mechanism <NUM> of the toy character <NUM>. In general, suitable materials for a simulated breakable egg shell may exhibit one or more of low elasticity, low plasticity, low ductility and low tensile strength. Upon action by the breakout mechanism <NUM>, the material should fracture, without significant absorption of the impact force. In other words, upon impact by the breakout mechanism <NUM>, the material should not significantly flex, but rather fracture along one or more of the defined fracture elements. In addition, the polymer composition may be selected to demonstrate breakage without the formation of sharp edges. During the breakage event, the selected polymer composition should enable broken and loosened pieces to separate and fall cleanly away from the housing <NUM>, with minimal unrealistic hanging due to flex or bending at undetached points.

It has been determined that polymer compositions having high filler content relative to the base polymer exhibit performance properties desired for simulating a breaking egg shell. An exemplary composition having high filler content may comprise about <NUM>-<NUM> weight-% base polymer, about <NUM>-<NUM> weight-% organic acid metal salt and about <NUM>-<NUM> weight-% inorganic/particulate filler. It will be appreciated that a variety of base polymers, organic acid metal salts and fillers may be selected to achieve the desired performance properties. In one exemplary embodiment suitable for use in forming the housing <NUM>, the composition is comprised of <NUM>-<NUM> weight-% ethylene-vinyl acetate, <NUM>-<NUM> weight-% zinc stearate and <NUM>-<NUM> weight-% calcium carbonate.

While exemplified using ethylene-vinyl acetate, it will be appreciated that a variety of base polymers may be used depending on the desired performance properties. Alternatives for the base polymer may include select thermoplastics, thermosets and elastomers. For example, in some embodiments, the base polymer may be a polyolefin (i.e., polypropylene, polyethylene). It will be further appreciated that the base polymer may be selected from a range of natural polymers used to produce bioplastics. Exemplary natural polymers include, but are not limited to, starch, cellulose and aliphatic polyesters.

While exemplified using calcium carbonate, it will be appreciated that an alternative particulate filler may be suitably used. Exemplary alternatives may include, but are not limited to, talc, mica, kaolin, wollastonite, feldspar, and aluminum hydroxide.

With reference to <FIG>, where the housing <NUM> is provided in the form of an egg shell, the wall thickness in structural regions <NUM>, that is on portions of the housing <NUM> surrounding the fracture elements (shown in <FIG> as fracture paths <NUM>) may be in the range of <NUM> to <NUM>. The selected wall thickness may take into account a number of factors, including ease of molding (i.e., injection molding), in particular with respect to melt flow performance through the mold tool for a selected polymer composition. For the exemplary polymer composition noted above, that is the composition comprised of <NUM>-<NUM> weight-% ethylene-vinyl acetate, <NUM>-<NUM> weight-% zinc stearate and <NUM>-<NUM> weight-% calcium carbonate, a wall thickness of <NUM> to <NUM> for the structural regions <NUM> may be selected to achieve good molding performance. With this composition, a thickness of <NUM> to <NUM> for the structural region <NUM> has also been found to provide sufficient strength to maintain the integrity of the housing <NUM> during transport and handling, particularly when being handled by children.

The arrangement of the plurality of fracture paths <NUM> formed on the inside face <NUM> of the housing <NUM> serves to facilitate the process of breaking the housing <NUM> by the breakout mechanism <NUM>. In a housing <NUM> provided in the form of a breakable egg shell, the fracture paths <NUM> are generally provided in a breakage zone <NUM> of the first housing member 12a. It will be appreciated, however, that the breakage zone <NUM> may be provided in one or more of the various housing members 12a, 12b, 12c. The fracture paths <NUM> may be formed in either a random or regular (i.e., geometric) pattern, depending on the desired breakage behavior. Turning to <FIG>, shown are a number of exemplary fracture elements that may be formed into the housing <NUM>.

<FIG> shows an embodiment where the fracture elements are presented as fracture paths <NUM> in the breakage zone <NUM>, the fracture paths <NUM> including a combination of continuous (i.e., interconnected) and discontinuous (i.e., dead-end) channels <NUM> formed on the inside face <NUM> of the housing <NUM>. To facilitate breakage, the channels <NUM> are positioned so as to provide a generally continuous centrally-located fracture path (shown at dotted line C) through the breakage zone <NUM>. The fracture paths <NUM> define a region of reduced wall thickness, generally <NUM> to <NUM>% thinner in comparison to the wall thickness of the structural regions <NUM>. In some embodiments, the fracture paths <NUM> are dimensioned to present a wall thickness that is <NUM>% thinner than the wall thickness of the surrounding structural region <NUM>. Accordingly, where a housing <NUM> is provided having a wall thickness of <NUM> in the structural region <NUM>, the fracture paths <NUM> will generally exhibit a wall thickness of <NUM>. As shown, the width of the channels <NUM> vary between <NUM> to <NUM> along the length thereof, with some channels exhibiting a generally decreasing width towards the terminal (i.e., dead-end) regions thereof.

<FIG> shows an embodiment where the fracture elements are presented as fracture paths <NUM> in the breakage zone <NUM>, the fracture paths <NUM> being randomly positioned, and where the channels <NUM> forming the fracture paths <NUM> are continuous (i.e., interconnected) therethrough. Similar to the embodiment of <FIG>, the fracture paths <NUM> in <FIG> define a region of reduced wall thickness, generally <NUM> to <NUM>% thinner in comparison to the wall thickness of the structural regions <NUM>. In some embodiments, the fracture paths <NUM> are dimensioned to present a wall thickness that is <NUM>% thinner than the wall thickness of the surrounding structural region <NUM>. Accordingly, where a housing <NUM> is provided having a wall thickness of <NUM> in the structural region <NUM>, the fracture paths <NUM> will generally exhibit a wall thickness of <NUM>. Although the width of the channels <NUM> may vary, in particular at regions where two or more channels intersect, the channels are formed having a width generally in the range of <NUM> to <NUM>.

<FIG> shows an embodiment where the fracture elements are presented as fracture paths <NUM> in the breakage zone <NUM>, the fracture paths <NUM> being arranged in a geometric pattern, and where the channels <NUM> forming the fracture path <NUM> are continuous (i.e., interconnected) therethrough. As shown, the geometric pattern includes a plurality of hexagons arranged in a grid, where the perimeter (i.e., sides) of the hexagons define the fracture path <NUM>. Each hexagon is further provided with a central fracture path 16a bisecting the hexagon, either through opposing vertices, or opposing sides. Similar to the embodiment of <FIG>, the fracture paths <NUM>/16a in <FIG> define a region of reduced wall thickness, generally <NUM> to <NUM>% thinner in comparison to the wall thickness of the structural regions <NUM>. In some embodiments, the fracture paths <NUM>/16a are dimensioned to present a wall thickness that is <NUM>% thinner than the wall thickness of the surrounding structural region <NUM>. Accordingly, where a housing <NUM> is provided having a wall thickness of <NUM> in the structural region <NUM>, the fracture paths <NUM>/16a will generally exhibit a wall thickness of <NUM>. Within each geometric shape, the area delimited by the surrounding fracture paths <NUM> may be formed with uniform wall thickness. In an alternative arrangement, the region <NUM> delimited by the surrounding fracture paths <NUM> may be tapered as shown in <FIG>. As shown, each region <NUM> includes a central ridge <NUM> having a first thickness (i.e., similar to or greater than the thickness of the structural region <NUM>) and a plurality of tapered walls <NUM> extending from the central ridge <NUM> in the direction towards an adjacent fracture paths <NUM>. In comparison to the embodiments of <FIG> and <FIG>, the width of the channels <NUM> is more uniform where the fracture paths <NUM> are arranged in a geometric pattern. Although the width of the channels may vary, the channels in some embodiments may be formed having a width of approximately <NUM>.

<FIG> illustrates an embodiment where the breakage zone <NUM> includes a series closely associated but discontinuous and randomly positioned fracture elements (shown as fracture units <NUM>). Each fracture unit <NUM> generally presents in the form of a T- or Y-shaped channel, having a width of <NUM> to <NUM>. The fracture unit <NUM> defines a region of reduced wall thickness, generally in the region of <NUM> to <NUM>% compared to the wall thickness of the structural regions <NUM>. In some embodiments, the fracture units <NUM> are dimensioned to present a wall thickness that is <NUM>% thinner than the wall thickness of the surrounding structural region <NUM>. Accordingly, where a housing <NUM> is provided having a wall thickness of <NUM> in the structural region <NUM>, the fracture units <NUM> will generally exhibit a wall thickness of <NUM>.

With reference to <FIG> and <FIG>, shown are additional alternative embodiments where a discontinuous array of fracture elements is provided to establish the breakage zone <NUM>. <FIG> and <FIG> present a plurality of fracture elements (shown as fracture units <NUM>) in the form of a circular and/or oval depressions formed in the housing <NUM>. The circular and/or oval fracture units <NUM> may be provided in various sizes and orientations, to achieve a generally random breakage behavior. In addition, the fracture units <NUM> may be arranged in a generally random pattern, as shown in <FIG>, or in a regular repeating pattern as shown in <FIG>. The fracture units <NUM> in <FIG> and <FIG> define a region of reduced wall thickness, generally <NUM> to <NUM>% thinner in comparison to the wall thickness of the structural regions <NUM>. In some embodiments, the fracture units <NUM> are dimensioned to present a wall thickness that is <NUM>% thinner than the wall thickness of the surrounding structural region <NUM>. Accordingly, where a housing <NUM> is provided having a wall thickness of <NUM> in the structural region <NUM>, the fracture units <NUM> will generally exhibit a wall thickness of <NUM>.

The fracture elements (fracture paths <NUM>/ fracture units <NUM>) may account for <NUM> to <NUM>% of the area within the breakage zone <NUM>. In some embodiments where the housing is required to fracture at a higher impact force, the fracture paths/units may account for <NUM> to <NUM>% of the area within the breakage zone <NUM>. Conversely, where the housing <NUM> is required to fracture at a lower impact force, the fracture elements may account for <NUM>% to <NUM>% of the area within the breakage zone <NUM>. In the embodiments shown in <FIG>, the fracture elements account for approximately <NUM> to <NUM>% of the area within the breakage zone. Selection the proportion of fracture elements relative to the structural region of the housing <NUM> will consider a number of factors, including, but not limited to, the materials used, the forces required to fracture the housing, as well as the shape of the housing. For example, in an embodiment where the polymer composition incorporates a base polymer having higher strength characteristics compared to ethylene-vinyl acetate, the housing may require a higher proportion of fracture elements (i.e., <NUM>% to <NUM>%) to achieve housing fracture under the same impact conditions. It will be appreciated that other embodiments may incorporate a proportion of fracture elements that may be less than <NUM>%, or greater than <NUM>%, depending on the intended application and the impact forces used to achieve housing fracture.

Although the housing <NUM> has been exemplified in the form of an egg shell, it will be appreciated that the materials and molding features discussed above may be applied to other articles of manufacture, including but not limited to other housing configurations as well as consumer packaging. For example, where the toy character is provided in the form of an action figure, the housing may be provided in the form of a building, with the action figure being configured to impact the housing from the inside upon being activated. It will be appreciated that a multitude of toy/housing combinations may be possible.

The toy character <NUM> is shown mounted only on the housing member 12c in <FIG>. Referring to <FIG> and <FIG>, the toy character <NUM> includes a toy character frame <NUM>, a breakout mechanism <NUM>, a breakout mechanism power source <NUM> and a controller <NUM>. The breakout mechanism <NUM> is operable to break the housing <NUM> (e.g., to fracture the housing <NUM> along at least one of the fracture paths <NUM>) to expose the toy character <NUM>. The breakout mechanism <NUM> includes a hammer <NUM>, an actuation lever <NUM> and a breakout mechanism cam <NUM>. The hammer <NUM> is movable between a retracted position (<FIG>) in which the hammer <NUM> is spaced from the housing <NUM> and an advanced position (<FIG>) in which the hammer <NUM> is positioned to break the housing <NUM>.

The actuation lever <NUM> is pivotably mounted via a pin joint <NUM> to the toy character frame <NUM> and is movable between a hammer retraction position (<FIG>) in which the actuation lever <NUM> is positioned to permit the hammer <NUM> to move to the retracted position, and a hammer driving position (<FIG>) in which the actuation lever <NUM> drives the hammer <NUM>. The actuation lever <NUM> is biased towards the hammer driving position by an actuation lever biasing member <NUM>. In other words, the actuation lever <NUM> is biased by the biasing member <NUM> towards driving the hammer <NUM> to the extended position. The actuation lever <NUM> has a first end <NUM> with a cam engagement surface <NUM> thereon, and a second end <NUM> with a hammer engagement surface <NUM> thereon, which will be described further below.

The breakout mechanism cam <NUM> may sit directly on an output shaft (shown at <NUM>) of a motor <NUM> and is thus rotatable by the motor <NUM>. The breakout mechanism cam <NUM> has a cam surface <NUM> that is engaged with the cam engagement surface <NUM> on the first end <NUM> of the actuation lever <NUM>. When the breakout mechanism cam <NUM> is rotated by the motor <NUM> (in the clockwise direction in the views shown in <FIG> and <FIG>), from the position shown in <FIG> to the position shown in <FIG>) a stepped region shown at <NUM> on the cam surface <NUM> causes the cam surface <NUM> to drop away from the actuation lever <NUM> abruptly, permitting the biasing member <NUM> to accelerate the actuation lever <NUM> to impact at relatively high speed with the hammer <NUM>, thereby driving the hammer <NUM> forward (outward) from the frame <NUM> at relatively high speed, which provides a high impact energy when the hammer <NUM> hits the housing <NUM>, so as to facilitate breaking of the housing <NUM>. In some embodiments, this will present the appearance of a bird pecking its way out of an egg.

As the breakout mechanism cam <NUM> continues to rotate, the cam surface <NUM> draws the actuation lever <NUM> back to the retracted position that is shown in <FIG>. The hammer engagement surface <NUM> of the actuation lever <NUM> may have a first magnet 52a there in that is attracted to a second magnet 52b in the hammer <NUM>. As a result, during the drawing back of the actuation lever <NUM>, the actuation lever <NUM> pulls the hammer <NUM> back to a retracted position shown in <FIG>.

The breakout mechanism cam <NUM> is rotatable by the motor <NUM> to cyclically cause retraction of the actuation lever <NUM> from the hammer <NUM> and then release of the actuation lever <NUM> to be driven into the hammer <NUM> by the actuation lever biasing member <NUM>. Thus, the motor <NUM> and the actuation lever biasing member <NUM> may together make up the breakout mechanism power source <NUM>.

The breakout mechanism biasing member <NUM> may be a helical coil tension spring as shown in the figures, or alternatively it may be any other suitable type of biasing member.

Additionally, the toy character <NUM> includes a rotation mechanism shown at <NUM> in <FIG>. The rotation mechanism <NUM> is configured to rotate the toy character <NUM> in the housing <NUM>. The controller <NUM> is configured to operate the rotation mechanism <NUM> when operating the breakout mechanism in order to break the housing <NUM> in a plurality of places.

The rotation mechanism <NUM> may be any suitable rotation mechanism. In the embodiment shown in <FIG>, the rotation mechanism <NUM> includes a gear <NUM> that is fixedly mounted to the bottom housing member 12c. The output shaft <NUM> of the motor <NUM> is a dual output shaft that extends from both sides of the motor <NUM> and drives first and second wheels 56a and 56b. On one of the wheels, (in the example shown, on the first wheel 56a) is a drive tooth <NUM>. When the motor <NUM> turns the output shaft <NUM>, the drive tooth <NUM> on the first wheel 56a engages the gear <NUM> once per revolution of the output shaft <NUM> and drives the toy character <NUM> to rotate relative to the housing <NUM>. A bushing <NUM> supports the toy character <NUM> for rotation about the axis (shown at Ag) of the gear <NUM>. In the example shown, the bushing <NUM> is slidably, rotatably engaged with a shaft <NUM> of the gear <NUM>, and is axially supported on support surface <NUM> of the bottom housing member 12c, as shown in <FIG>. The toy character <NUM> may be releasably held to the bushing <NUM> via projections <NUM> on the bushing <NUM> that engage apertures <NUM> on the toy character frame <NUM>. When the toy character <NUM> is desired to be removed from the bushing <NUM>, a user may pull the toy character <NUM> off of the projections <NUM>. The bushing <NUM> also supports the wheels 56a and 56b off of the housing <NUM>. As a result, while the toy character <NUM> is in the housing <NUM>, rotational indexing of the toy character <NUM> takes place by sliding of the bushing <NUM> on the bottom housing member 12c and without engagement of the wheels 56a and 56b on the housing member 12c.

As can be seen from the description above, once per revolution of the output shaft <NUM>, the rotation mechanism <NUM> rotates the toy character <NUM> by a selected angular amount (i.e., the rotation mechanism <NUM> rotationally indexes the toy character <NUM>), and the actuation lever <NUM> is drawn back to a retracted position and then released to drive the hammer <NUM> forward to engage and break the housing <NUM>. Thus, continued rotation of the motor <NUM> causes the toy character <NUM> to eventually break through the entire perimeter of the housing <NUM>.

Once the toy character <NUM> has broken through the housing <NUM>, a user can help to free the toy character <NUM> from the housing <NUM>. It will be noted that the housing member 12c may be left to serve as a base for the toy character <NUM> if desired in some embodiments. Once the toy character <NUM> is freed from the housing <NUM> and the hammer <NUM> is no longer needed to break through the housing <NUM>, the user may move at least one release member from a pre-breakout position to a post-breakout position. In the example shown in <FIG>, there are two release members, namely a first release member 70a, and a second release member 70b. Prior to breaking of the housing <NUM> to expose the toy character <NUM>, the release members 70a and 70b are in the pre-breakout position. When in the pre-breakout position, the first release member 70a connects the first end (shown at <NUM>) of the actuation lever biasing member <NUM> to the toy character frame <NUM>. The second end (shown at <NUM>) of the biasing member <NUM> is connected to the actuation lever <NUM>, and therefore, the biasing member <NUM> is connected to drive the hammer <NUM> forward (via actuation of the actuation lever <NUM>) to break the housing <NUM>. Movement of the release member 70a to the post-breakout position in the example shown, entails removal of the release member 70a such that the biasing member <NUM> is disabled from driving the actuation lever <NUM> and therefore the hammer <NUM>, as shown in <FIG>. As a result, when the motor <NUM> rotates, which causes rotation of the breakout mechanism cam <NUM>, the passing of the stepped region <NUM> of the cam surface <NUM> does not cause the actuation lever <NUM> to be driven into the hammer <NUM>.

With reference to <FIG>, the second release member 70b, when in the pre-breakout position, holds a locking lever <NUM> in a locking position so as to hold a hammer biasing structure <NUM> in a non-use position. In the non-use position the hammer biasing structure <NUM> is fixedly held to the actuation lever <NUM> and acts as one with the actuation lever <NUM>. With reference to <FIG> and <FIG>, when the second release member 70b is moved from the pre-breakout position to the post-breakout position, the locking lever <NUM> releases the hammer biasing structure <NUM>. The hammer biasing structure <NUM> includes a pivot arm <NUM> that is pivotally connected to the actuation lever <NUM> (e.g., via a pin joint <NUM>), and a pivot arm biasing member <NUM> that may be a compression spring or any other suitable type of spring that acts between the actuation lever <NUM> and the pivot arm <NUM> so as to urge the pivot arm <NUM> into the hammer <NUM> to urge the hammer <NUM> towards the extended position shown in <FIG>. As a result, the hammer <NUM> can integrate into the toy character's appearance. In the embodiment shown, wherein the toy character <NUM> is in the form of a bird, the hammer <NUM> is the beak of the bird. Because the hammer <NUM> is urged outwards by the biasing member <NUM> and is not locked in the extended position, it may be pushed in against the biasing force of the biasing member <NUM> by an external force (e.g., by the user), as shown in <FIG>, which can reduce the risk of a poking injury to a child playing with the toy character <NUM>.

Any suitable scheme may be used to initiate breaking out of the housing <NUM> by the toy character <NUM>. For example, as shown in <FIG>, at least one sensor may be provided in the toy assembly <NUM> which detects interaction with a user while the toy character <NUM> is in the housing <NUM>. For example, a capacitive sensor <NUM> may be provided on the bottom of the housing member 12c so as to detect holding by a user. A microphone <NUM> may be provided on the toy character frame <NUM> to detect audio input by a user. A pushbutton <NUM> may be provided on the front of the toy character <NUM>. A tilt sensor <NUM> may be provided on the toy character <NUM> to detect tilting of the toy character <NUM> by the user. The controller <NUM> may count the number of interactions that a user has had with the toy assembly <NUM> and operate the breakout mechanism <NUM> so as to break the housing <NUM> and expose the toy character <NUM> if a selected condition is met. For example, the condition may be a selected number of interactions with a user, such as <NUM> interactions. Interaction with the toy character <NUM> using the microphone <NUM> could entail the user saying a command that is recognized by the controller <NUM>, or alternatively it could entail the user making any kind of noise such as a clap or a tap, which would be received by the microphone <NUM>. An interaction could entail the user holding or touching the housing <NUM> in places where the capacitive sensor will receive it. In another example, an interaction could entail the user pushing the pushbutton <NUM> of the toy character <NUM> by pressing on the correct spot on the housing <NUM>, which may be sufficiently flexible and resilient to transmit the force of the press through to the pushbutton <NUM>. The pushbutton <NUM> may control operation of an LED <NUM> that is inside the toy character <NUM> and is sufficiently bright to view through the housing <NUM>. The LED <NUM> may illuminate in different colours (controlled by the controller <NUM>) to indicate to the user the 'mood' of the toy character <NUM>, which may depend on factors including the interactions that have occurred between the toy character <NUM> and the user.

When the toy character <NUM> is outside of the housing <NUM>, the toy character <NUM> may carry out movements that are different than those carried out inside the housing <NUM>. For example, the toy character <NUM> may have at least one limb <NUM>. In the example shown, there are provided two limbs <NUM> which are shown as wings but which may be any suitable type of limb. When inside the housing, the wings <NUM> are positioned in a pre-breakout position in which they are non-functional, as shown in <FIG>, <FIG> and <FIG>, and, when outside the housing, are positioned in a post-breakout position in which they are functional, as shown in <FIG>. As shown in <FIG>, the wings <NUM> are connected to the character frame <NUM> via a wing connector link <NUM> that is pivotally mounted at one end to the associated wing <NUM> and at another end to the character frame <NUM>. For each wing <NUM>, a wing driver arm <NUM> is pivotally connected at one end to the associated wing <NUM> and has a wing driver arm wheel <NUM> at the other end. The wing driver arm wheels <NUM> rest on the toy character's main wheels 56a and 56b when the toy character <NUM> is in the post-breakout position. The toy character's main wheels 56a and 56b have a cam profile on them with at least one lobe <NUM> on each wheel (shown in <FIG>, in which two lobes <NUM> are provided on each wheel). The lobes <NUM> serve two purposes. Firstly, as the motor <NUM> turns, the wheels 56a and 56b drive the toy character <NUM> along the ground, and the lobes <NUM> lend a wobble to the toy character <NUM> to give it a more lifelike appearance when it rolls along the ground. Secondly, as the wheels 56a and 56b turn, the presence of the lobes <NUM> cause the wheels 56a and 56b to act as wing driver cams, which drive the wing driver arms <NUM> up and down as the wing driver arm wheels <NUM> follow the cam profiles of the main wheels 56a and 56b. The up and down movement of the wing driver arms <NUM> in turn, drives the wings <NUM> to pivot up and down, giving the toy character <NUM> the appearance of flapping its wings as it travels along the ground. Preferably, the lobes <NUM> on the first wheel 56a are offset rotationally relative to the lobes <NUM> on the second wheel 56b so that the toy character <NUM> has a side-to-side wobble as the toy character rolls to enhance the lifelike appearance of its motion.

For each wing connector link <NUM>, a wing connector link biasing member <NUM> (<FIG>) biases the associated wing connector link <NUM> to urge the associated wing <NUM> downward to maintain contact between the driver arm wheels <NUM> and the main wheels 56a and 56b when the character is in the post-breakout position shown in <FIG>.

In the example shown, where the limbs <NUM> are wings, the driver arms <NUM> are referred to as wing driver arms, the driver arm wheels <NUM> are referred to as wing driver arm wheels <NUM> and the wheels 56a and 56b are referred to as wing driver cams. However, it will be understood that if the wings <NUM> were any other suitable type of limbs, the driver arms <NUM> and the driver arm wheels <NUM> may more broadly be referred to as limb driver arms <NUM> and limb driver arm wheels <NUM> respectively, and the wheels 56a and 56b may be referred to as limb driver cams.

The motor <NUM> drives the limbs <NUM> in the example shown, by driving the wheels 56a and 56b. Thus, when the limbs <NUM> are in the post-breakout position, the motor <NUM> is operatively connected to the limbs <NUM>.

The motor <NUM> is thus the limb power source. However, the motor <NUM> is just an example of a suitable limb power source, and alternatively any other suitable type of limb power source could be used to drive the limbs <NUM>.

When the wings <NUM> are in the pre-breakout position (<FIG>), the links <NUM> may hinge relative to the character frame <NUM> as needed so that the wings fit within the confines of the housing <NUM>. In the example shown the wing connector links <NUM> hinge upwardly against the biasing force of the biasing members <NUM>. While in the housing <NUM>, the wings <NUM> thus remain in their non-functional position wherein the wing driver arms <NUM> are held such that the wing driver arm wheels <NUM> are disengaged from the toy character's main wheels 56a and 56b. Thus, the motor <NUM> (i.e., the limb power source) is operatively disconnected from the limbs <NUM> when the limbs <NUM> are in the pre-breakout position. As a result, when the toy character <NUM> is in the housing <NUM> and the motor <NUM> rotates (e.g., to cause movement of the breakout mechanism <NUM>), the rotation of the main wheels 56a and 56b does not cause movement of the wings <NUM>. As a result, the wings <NUM> do not cause damage to the housing <NUM> during operation of the motor <NUM> while the character <NUM> is in the housing <NUM>.

The motor <NUM> depicted in the figures includes an energy source, which may be one or more batteries.

Reference is made to <FIG>, which illustrates a way that a user can play with the toy assembly <NUM> prior to breakout of the toy character <NUM> from the housing <NUM>. The lower housing member 12b is shown as transparent in <FIG> to show the toy character <NUM> inside. At a first point in time, the user may scan the toy assembly <NUM> by any suitable means, such as by a camera <NUM> on a smartphone <NUM> to produce a first progress scan <NUM> of the toy assembly <NUM> (i.e., which may be an image of the toy assembly <NUM> taken from the smartphone camera <NUM>). The user may then upload the scan <NUM> to a server <NUM> as part of, or after, registering the toy assembly <NUM> via a network such as the internet, shown at <NUM>. The server <NUM> may, in response to the uploaded scan, generate an output image 158a representing a first virtual stage of development of the toy character <NUM> in the housing <NUM>, so as to convey the impression to the user that the toy character <NUM> is a living entity growing inside the housing <NUM>. The output image 158a may be displayed electronically (e.g., on the smartphone <NUM>). The user may at a second, later point in time take a second progress scan <NUM> of the toy assembly <NUM> and may upload it to the server <NUM>, whereupon the server <NUM> will generate a second output image 158b (shown in <FIG>) that represents a second virtual stage of development of the toy character <NUM> inside the housing <NUM>. In the second virtual stage of development the toy character <NUM> may appear to be further developed than in the first virtual stage of development.

<FIG> is a flow diagram of a method <NUM> of managing an interaction between a user and the toy assembly <NUM> in accordance with the actions depicted in <FIG>. The method <NUM> begins at <NUM>, and includes a step <NUM> which is receiving from the user a registration of the toy assembly <NUM>. This may take place by receiving from a user, information regarding the model number or serial number of the toy assembly <NUM>. Step <NUM> includes receiving from the user after step <NUM>, a first progress scan of the toy assembly, as depicted in <FIG>. Step <NUM> includes displaying an image of the toy character <NUM> in a first stage of virtual development, as depicted in <FIG>. Step <NUM> includes receiving from the user after step <NUM>, a second progress scan of the toy assembly <NUM>, as depicted in <FIG> again. Step <NUM> includes displaying a second output image 158b of the toy character <NUM> in a second stage of virtual development that is different than the first output image 158a depicting the first stage of development, as shown in <FIG>.

While it has been described for the toy assembly <NUM> to include a controller and sensors, and to include the breakout mechanism inside the toy character <NUM>, many other configurations are possible. For example, the toy assembly <NUM> could be provided without a controller or any sensors. Instead the toy character <NUM> could be powered by an electric motor that is controlled via a power switch that is actuatable from outside the housing <NUM> (e.g., the switch may be operated by a lever that extends through the housing <NUM> to the exterior of the housing <NUM>).

The breakout mechanism <NUM> has been shown to be provided inside the toy character <NUM>. It will be understood that this location is just an example of a location in association with the housing <NUM> in which the breakout mechanism <NUM> can be positioned. In other embodiments, the breakout mechanism can be positioned outside the housing <NUM>, while remaining in association with the housing <NUM>. For example, in embodiments in which the housing <NUM> is shaped like an egg (as is the case in the example shown in the figures), a 'nest' can be provided, which can hold the egg. The nest may have a breakout mechanism built into it that is actuatable to break the egg to reveal the toy character <NUM> within. Thus, in an aspect, a toy assembly may be provided, that includes a housing, such as the housing <NUM>, a toy character inside the housing, that is similar to the toy character <NUM> but wherein a breakout mechanism is provided that is associated with the housing, whether the breakout mechanism is within the housing or outside of the housing, or partially within and partially outside of the housing, and that is operable to break the housing <NUM> to expose the toy character <NUM>. The breakout mechanism is powered by a breakout mechanism power source (e.g., a spring, or a motor) that is associated with the housing <NUM>. In some embodiments (e.g., as shown in <FIG>), the breakout mechanism includes a hammer (such as the hammer <NUM>), which the breakout mechanism power source is operatively connected to, so as to drive the hammer to break the housing <NUM>. In some embodiments (e.g., as shown in <FIG>), the breakout mechanism power source is operatively connected to the hammer to reciprocate the hammer to break the housing <NUM>.

Another aspect of the invention relates to the movement of the toy character <NUM> when in the pre-breakout position and when in the post-breakout position. More specifically, the toy character <NUM> may be said to include a functional mechanism set that includes all of the movement elements of the toy character <NUM>, including, for example, the limbs <NUM>, the main wheels <NUM>, the limb connector links <NUM> and associated biasing members <NUM>, the limb driver arms <NUM>, the driver arm wheels <NUM>, the hammer <NUM>, the actuation lever <NUM>, the breakout mechanism cam <NUM>, the motor <NUM> and the actuation lever biasing member <NUM>. The toy character <NUM> is removable from the housing <NUM> and is positionable in a post-breakout position. When the toy character <NUM> is in the pre-breakout position, the functional mechanism set is operable to perform a first set of movements. In the example shown, the limb power source (i.e., the motor <NUM>) is operatively disconnected from the limbs <NUM>, and so movement of the limb power source <NUM> does not drive movement of the limbs <NUM>. However, in the pre-breakout position, the breakout mechanism power source drives movement of the breakout mechanism <NUM> (by reciprocating the hammer <NUM> and indexing the toy character <NUM> around in the housing <NUM>) so as to break the housing <NUM> and expose the toy character <NUM>. When the toy character <NUM> is in the post-breakout position, the functional mechanism set that is operable to perform a second set of movements that is different than the first set of movements. For example, when the toy character <NUM> is in the post-breakout position the limb power source <NUM> is operatively connected to the limbs <NUM> and can drive movement of the limbs <NUM>, but the breakout mechanism <NUM> is not driven by the breakout mechanism power source.

Some optional aspects of the play pattern for the toy assembly are described below. While the toy character <NUM> is in the housing <NUM> (when the toy character <NUM> is still in the pre-break out stage of development), the user can interact with the toy character in several ways. For example, the user can tap on the housing <NUM>. The tapping can be picked up by the microphone on the toy character <NUM>. The controller <NUM> can interpret the input to the microphone, and, upon determining that the input was from a tap, the controller <NUM> can output a sound from the speaker that is a tap sound, so as to appear as if the toy character <NUM> is tapping back to the user. Alternatively, or additionally, the controller <NUM> may initiate movement of the hammer <NUM> as described above, depending on whether the controller <NUM> can control the speed of the hammer <NUM>, so as to knock the hammer <NUM> against the interior wall of the housing <NUM>, lightly enough that it can be sensed by the user, but not so hard that it risks breaking the housing <NUM>. The controller <NUM> may be programmed (or otherwise configured) to emit sounds indicating annoyedness in the event that the user taps too many times within a certain amount of time or according to some other criteria. Optionally, if the user turns the toy assembly <NUM> upside down a first time, the controller <NUM> may be programmed to emit a 'Weee!' sound from the speaker of the toy character <NUM>. If the user turns the toy assembly <NUM> upside down more than a selected number of times within a certain period of time, then the controller <NUM> may be programmed to emit a sound (or some other output) that indicates that the toy character <NUM> is queasy. Optionally, when the controller <NUM> detects, via the capacitive sensors, that the user is holding the housing <NUM>, the controller <NUM> may be programmed to emit a heartbeat sound from the toy character <NUM>. Optionally, the controller <NUM> may be configured to indicate that it is cold using any suitable criteria and may be programmed to stop indicating that it is cold when the controller <NUM> detects that the user is holding or rubbing the housing <NUM>. Optionally, the controller <NUM> is programmed to emit sounds indicating that the toy character <NUM> has the hiccups and to stop indicating this upon receiving a sufficient number of taps from the user. The controller <NUM> may be programmed to indicate to the user that the toy character <NUM> is bored and would like to play and may be programmed to stop such indication when the user interacts with the toy assembly <NUM>.

Optionally, when the controller <NUM> has determined that the criteria have been met for it to leave the pre-break out stage of development and break out of the housing <NUM>, the controller <NUM> may cause the LED to flash a selected sequence. For example, the LED may be caused to flash a rainbow sequence (red, then orange, then yellow, then green, then blue, then violet). After this, the toy character <NUM> may begin hitting the housing <NUM> a selected number of times, after which it may stop and wait for the user to interact further with it before beginning to hit the housing <NUM> again by a selected number of times.

Optionally, after the toy character <NUM> has initially broken out of the housing <NUM>, the controller <NUM> may be programmed to act in a first stage of development after 'hatching' (i.e., after the toy character <NUM> is released from the housing <NUM>) to emit sounds that are baby-like and to move in a baby-like manner, such as for example only being able to spin in a circle. During this first stage, the controller <NUM> may be programmed to require the user to interact with the toy character <NUM> in selected ways that symbolize petting of the toy character <NUM>, feeding the toy character <NUM>, burping the toy character <NUM>, comforting the toy character <NUM>, caring for the toy character <NUM> when the toy character <NUM> emits output that is indicative of being sick, putting the toy character <NUM> down for a nap, and playing with the toy character <NUM> when the toy character <NUM> emits output that is indicative of being bored. In this first stage, the toy character <NUM> may emit output that indicates fear from sounds beyond a selected loudness. In this stage, the toy character may generally emit baby-like sounds, such as gurgling sounds when the user attempts to communicate with it verbally.

Optionally, after some criteria are met during the first stage (e.g., a sufficient amount of time has passed, or a sufficient number of interactions (e.g., <NUM> interactions) have passed between the user and the toy character <NUM>) the controller <NUM> may be programmed to change its mode of operation to a second stage after 'hatching' (i.e., after the toy character <NUM> is released from the housing <NUM>). Optionally, the LED will emit the rainbow sequence again to indicate that the criteria have been met and that the toy character is changing its stage of development.

In the second stage of development, the toy character <NUM> can move linearly as well as moving in a circle. Additionally, the sounds emitted from the toy character <NUM> may sound more mature. Initially in the second stage of development after hatching, the controller <NUM> may be programmed to drive the toy character <NUM> to move linearly, but not smoothly - the motor <NUM> may be driven and stopped in a random manner to give the appearance of a toddler learning to walk. Over time the motor <NUM> is driven with less stopping giving the toy character <NUM> the appearance of a more mature capability to 'walk'. In this second stage of development, the toy character <NUM> may be capable of emitting sounds at the cadence that the user used when speaking to the toy character <NUM>. Also in this second stage of development, games involving interaction with the toy character <NUM> may be unlocked and played by the user.

<FIG> illustrates a breakout mechanism <NUM> in accordance with another embodiment of the present disclosure. The breakout mechanism <NUM> includes a base member <NUM> that is generally cup-shaped, having a feature, a plunger locking recess <NUM>, in its side wall and a slot <NUM> in its base wall. A plunger member <NUM> has a tubular body <NUM> and a rounded cap <NUM>. The outer circumference of the tubular body <NUM> of the plunger member <NUM> is dimensioned to be smaller than the internal circumference of the side wall of the base member <NUM>, enabling the tubular body <NUM> to shift laterally as needed within the base member <NUM>. A feature along the outer surface of the tubular body <NUM>, a protrusion <NUM>, at a proximal end of the body <NUM> (i.e. the opposite end from the rounded cap <NUM>) is sized to fit within the plunger locking recess <NUM> of the base member <NUM>.

A biasing element, in particular a spring <NUM>, is fitted inside of the tubular body <NUM> of the plunger member <NUM> and exerts a biasing force between the plunger member <NUM> and the base member <NUM>. A collar <NUM> is mounted (e.g. via a thermal bond, adhesive, or any other suitable means) around the tubular body <NUM> of the plunger member <NUM> and prevents the full exit of the plunger member <NUM> from the base member <NUM> via abutment of the protrusion <NUM> against the collar <NUM>. The spring <NUM> is in a compressed state between the rounded cap <NUM> of the plunger member <NUM> and the base wall of the base member <NUM> when the plunger member <NUM> is in a retracted position, in which the plunger member <NUM> within the base member <NUM>, as shown in <FIG>.

A release element, namely a wedge <NUM>, is inserted into the slot <NUM> when the plunger member <NUM> is fully inserted into the base member <NUM>, so as to hold the tubular body <NUM> of the plunger member <NUM> to one side of the interior of the base member <NUM> and positioning the protrusion <NUM> in the plunger locking recess <NUM>. A ridge <NUM> along the wedge <NUM> limits insertion of the wedge <NUM> into the slot <NUM>.

<FIG> shows the breakout mechanism <NUM> in a compacted state, wherein the plunger member <NUM> is in a retracted position within the base member <NUM> with the spring <NUM> in compression. The wedge <NUM> has been inserted into the slot <NUM>, and is biased against the tubular body <NUM> by an internal protuberance <NUM> within the slot, urging the tubular body <NUM> of the plunger member <NUM> to one side of the interior of the base member <NUM> and the protrusion <NUM> into the recess <NUM> to inhibit biasing of the plunger member <NUM> by the spring <NUM>.

The release element can, in some alternative embodiments, restrict expansion of the spring or other biasing element.

<FIG> shows the breakout mechanism in an expanded state. Removal of the wedge <NUM> enables the tubular body <NUM> of the plunger member <NUM> to shift within the base member <NUM>, permitting the protrusion <NUM> to exit the plunger locking recess <NUM> and releasing the plunger member <NUM> to be moved outwardly from the base member <NUM> by the separating force of the spring <NUM>.

The breakout mechanism <NUM> can form part of a toy character similar to the toy character <NUM>. For example, the plunger member <NUM> and the base member <NUM> may together be included in the housing of the toy character. Thus, the plunger member <NUM> and the base member <NUM> may be configured as needed so that they contribute to the appearance of a young bird, reptile, or the like. Further, the breakout mechanism <NUM> can be placed within a housing, such as an egg, that may be fractured via the biasing force of the spring <NUM> urging the plunger member <NUM> outwardly toward an extended position (<FIG>) relative to the base member <NUM>. The housing has an aperture permitting the wedge <NUM> to be removed from the breakout mechanism <NUM>. The spring <NUM> can exert a sufficiently strong biasing force to separate the plunger member <NUM> and the base member <NUM> and fracture a housing in which the breakout mechanism <NUM> is placed.

<FIG> is a sectional view of a housing in which the breakout mechanism <NUM> of <FIG> may be deployed. The housing in this example is in the form of an simulated egg shell <NUM> that has a series of fracture paths <NUM> formed along its interior, the fracture paths <NUM> having a decreased shell thickness relative to the surrounding portions of the egg shell <NUM>. A wedge access aperture <NUM> in the egg shell <NUM> permits the pass-through of an end of the wedge <NUM> so as to permit a user to grasp the wedge <NUM> and remove it to activate the breakout mechanism <NUM>.

<FIG> illustrates a breakout mechanism <NUM> in accordance with another embodiment. The breakout mechanism <NUM> includes a base member <NUM> being formed of two base member portions 404a, 404b, and a plunger member <NUM> formed of two plunger member portions 408a, 408b. The base member <NUM> has a tubular side wall <NUM> with a generally hollow interior in which the plunger member <NUM> is received, and an interior lip <NUM> along the top of the side wall <NUM>. The plunger member <NUM> has a tubular side wall <NUM>, and an exterior ridge <NUM> along the bottom of the side wall <NUM> that cooperates with the interior lip <NUM> of the base member <NUM> to inhibit full exit of the plunger member <NUM> from the base member <NUM>. The plunger member <NUM> also has a set of internal walls <NUM> that define a channel. A screw drive <NUM> is secured inside of the base member <NUM> and includes a motor <NUM> that turns a threaded shaft <NUM> (via a suitable mechanical drive will be easily configured by one skilled in the art based on the packaging requirements of the particular application), and a battery <NUM> for powering the motor <NUM>. A traveler <NUM> having an internally threaded portion receives the threaded shaft <NUM>. The traveler <NUM> is generally tubular and has a rectangular exterior profile dimensioned to prevent rotation in the channel defined by the internal walls <NUM> of the plunger member <NUM>. A lip <NUM> on the exterior of the traveler <NUM> limits insertion into the channel defined by the internal walls <NUM> as it abuts against the lower edge of the internal walls <NUM>. A biasing element <NUM> (which is shown as a helical compression spring and which, for convenience may be referred to as a spring <NUM>) is fitted inside the end of the traveler <NUM> opposite the threaded shaft <NUM>. A magnetic switch <NUM> is provided in the breakout mechanism <NUM> and controls power to the motor <NUM> from the battery <NUM>. The magnetic switch <NUM> is actuatable (i.e. closed) by the presence of a magnet <NUM> proximate to the housing, as shown in <FIG>, thereby powering the screw drive <NUM>.

<FIG> shows the breakout mechanism <NUM> in a compacted state positioned inside a housing. In the illustrated embodiment, the housing is an egg shell <NUM>. The egg shell <NUM> includes a fracturable shell portion <NUM> secured to an annular shell portion <NUM>. The annular shell portion <NUM> snap-fits to a base shell portion <NUM>. The traveler <NUM> is positioned inside the channel created by the internal walls <NUM> of the plunger member <NUM> and is positioned at a lower end of the threaded shaft <NUM>. The spring <NUM> is compressed between a shoulder in the interior of the traveler <NUM> and an end surface in the channel. The motor <NUM> is used to drive the screw drive <NUM> to drive progressively increasing flexure of the spring <NUM> so as to increase a biasing force exerted by the spring <NUM> urging the plunger member <NUM> outward from the base member <NUM>.

<FIG> shows the breakout mechanism <NUM> in an expanded state after activation of the screw drive <NUM> via placement of a magnet proximate to the egg shell <NUM> adjacent the motor <NUM>. The screw drive <NUM> operably exerts a separating force urging the plunger member <NUM> and the base member <NUM> apart. Upon sufficient fracturing of the egg shell <NUM>, the spring <NUM> expands from a compressed state to push apart the broken egg shell <NUM> abruptly to heighten the realism of the hatching action.

<FIG> shows a toy character <NUM> that includes a breakout mechanism similar to the breakout mechanism <NUM> shown in <FIG>. The breakout mechanism shown in <FIG> has a base member <NUM> and a plunger member <NUM> shown in an expanded state. The toy character <NUM> includes a swiveling wheel assembly <NUM> that has a pair of wheels <NUM> that are driven, optionally by the same motor that drives the base member <NUM> and the plunger member <NUM> apart. A pair of non-swivelling wheels <NUM> is attached to the base member <NUM>. The swivelling wheel assembly may be connected to the motor in such a way that the wheel assembly <NUM> is intermittently rotated by some angle by the motor. This provides somewhat erratic movement to the breakout mechanism <NUM>. This erratic movement can convey a sense of realism to the character during its movement.

Again, the breakout mechanisms described and illustrated herein may be provided a decorative cover to simulate the appearance of any suitable character.

<FIG> illustrate a housing fracturing mechanism <NUM> according to an embodiment. The housing fracturing mechanism <NUM> has a base frame member <NUM> that includes an outer bowl <NUM> secured to an inner bowl <NUM>. The outer bowl <NUM> has an inner lip <NUM> about its top periphery. An upper frame member <NUM> is rotatably coupled to the base frame member <NUM> about the top periphery of the outer bowl <NUM>. An inner lip <NUM> of the upper frame member <NUM> securely receives the inner lip <NUM> of the outer bowl <NUM>. Three cutting elements <NUM> are pivotally coupled at a first end thereof to the base frame member <NUM> via a fastener such as a partially threaded screw <NUM>. A second end <NUM> of the cutting elements <NUM> is slidably coupled to the upper frame member <NUM> via their protrusion through openings <NUM> in a side wall of the upper frame member <NUM>. The cutting elements <NUM> are somewhat arcuate in shape and define an aperture <NUM> into which a housing <NUM> to be fractured may be positioned.

As will be understood, rotation of the upper frame member <NUM> in a counterclockwise direction relative to the base frame member <NUM> causes the cutting elements <NUM> to pivot and intersect / constrict the aperture <NUM> like an analog camera aperture. Sharp protrusions <NUM> along the cutting elements <NUM> project towards the aperture <NUM> and act to puncture and/or crack the housing <NUM>. In this manner, the housing <NUM> placed in the housing fracturing mechanism <NUM> may be fractured.

As will be understood, the cutting elements can be slidably connected to the upper frame member via a number of ways, such as by having a channel therein into which is secured a fastener fastened to the upper frame member. Further, the cutting elements may be pivotally connected to the upper frame member and slidably connected to the base frame member.

One or more cutting elements can be employed and can act to compress the housing to be fractured against other cutting elements or against a portion of the frames.

<FIG> illustrate a housing fracturing mechanism <NUM> in accordance with another embodiment. The housing fracturing mechanism <NUM> includes a pair of cutting elements <NUM> that are pivotally coupled via a fastener <NUM>, such as a bolt or rivet. One or both of the cutting elements <NUM> has a recess <NUM> in a cutting edge <NUM> thereof. A housing to be broken can be placed in the one or more recesses <NUM> and can be broken via pivoting of the cutting elements <NUM>, as shown in <FIG>, thereby permitting access to the toy character provided in the housing.

Toy characters employing the breakout mechanisms described above, particularly those illustrated in <FIG> and <FIG>, can be used in conjunction with companion toy characters that may or may not be placed inside a housing with the toy characters.

<FIG> shows a breakout mechanism <NUM> for a toy character similar to that of <FIG> in an expanded state. The breakout mechanism <NUM> has a base member <NUM> that nests within a plunger member <NUM> in a compacted state and is urged away from the plunger member <NUM> via a screw drive having a motor to the expanded state shown. Movement of the toy character on a surface is provided by wheels <NUM> that have a cam profile on them with at least one lobe on each wheel, similar to those shown in <FIG>). The wheels <NUM> are driven by the motor.

<FIG> shows a companion mechanism <NUM> for a companion toy character that is placed in a housing with the toy character (employing the breakout mechanism <NUM> of <FIG>). The companion mechanism <NUM> has a main body <NUM> and a wheel base <NUM> that nests within the main body <NUM>, but is biased outwards via an internal helical metal coil spring to an expanded state as shown. The wheel base <NUM> has a set of wheels <NUM> enabling movement of the companion mechanism <NUM> along a surface with minimal pushing.

<FIG> shows the breakout mechanism <NUM> of <FIG> and the companion mechanism <NUM> of <FIG> in a stacked compacted state. In the compacted state, the screw drive of the breakout mechanism <NUM> has not yet been activated to drive the plunger member <NUM> away from the base member <NUM>. The companion mechanism <NUM> is also in a compacted state, with the wheel base <NUM> being held under compression within the main body <NUM> against the force of the helical metal coil spring. The companion mechanism <NUM> is atop the plunger member <NUM> of the breakout mechanism <NUM>.

<FIG> is a sectional view of a housing in the form of an egg shell <NUM> having two toy characters positioned inside. A primary toy character <NUM> employs the breakout mechanism <NUM>, which is in a compacted state. A ancillary toy character <NUM> employs the companion mechanism <NUM>, which is also in a compacted state. Upon activation of the motor and attached screw drive of the breakout mechanism <NUM> within the primary toy character <NUM>, such as via a magnet to draw two contacts together to close a circuit, the screw drive urges the plunger member <NUM> away from the base member <NUM>, causing the breakout mechanism <NUM> to expand and push the ancillary toy character <NUM> through the egg shell <NUM> to fracture it. At the same time, the wheels <NUM> commence to rotate, and their lobes help push against the interior of the egg shell <NUM> to fracture it.

Upon its fracturing, the companion mechanism <NUM> within the toy character <NUM> is no longer held in compression and the wheel base <NUM> is urged away from the main body <NUM> by the helical metal coil spring.

Once the primary toy character <NUM> is freed from the egg shell <NUM>, the wheels <NUM> cause the primary toy character <NUM> to move across a surface upon which it is placed.

The breakout mechanism <NUM> and the companion mechanism <NUM> can include electronic components that are activated upon expansion. In the case of the breakout mechanism <NUM>, the electronic components can be placed on the same circuit as the motor and be activated upon closing of the circuit. For the companion mechanism <NUM>, its electronic components may be activated upon the closing of a circuit once the main body <NUM> and the wheel base <NUM> are urged apart by the helical metal coil spring.

The electronic components can enable the primary toy character <NUM> and the ancillary toy character <NUM> to make audible noises such as bird chirps, display lights, etc. Further, the primary toy character <NUM> and the ancillary toy character <NUM> can "interact" through sensing the other. For example, the primary toy character <NUM> can be equipped with an audio speaker for generating a bird chirping noise, and the ancillary toy character <NUM> can be equipped with an audio sensor (i.e. a microphone), a processor to discern the bird chirping noise from other audio signals, and an audio speaker to output a corresponding higher-pitched bird chirp. Both the primary toy character <NUM> and the ancillary toy character <NUM> can be equipped with sensors, such as microphones, light detectors, network antennas, etc., processors, and output devices, such as audio speakers, light emitting diodes, network radios, etc. In this manner, the primary toy character <NUM> and the ancillary toy character <NUM> can interact, with one setting off the other.

In one embodiment, the audio and/or light signals output by an ancillary toy character can be received and used by a primary toy character to locate and move to the ancillary toy character.

<FIG> shows another companion mechanism <NUM> for a smaller ancillary toy character similar to the companion mechanism <NUM> of <FIG> in accordance with another embodiment. The companion mechanism <NUM> has a main body <NUM> and a wheel base <NUM> that nests within the main body <NUM>, and that is biased outwards via an internal helical metal coil spring to an expanded state as shown. The wheel base <NUM> has a set of wheels <NUM> enabling movement of the companion mechanism <NUM> along a surface with minimal pushing.

<FIG> shows a breakout mechanism <NUM> similar to that of <FIG> and two of the companion mechanisms <NUM> of <FIG> in a stacked compacted state. The breakout mechanism <NUM> has a base member <NUM> that nests within a plunger member <NUM> in a compacted state as shown, and is urged away from the plunger member <NUM> to an expanded state via a screw drive. Movement of the breakout mechanism <NUM> on a surface is provided by wheels <NUM> that have a cam profile on them with at least one lobe on each wheel, similar to those shown in <FIG>).

Each of the two companion mechanisms <NUM> has its wheel base <NUM> being held under compression within the main body <NUM> against the force of the helical metal coil spring. One of the companion mechanisms <NUM> is positioned atop of the other companion mechanism <NUM>, which is, in turn, positioned atop the plunger member <NUM> of the breakout mechanism <NUM>.

<FIG> is a sectional view of a housing in the form of an egg shell <NUM> having three toy characters positioned inside. A primary toy character <NUM> employs the breakout mechanism <NUM>, which is in a compacted state. Each of two ancillary toy characters <NUM> employ the companion mechanism <NUM>, which is also in a compacted state. Upon activation of the screw drive of the breakout mechanism <NUM> within the primary toy character <NUM>, such as via a magnet to draw two contacts together to close a circuit, the screw drive urges the plunger member <NUM> away from the base member <NUM>, causing the breakout mechanism <NUM> of the primary toy character <NUM> to expand and push the toy characters <NUM> positioned on top through the egg shell <NUM> to fracture it. Upon its fracturing, the companion mechanism <NUM> within each of the ancillary toy characters <NUM> is no longer held in compression and the wheel base <NUM> is urged away from the main body <NUM> by the helical metal coil spring.

The primary toy character <NUM> and the ancillary toy characters <NUM> can include electronic componentry to provide additional functionality as described above with regards to the primary toy character <NUM> and the ancillary toy character <NUM>.

A breakout mechanism can be configured with one or more additional behaviors when the breakout mechanism is placed back in a housing. For example, the breakout mechanism may move, emit audible noises, light up, etc..

<FIG> shows an exemplary breakout mechanism <NUM> that is configured with additional behaviors when placed in a housing. The housing is an egg shell <NUM> that has a raised inner ring <NUM>. A small magnet <NUM> magnetizes a metal rod <NUM> that protrudes from the centre of the bottom inside surface of the egg shell <NUM>. An adapter disk <NUM> is positioned atop of the raised inner ring <NUM> of the egg shell <NUM>. The adapter disk <NUM> snaps onto the breakout mechanism <NUM> and enables movement of the breakout mechanism <NUM> relative to the egg shell <NUM> as part of an additional behavior. A frustoconical metal disk <NUM> is secured to the bottom of the breakout mechanism <NUM> to guide placement of the metal rod <NUM> to a Hall sensor <NUM> inside of the breakout mechanism <NUM>. The Hall sensor <NUM> senses the magnetism of the metal rod <NUM> to detect when the breakout mechanism <NUM> is positioned inside of the egg shell <NUM>.

<FIG> shows a bottom portion of the egg shell <NUM> with the raised inner ring <NUM> along its inside surface. A crenelated ring <NUM> protrudes from the interior surface of the bottom of the egg shell <NUM> within the raised inner ring <NUM>. A post anchor <NUM> inside of the crenelated ring <NUM> has an aperture in which the metal rod <NUM> is secured.

<FIG> show the adapter disk <NUM> having an annular plate <NUM> with a peripheral lip <NUM> extending downwards. A pair of wheel recesses 1048a, 1048b are dimensioned to receive wheels of the breakout mechanism <NUM>. One of the wheel recesses, 1048a, is deeper than required to receive a wheel of the breakout mechanism <NUM>. A disk grip <NUM> projects from a bottom surface of the annular plate <NUM>. Together, the wheel recess 1048a and the disk grip <NUM> enable a person to pull the adapter disk <NUM> off of the breakout mechanism <NUM> onto which it snaps so that the wheels of the breakout mechanism <NUM> may be exposed and used to mobilize the breakout mechanism <NUM> on a surface. A central gear disk <NUM> is rotatably coupled to the annular plate <NUM> and has a number of gear teeth on its upper surface. Two arcuate walls <NUM> extend from a lower surface of the central gear disk <NUM>. The arcuate walls <NUM> have thickened vertical edges <NUM>. A through-hole <NUM> enables passage of the metal rod <NUM> through the adapter disk <NUM>. A pair of securement posts <NUM> extend from the upper surface of the annular plate <NUM> to releasably engage corresponding holes in the bottom surface of the breakout mechanism <NUM>.

The breakout mechanism <NUM> is configured such that, prior to its triggering to fracture the egg shell <NUM>, detection of the magnetism of the metal rod <NUM> does not trigger the motor of the breakout mechanism <NUM>. To trigger the additional behaviors of the breakout mechanism <NUM> thereafter, the adapter disk <NUM> is secured to the bottom of the breakout mechanism <NUM> via the securement posts <NUM>, and the combined breakout mechanism <NUM> and adapter disk <NUM> are placed into the bottom portion of the egg shell <NUM>. The arcuate walls <NUM> of the adapter disk <NUM> fit within the crenelated ring <NUM> of the egg shell <NUM>, and the thickened vertical edges <NUM> engage the crenelated ring <NUM> to inhibit rotation of the central gear disk <NUM> relative to the egg shell <NUM>.

During placement of the breakout mechanism <NUM> and the adapter disk <NUM>, the metal rod <NUM> inserts into the breakout mechanism <NUM> guided by the frustoconical metal disk <NUM> so that the metal rod <NUM> engages the Hall sensor <NUM>. The magnetism of the metal rod <NUM> is sensed by the Hall sensor <NUM> and triggers the motor of the breakout mechanism <NUM> to start up.

The breakout mechanism <NUM> includes an angled piston arm coupled to the motor that projects from its bottom surface. The motor drives the angled piston arm cycles between extending angularly below the bottom surface of the breakout mechanism <NUM> and retracting back into it by its off-center attachment to a rotating disk driven by the motor. On its downward stroke, the angled piston arm engages the gear teeth on the upper surface of the central gear disk <NUM> to rotate the breakout mechanism <NUM> and annular plate <NUM> secured thereto relative to the central gear disk <NUM>. On the upward stroke of the angled piston arm, the breakout mechanism <NUM> and the annular plate <NUM> secured to it remain stationary relative to the egg shell <NUM>. As will be understood, continued operation of the motor of the breakout mechanism <NUM> causes it to intermittently rotate within the egg shell <NUM>.

The motor of the breakout mechanism <NUM> can also drive other mechanisms, such as the rotation of extending wing members, providing the illusion that the breakout mechanism <NUM> is flapping its wings.

In addition, the Hall sensor <NUM> may trigger other elements of the breakout mechanism <NUM>. For example, the breakout mechanism <NUM> can include one or more of lights, an audio speaker emitting a bird chirp, etc. that can be triggered by the Hall sensor <NUM>.

Other types of sensors and mechanisms can be used in place of the Hall sensor to trigger the additional behaviors. For example, the metal rod may complete an electrical circuit to drive the motor when inserted into the breakout mechanism. In a further example, a rod can urge two metal contacts into contact to complete a circuit to drive the motor when inserted into the breakout mechanism.

Movement of the breakout mechanism relative to the housing can be achieved in other manners. For example, a circular track on the inside of the housing can enable the rotation of one wheel to rotate the breakout mechanism relative to the housing.

The dimensions and shape of the recesses, and the materials of the cutting elements can be varied to accommodate housing shapes, materials, and dimensions.

The breakout mechanism and companion mechanisms can be provided with one or more switches to modify their behavior. The switches can take the form of buttons, physical switches, etc. and can include audio sensors, optical/motion sensors, magnetic sensors, electrical sensors, heat sensors, etc..

In the figures, a toy character has been shown as being provided in the housing. However, it will be noted that the toy character is but one example of an inner object that is provided in the housing. In some embodiments described herein, the inner object may be animate and may include a breakout mechanism. In some embodiments the inner object may not be animate. In some embodiments the inner object may be animate but may not itself include a breakout mechanism. In some embodiments the inner object may be a toy character. In some embodiments, the inner object may not be a character in the sense that it may not be configured to appear as a sentient entity.

Claim 1:
A toy assembly (<NUM>), comprising:
a housing (<NUM>); and
an inner object inside the housing (<NUM>), wherein the inner object includes a breakout mechanism (<NUM>) that is operable to break the housing to expose the inner object, wherein the breakout mechanism (<NUM>) includes a hammer (<NUM>),
characterized in that the hammer is actuated by an actuation lever (<NUM>), and the breakout mechanism (<NUM>) further includes a hammer biasing structure (<NUM>), wherein the hammer biasing structure (<NUM>) includes a pivot arm (<NUM>) pivotally connected to the actuation lever (<NUM>) and a pivot arm biasing member (<NUM>) that acts between the pivot arm (<NUM>) and the actuation lever (<NUM>) to urge the pivot arm (<NUM>) into the hammer (<NUM>) to urge the hammer (<NUM>) towards an extended position, wherein the hammer (<NUM>) is not locked in the extended position, so as to reduce a risk of a poking injury to a user of the toy assembly (<NUM>).