Patent ID: 12257525

DETAILED DESCRIPTION

Reference is made toFIGS.1A and1B, which show a toy assembly10in accordance with an embodiment of the present disclosure. The toy assembly10includes a housing12and a toy character14that is positioned in the housing12. For the purposes of showing the toy character14inside the housing12, parts of the housing12are shown as transparent inFIGS.1A and1B, however the housing12may, in the physical assembly, be opaque in the sense that, under typical ambient lighting conditions, the toy character14would be not visible to a user through the housing12. In the embodiment shown, the housing12is in the form of an egg shell and the toy character14inside the housing12is in the form of a bird. However, the housing12and toy character14may have any other suitable shapes. For manufacturing purposes, the housing12may be formed from a plurality of housing members, individual shown as a first housing member12a, a second housing member12band a third housing member12c, which are fixedly joined together so as to substantially enclose the toy character14. In some embodiments the housing12could alternatively only partially enclose the toy character14so that the toy character could be visible from some angles even when it is inside the housing12.

The toy character14is configured to break the housing12from within the housing12, as to expose the toy character14. In embodiments in which the housing12is in the form of an egg, the act of breaking the housing12will appear to the user as if the toy character14is hatching from the egg, particular in embodiments in which the toy character14is 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 inFIG.2, the housing12may include a plurality of irregular fracture paths16formed therein. As a result, when the toy character14breaks the housing14it appears to the user that the housing12has been broken randomly by the toy character14, to impart realism to the process of breaking the housing. The irregular fracture paths16may have any suitable shape. For example, the fracture paths16may be generally arcuate, so as to inhibit the presence of sharp corners in the housing12during breakage of the housing12by the toy character14. The irregular fracture paths16may be formed in any suitable way. For example, the fracture paths may be molded directly into one or more of the housing members12a-12c. In the example shown, the fracture paths16are provided on the inside face (shown at18) of the housing12so as to not be visible to the user prior to breakage of the housing12. As a result of the fracture paths16, the housing12is configured to fracture along at least one of the fracture paths16when subjected to a sufficient force.

The housing12may 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 inFIG.1A, the polymer composition may be selected so as to exhibit a realistic breakage behavior upon impact from the breakout mechanism22of the toy character14. 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 mechanism22, the material should fracture, without significant absorption of the impact force. In other words, upon impact by the breakout mechanism22, 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 housing12, 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 15-25 weight-% base polymer, about 1-5 weight-% organic acid metal salt and about 75-85 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 housing12, the composition is comprised of 15-25 weight-% ethylene-vinyl acetate, 1-5 weight-% zinc stearate and 75-85 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 toFIG.2, where the housing12is provided in the form of an egg shell, the wall thickness in structural regions17, that is on portions of the housing12surrounding the fracture elements (shown inFIG.2as fracture paths16) may be in the range of 0.5 to 1.0 mm. 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 15-25 weight-% ethylene-vinyl acetate, 1-5 weight-% zinc stearate and 75-85 weight-% calcium carbonate, a wall thickness of 0.7 to 0.8 mm for the structural regions17may be selected to achieve good molding performance. With this composition, a thickness of 0.7 to 0.8 mm for the structural region17has also been found to provide sufficient strength to maintain the integrity of the housing12during transport and handling, particularly when being handled by children.

The arrangement of the plurality of fracture paths16formed on the inside face18of the housing12serves to facilitate the process of breaking the housing12by the breakout mechanism22. In a housing12provided in the form of a breakable egg shell, the fracture paths16are generally provided in a breakage zone19of the first housing member12a. It will be appreciated, however, that the breakage zone19may be provided in one or more of the various housing members12a,12b,12c. The fracture paths16may be formed in either a random or regular (i.e., geometric) pattern, depending on the desired breakage behavior. Turning toFIGS.15to19B, shown are a number of exemplary fracture elements that may be formed into the housing12.

FIG.15shows an embodiment where the fracture elements are presented as fracture paths16in the breakage zone19, the fracture paths16including a combination of continuous (i.e., interconnected) and discontinuous (i.e., dead-end) channels21formed on the inside face18of the housing12. To facilitate breakage, the channels21are positioned so as to provide a generally continuous centrally-located fracture path (shown at dotted line C) through the breakage zone19. The fracture paths16define a region of reduced wall thickness, generally 40 to 60% thinner in comparison to the wall thickness of the structural regions17. In some embodiments, the fracture paths16are dimensioned to present a wall thickness that is 50% thinner than the wall thickness of the surrounding structural region17. Accordingly, where a housing12is provided having a wall thickness of 0.8 mm in the structural region17, the fracture paths16will generally exhibit a wall thickness of 0.4 mm. As shown, the width of the channels21vary between 0.5 to 1.5 mm along the length thereof, with some channels exhibiting a generally decreasing width towards the terminal (i.e., dead-end) regions thereof.

FIG.16shows an embodiment where the fracture elements are presented as fracture paths16in the breakage zone19, the fracture paths16being randomly positioned, and where the channels21forming the fracture paths16are continuous (i.e., interconnected) therethrough. Similar to the embodiment ofFIG.15, the fracture paths16inFIG.15define a region of reduced wall thickness, generally 40 to 60% thinner in comparison to the wall thickness of the structural regions17. In some embodiments, the fracture paths16are dimensioned to present a wall thickness that is 50% thinner than the wall thickness of the surrounding structural region17. Accordingly, where a housing12is provided having a wall thickness of 0.8 mm in the structural region17, the fracture paths16will generally exhibit a wall thickness of 0.4 mm. Although the width of the channels21may vary, in particular at regions where two or more channels intersect, the channels are formed having a width generally in the range of 0.8 to 1.2 mm.

FIG.17Ashows an embodiment where the fracture elements are presented as fracture paths16in the breakage zone19, the fracture paths16being arranged in a geometric pattern, and where the channels21forming the fracture path16are 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 path16. Each hexagon is further provided with a central fracture path16abisecting the hexagon, either through opposing vertices, or opposing sides. Similar to the embodiment ofFIG.15, the fracture paths16/16ainFIG.17Adefine a region of reduced wall thickness, generally 40 to 60% thinner in comparison to the wall thickness of the structural regions17. In some embodiments, the fracture paths16/16aare dimensioned to present a wall thickness that is 50% thinner than the wall thickness of the surrounding structural region17. Accordingly, where a housing12is provided having a wall thickness of 0.8 mm in the structural region17, the fracture paths16/16awill generally exhibit a wall thickness of 0.4 mm. Within each geometric shape, the area delimited by the surrounding fracture paths16may be formed with uniform wall thickness. In an alternative arrangement, the region25delimited by the surrounding fracture paths16may be tapered as shown inFIG.17b. As shown, each region25includes a central ridge27having a first thickness (i.e., similar to or greater than the thickness of the structural region17) and a plurality of tapered walls29extending from the central ridge27in the direction towards an adjacent fracture paths16. In comparison to the embodiments ofFIGS.15and16, the width of the channels21is more uniform where the fracture paths16are 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 0.8 mm.

FIG.18illustrates an embodiment where the breakage zone19includes a series closely associated but discontinuous and randomly positioned fracture elements (shown as fracture units23). Each fracture unit23generally presents in the form of a T- or Y-shaped channel, having a width of 0.5 to 1.5 mm. The fracture unit23defines a region of reduced wall thickness, generally in the region of 40 to 60% compared to the wall thickness of the structural regions17. In some embodiments, the fracture units23are dimensioned to present a wall thickness that is 50% thinner than the wall thickness of the surrounding structural region17. Accordingly, where a housing12is provided having a wall thickness of 0.8 mm in the structural region17, the fracture units23will generally exhibit a wall thickness of 0.4 mm.

With reference toFIGS.19A and19B, shown are additional alternative embodiments where a discontinuous array of fracture elements is provided to establish the breakage zone19.FIGS.19A and19Bpresent a plurality of fracture elements (shown as fracture units23) in the form of a circular and/or oval depressions formed in the housing12. The circular and/or oval fracture units23may be provided in various sizes and orientations, to achieve a generally random breakage behavior. In addition, the fracture units23may be arranged in a generally random pattern, as shown inFIG.19A, or in a regular repeating pattern as shown inFIG.19B. The fracture units23in FIGS.19A and19B define a region of reduced wall thickness, generally 40 to 60% thinner in comparison to the wall thickness of the structural regions17. In some embodiments, the fracture units23are dimensioned to present a wall thickness that is 50% thinner than the wall thickness of the surrounding structural region17. Accordingly, where a housing12is provided having a wall thickness of 0.8 mm in the structural region17, the fracture units23will generally exhibit a wall thickness of 0.4 mm.

The fracture elements (fracture paths16/fracture units23) may account for 20 to 80% of the area within the breakage zone19. In some embodiments where the housing is required to fracture at a higher impact force, the fracture paths/units may account for 20 to 30% of the area within the breakage zone19. Conversely, where the housing12is required to fracture at a lower impact force, the fracture elements may account for 70% to 80% of the area within the breakage zone19. In the embodiments shown in Figures through19B, the fracture elements account for approximately 40 to 60% of the area within the breakage zone. Selection the proportion of fracture elements relative to the structural region of the housing12will 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., 70% to 80%) 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 20%, or greater than 80%, depending on the intended application and the impact forces used to achieve housing fracture.

Although the housing12has 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 character14is shown mounted only on the housing member12cinFIG.3. Referring toFIGS.4and5, the toy character14includes a toy character frame20, a breakout mechanism22, a breakout mechanism power source24and a controller28. The breakout mechanism22is operable to break the housing12(e.g., to fracture the housing12along at least one of the fracture paths16) to expose the toy character14. The breakout mechanism22includes a hammer30, an actuation lever32and a breakout mechanism cam34. The hammer30is movable between a retracted position (FIG.4) in which the hammer30is spaced from the housing12and an advanced position (Figure in which the hammer30is positioned to break the housing12.

The actuation lever32is pivotably mounted via a pin joint40to the toy character frame20and is movable between a hammer retraction position (FIG.4) in which the actuation lever32is positioned to permit the hammer30to move to the retracted position, and a hammer driving position (FIG.5) in which the actuation lever32drives the hammer30. The actuation lever32is biased towards the hammer driving position by an actuation lever biasing member38. In other words, the actuation lever32is biased by the biasing member38towards driving the hammer30to the extended position. The actuation lever32has a first end42with a cam engagement surface44thereon, and a second end46with a hammer engagement surface48thereon, which will be described further below.

The breakout mechanism cam34may sit directly on an output shaft (shown at49) of a motor36and is thus rotatable by the motor36. The breakout mechanism cam34has a cam surface50that is engaged with the cam engagement surface44on the first end42of the actuation lever32. When the breakout mechanism cam34is rotated by the motor36(in the clockwise direction in the views shown inFIGS.4and5), from the position shown inFIG.4to the position shown inFIG.5) a stepped region shown at51on the cam surface50causes the cam surface50to drop away from the actuation lever32abruptly, permitting the biasing member38to accelerate the actuation lever32to impact at relatively high speed with the hammer30, thereby driving the hammer30forward (outward) from the frame20at relatively high speed, which provides a high impact energy when the hammer30hits the housing12, so as to facilitate breaking of the housing12. In some embodiments, this will present the appearance of a bird pecking its way out of an egg.

As the breakout mechanism cam34continues to rotate, the cam surface50draws the actuation lever32back to the retracted position that is shown inFIG.4. The hammer engagement surface48of the actuation lever32may have a first magnet52athere in that is attracted to a second magnet52bin the hammer30. As a result, during the drawing back of the actuation lever32, the actuation lever32pulls the hammer30back to a retracted position shown inFIG.4.

The breakout mechanism cam34is rotatable by the motor36to cyclically cause retraction of the actuation lever32from the hammer30and then release of the actuation lever32to be driven into the hammer30by the actuation lever biasing member38. Thus, the motor36and the actuation lever biasing member38may together make up the breakout mechanism power source24.

The breakout mechanism biasing member38may 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 character14includes a rotation mechanism shown at53inFIG.6. The rotation mechanism53is configured to rotate the toy character14in the housing12. The controller28is configured to operate the rotation mechanism53when operating the breakout mechanism in order to break the housing12in a plurality of places.

The rotation mechanism53may be any suitable rotation mechanism. In the embodiment shown inFIG.6, the rotation mechanism53includes a gear54that is fixedly mounted to the bottom housing member12c. The output shaft49of the motor36is a dual output shaft that extends from both sides of the motor36and drives first and second wheels56aand56b. On one of the wheels, (in the example shown, on the first wheel56a) is a drive tooth58. When the motor36turns the output shaft49, the drive tooth58on the first wheel56aengages the gear54once per revolution of the output shaft49and drives the toy character14to rotate relative to the housing12. A bushing supports the toy character14for rotation about the axis (shown at Ag) of the gear54. In the example shown, the bushing60is slidably, rotatably engaged with a shaft62of the gear54, and is axially supported on support surface64of the bottom housing member12c, as shown inFIG.6A. The toy character14may be releasably held to the bushing via projections66on the bushing60that engage apertures68on the toy character frame20. When the toy character14is desired to be removed from the bushing60, a user may pull the toy character14off of the projections66. The bushing60also supports the wheels56aand56boff of the housing12. As a result, while the toy character14is in the housing12, rotational indexing of the toy character14takes place by sliding of the bushing60on the bottom housing member12cand without engagement of the wheels56aand56bon the housing member12c.

As can be seen from the description above, once per revolution of the output shaft49, the rotation mechanism53rotates the toy character14by a selected angular amount (i.e., the rotation mechanism53rotationally indexes the toy character14), and the actuation lever32is drawn back to a retracted position and then released to drive the hammer30forward to engage and break the housing12. Thus, continued rotation of the motor36causes the toy character14to eventually break through the entire perimeter of the housing12.

Once the toy character14has broken through the housing12, a user can help to free the toy character14from the housing12. It will be noted that the housing member12cmay be left to serve as a base for the toy character14if desired in some embodiments. Once the toy character14is freed from the housing12and the hammer is no longer needed to break through the housing12, the user may move at least one release member from a pre-breakout position to a post-breakout position. In the example shown inFIG.5, there are two release members, namely a first release member70a, and a second release member70b. Prior to breaking of the housing12to expose the toy character14, the release members70aand70bare in the pre-breakout position. When in the pre-breakout position, the first release member70aconnects the first end (shown at72) of the actuation lever biasing member38to the toy character frame20. The second end (shown at74) of the biasing member38is connected to the actuation lever32, and therefore, the biasing member38is connected to drive the hammer30forward (via actuation of the actuation lever32) to break the housing12. Movement of the release member70ato the post-breakout position in the example shown, entails removal of the release member70asuch that the biasing member38is disabled from driving the actuation lever32and therefore the hammer30, as shown inFIG.7. As a result, when the motor36rotates, which causes rotation of the breakout mechanism cam34, the passing of the stepped region51of the cam surface50does not cause the actuation lever32to be driven into the hammer30.

With reference toFIG.4, the second release member70b, when in the pre-breakout position, holds a locking lever78in a locking position so as to hold a hammer biasing structure80in a non-use position. In the non-use position the hammer biasing structure80is fixedly held to the actuation lever32and acts as one with the actuation lever32. With reference toFIGS.7and8, when the second release member70bis moved from the pre-breakout position to the post-breakout position, the locking lever78releases the hammer biasing structure80. The hammer biasing structure80includes a pivot arm82that is pivotally connected to the actuation lever32(e.g., via a pin joint84), and a pivot arm biasing member86that may be a compression spring or any other suitable type of spring that acts between the actuation lever32and the pivot arm82so as to urge the pivot arm82into the hammer30to urge the hammer30towards the extended position shown inFIG.7. As a result, the hammer30can integrate into the toy character's appearance. In the embodiment shown, wherein the toy character14is in the form of a bird, the hammer30is the beak of the bird. Because the hammer30is urged outwards by the biasing member86and is not locked in the extended position, it may be pushed in against the biasing force of the biasing member86by an external force (e.g., by the user), as shown inFIG.8, which can reduce the risk of a poking injury to a child playing with the toy character14.

Any suitable scheme may be used to initiate breaking out of the housing12by the toy character14. For example, as shown inFIG.9, at least one sensor may be provided in the toy assembly10which detects interaction with a user while the toy character14is in the housing12. For example, a capacitive sensor90may be provided on the bottom of the housing member12cso as to detect holding by a user. A microphone92may be provided on the toy character frame20to detect audio input by a user. A pushbutton94may be provided on the front of the toy character14. A tilt sensor96may be provided on the toy character14to detect tilting of the toy character14by the user. The controller28may count the number of interactions that a user has had with the toy assembly10and operate the breakout mechanism22so as to break the housing12and expose the toy character14if a selected condition is met. For example, the condition may be a selected number of interactions with a user, such as 120 interactions. Interaction with the toy character14using the microphone92could entail the user saying a command that is recognized by the controller28, 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 microphone92. An interaction could entail the user holding or touching the housing12in places where the capacitive sensor will receive it. In another example, an interaction could entail the user pushing the pushbutton94of the toy character14by pressing on the correct spot on the housing12, which may be sufficiently flexible and resilient to transmit the force of the press through to the pushbutton94. The pushbutton94may control operation of an LED that is inside the toy character14and is sufficiently bright to view through the housing12. The LED95may illuminate in different colours (controlled by the controller28) to indicate to the user the ‘mood’ of the toy character14, which may depend on factors including the interactions that have occurred between the toy character14and the user.

When the toy character14is outside of the housing12, the toy character14may carry out movements that are different than those carried out inside the housing12. For example, the toy character14may have at least one limb96. In the example shown, there are provided two limbs96which are shown as wings but which may be any suitable type of limb. When inside the housing, the wings96are positioned in a pre-breakout position in which they are non-functional, as shown inFIGS.10A,10B and10C, and, when outside the housing, are positioned in a post-breakout position in which they are functional, as shown inFIG.10D. As shown inFIG.10D, the wings96are connected to the character frame20via a wing connector link100that is pivotally mounted at one end to the associated wing96and at another end to the character frame20. For each wing96, a wing driver arm104is pivotally connected at one end to the associated wing96and has a wing driver arm wheel106at the other end. The wing driver arm wheels106rest on the toy character's main wheels56aand56bwhen the toy character14is in the post-breakout position. The toy character's main wheels56aand56bhave a cam profile on them with at least one lobe108on each wheel (shown inFIG.6, in which two lobes108are provided on each wheel). The lobes108serve two purposes. Firstly, as the motor36turns, the wheels56aand56bdrive the toy character14along the ground, and the lobes108lend a wobble to the toy character14to give it a more lifelike appearance when it rolls along the ground. Secondly, as the wheels56aand56bturn, the presence of the lobes108cause the wheels56aand56bto act as wing driver cams, which drive the wing driver arms104up and down as the wing driver arm wheels106follow the cam profiles of the main wheels56aand56b. The up and down movement of the wing driver arms104in turn, drives the wings96to pivot up and down, giving the toy character14the appearance of flapping its wings as it travels along the ground. Preferably, the lobes108on the first wheel56aare offset rotationally relative to the lobes108on the second wheel56bso that the toy character14has a side-to-side wobble as the toy character rolls to enhance the lifelike appearance of its motion.

For each wing connector link100, a wing connector link biasing member102(FIG.10C) biases the associated wing connector link100to urge the associated wing96downward to maintain contact between the driver arm wheels106and the main wheels56aand56bwhen the character is in the post-breakout position shown inFIG.10D.

In the example shown, where the limbs96are wings, the driver arms104are referred to as wing driver arms, the driver arm wheels106are referred to as wing driver arm wheels106and the wheels56aand56bare referred to as wing driver cams. However, it will be understood that if the wings96were any other suitable type of limbs, the driver arms104and the driver arm wheels106may more broadly be referred to as limb driver arms104and limb driver arm wheels106respectively, and the wheels56aand56bmay be referred to as limb driver cams.

The motor36drives the limbs96in the example shown, by driving the wheels56aand56b. Thus, when the limbs96are in the post-breakout position, the motor36is operatively connected to the limbs96.

The motor36is thus the limb power source. However, the motor36is 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 limbs96.

When the wings96are in the pre-breakout position (FIGS.10A-10C), the links100may hinge relative to the character frame20as needed so that the wings fit within the confines of the housing12. In the example shown the wing connector links100hinge upwardly against the biasing force of the biasing members102. While in the housing12, the wings96thus remain in their non-functional position wherein the wing driver arms104are held such that the wing driver arm wheels106are disengaged from the toy character's main wheels56aand56b. Thus, the motor36(i.e., the limb power source) is operatively disconnected from the limbs96when the limbs96are in the pre-breakout position. As a result, when the toy character14is in the housing12and the motor36rotates (e.g., to cause movement of the breakout mechanism22), the rotation of the main wheels56aand56bdoes not cause movement of the wings96. As a result, the wings96do not cause damage to the housing12during operation of the motor36while the character14is in the housing12.

The motor36depicted in the figures includes an energy source, which may be one or more batteries.

Reference is made toFIG.11, which illustrates a way that a user can play with the toy assembly10prior to breakout of the toy character14from the housing12. The lower housing member12bis shown as transparent inFIG.11to show the toy character14inside. At a first point in time, the user may scan the toy assembly by any suitable means, such as by a camera150on a smartphone152to produce a first progress scan153of the toy assembly10(i.e., which may be an image of the toy assembly10taken from the smartphone camera150). The user may then upload the scan153to a server154as part of, or after, registering the toy assembly10via a network such as the internet, shown at156. The server156may, in response to the uploaded scan, generate an output image158arepresenting a first virtual stage of development of the toy character14in the housing12, so as to convey the impression to the user that the toy character14is a living entity growing inside the housing12. The output image158amay be displayed electronically (e.g., on the smartphone152). The user may at a second, later point in time take a second progress scan153of the toy assembly10and may upload it to the server154, whereupon the server154will generate a second output image158b(shown inFIG.13B) that represents a second virtual stage of development of the toy character14inside the housing12. In the second virtual stage of development the toy character14may appear to be further developed than in the first virtual stage of development.

FIG.14is a flow diagram of a method200of managing an interaction between a user and the toy assembly10in accordance with the actions depicted inFIGS.11-13. The method200begins at201, and includes a step202which is receiving from the user a registration of the toy assembly14. This may take place by receiving from a user, information regarding the model number or serial number of the toy assembly14. Step204includes receiving from the user after step202, a first progress scan of the toy assembly, as depicted inFIG.12. Step206includes displaying an image of the toy character14in a first stage of virtual development, as depicted inFIG.13A. Step208includes receiving from the user after step206, a second progress scan of the toy assembly10, as depicted inFIG.12again. Step210includes displaying a second output image158bof the toy character14in a second stage of virtual development that is different than the first output image158adepicting the first stage of development, as shown inFIG.13B.

While it has been described for the toy assembly10to include a controller and sensors, and to include the breakout mechanism inside the toy character14, many other configurations are possible. For example, the toy assembly10could be provided without a controller or any sensors. Instead the toy character14could be powered by an electric motor that is controlled via a power switch that is actuatable from outside the housing12(e.g., the switch may be operated by a lever that extends through the housing12to the exterior of the housing12).

The breakout mechanism22has been shown to be provided inside the toy character14. It will be understood that this location is just an example of a location in association with the housing12in which the breakout mechanism22can be positioned. In other embodiments, the breakout mechanism can be positioned outside the housing12, while remaining in association with the housing12. For example, in embodiments in which the housing12is 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 character14within. Thus, in an aspect, a toy assembly may be provided, that includes a housing, such as the housing12, a toy character inside the housing, that is similar to the toy character14but 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 housing12to expose the toy character14. The breakout mechanism is powered by a breakout mechanism power source (e.g., a spring, or a motor) that is associated with the housing12. In some embodiments (e.g., as shown inFIG.3), the breakout mechanism includes a hammer (such as the hammer30), which the breakout mechanism power source is operatively connected to, so as to drive the hammer to break the housing12. In some embodiments (e.g., as shown inFIG.4), the breakout mechanism power source is operatively connected to the hammer to reciprocate the hammer to break the housing12.

Another aspect of the invention relates to the movement of the toy character14when in the pre-breakout position and when in the post-breakout position. More specifically, the toy character14may be said to include a functional mechanism set that includes all of the movement elements of the toy character14, including, for example, the limbs96, the main wheels56, the limb connector links100and associated biasing members102, the limb driver arms104, the driver arm wheels106, the hammer30, the actuation lever32, the breakout mechanism cam34, the motor36and the actuation lever biasing member38. The toy character14is removable from the housing12and is positionable in a post-breakout position. When the toy character14is 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 motor36) is operatively disconnected from the limbs96, and so movement of the limb power source36does not drive movement of the limbs96. However, in the pre-breakout position, the breakout mechanism power source drives movement of the breakout mechanism22(by reciprocating the hammer30and indexing the toy character14around in the housing12) so as to break the housing12and expose the toy character14. When the toy character14is 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 character14is in the post-breakout position the limb power source36is operatively connected to the limbs96and can drive movement of the limbs96, but the breakout mechanism22is 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 character14is in the housing12(when the toy character14is 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 housing12. The tapping can be picked up by the microphone on the toy character14. The controller28can interpret the input to the microphone, and, upon determining that the input was from a tap, the controller28can output a sound from the speaker that is a tap sound, so as to appear as if the toy character14is tapping back to the user. Alternatively, or additionally, the controller28may initiate movement of the hammer30as described above, depending on whether the controller28can control the speed of the hammer30, so as to knock the hammer30against the interior wall of the housing12, lightly enough that it can be sensed by the user, but not so hard that it risks breaking the housing12. The controller28may 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 assembly10upside down a first time, the controller28may be programmed to emit a ‘Weee!’ sound from the speaker of the toy character14. If the user turns the toy assembly10upside down more than a selected number of times within a certain period of time, then the controller28may be programmed to emit a sound (or some other output) that indicates that the toy character14is queasy. Optionally, when the controller28detects, via the capacitive sensors, that the user is holding the housing12, the controller28may be programmed to emit a heartbeat sound from the toy character14. Optionally, the controller28may 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 controller28detects that the user is holding or rubbing the housing12. Optionally, the controller28is programmed to emit sounds indicating that the toy character14has the hiccups and to stop indicating this upon receiving a sufficient number of taps from the user. The controller28may be programmed to indicate to the user that the toy character14is bored and would like to play and may be programmed to stop such indication when the user interacts with the toy assembly10.

Optionally, when the controller28has determined that the criteria have been met for it to leave the pre-break out stage of development and break out of the housing12, the controller28may 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 character14may begin hitting the housing12a selected number of times, after which it may stop and wait for the user to interact further with it before beginning to hit the housing12again by a selected number of times.

Optionally, after the toy character14has initially broken out of the housing12, the controller28may be programmed to act in a first stage of development after ‘hatching’ (i.e., after the toy character14is released from the housing12) 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 controller28may be programmed to require the user to interact with the toy character14in selected ways that symbolize petting of the toy character14, feeding the toy character14, burping the toy character14, comforting the toy character14, caring for the toy character14when the toy character14emits output that is indicative of being sick, putting the toy character14down for a nap, and playing with the toy character14when the toy character14emits output that is indicative of being bored. In this first stage, the toy character14may 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., 120 interactions) have passed between the user and the toy character14) the controller28may be programmed to change its mode of operation to a second stage after ‘hatching’ (i.e., after the toy character14is released from the housing12). 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 character14can move linearly as well as moving in a circle. Additionally, the sounds emitted from the toy character14may sound more mature. Initially in the second stage of development after hatching, the controller28may be programmed to drive the toy character14to move linearly, but not smoothly—the motor38may be driven and stopped in a random manner to give the appearance of a toddler learning to walk. Over time the motor38is driven with less stopping giving the toy character14the appearance of a more mature capability to ‘walk’. In this second stage of development, the toy character14may be capable of emitting sounds at the cadence that the user used when speaking to the toy character14. Also in this second stage of development, games involving interaction with the toy character14may be unlocked and played by the user.

FIG.20illustrates a breakout mechanism300in accordance with another embodiment of the present disclosure. The breakout mechanism300includes a base member304that is generally cup-shaped, having a feature, a plunger locking recess308, in its side wall and a slot312in its base wall. A plunger member316has a tubular body320and a rounded cap324. The outer circumference of the tubular body320of the plunger member316is dimensioned to be smaller than the internal circumference of the side wall of the base member304, enabling the tubular body320to shift laterally as needed within the base member316. A feature along the outer surface of the tubular body320, a protrusion328, at a proximal end of the body320(i.e. the opposite end from the rounded cap324) is sized to fit within the plunger locking recess308of the base member304.

A biasing element, in particular a spring332, is fitted inside of the tubular body320of the plunger member316and exerts a biasing force between the plunger member316and the base member304. A collar336is mounted (e.g. via a thermal bond, adhesive, or any other suitable means) around the tubular body320of the plunger member316and prevents the full exit of the plunger member316from the base member304via abutment of the protrusion328against the collar336. The spring332is in a compressed state between the rounded cap324of the plunger member316and the base wall of the base member304when the plunger member316is in a retracted position, in which the plunger member316within the base member304, as shown inFIG.25.

A release element, namely a wedge340, is inserted into the slot312when the plunger member316is fully inserted into the base member304, so as to hold the tubular body320of the plunger member316to one side of the interior of the base member304and positioning the protrusion328in the plunger locking recess308. A ridge344along the wedge340limits insertion of the wedge340into the slot312.

FIG.21shows the breakout mechanism300in a compacted state, wherein the plunger member316is in a retracted position within the base member304with the spring332in compression. The wedge340has been inserted into the slot312, and is biased against the tubular body320by an internal protuberance346within the slot, urging the tubular body320of the plunger member316to one side of the interior of the base member304and the protrusion328into the recess308to inhibit biasing of the plunger member316by the spring332.

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

FIG.22shows the breakout mechanism in an expanded state. Removal of the wedge340enables the tubular body320of the plunger member316to shift within the base member304, permitting the protrusion328to exit the plunger locking recess308and releasing the plunger member316to be moved outwardly from the base member304by the separating force of the spring332.

The breakout mechanism300can form part of a toy character similar to the toy character14. For example, the plunger member316and the base member304may together be included in the housing of the toy character. Thus, the plunger member316and the base member304may be configured as needed so that they contribute to the appearance of a young bird, reptile, or the like. Further, the breakout mechanism300can be placed within a housing, such as an egg, that may be fractured via the biasing force of the spring332urging the plunger member316outwardly toward an extended position (FIG.22) relative to the base member304. The housing has an aperture permitting the wedge340to be removed from the breakout mechanism300. The spring332can exert a sufficiently strong biasing force to separate the plunger member316and the base member304and fracture a housing in which the breakout mechanism300is placed.

FIG.23is a sectional view of a housing in which the breakout mechanism300ofFIGS.21to23may be deployed. The housing in this example is in the form of an simulated egg shell360that has a series of fracture paths364formed along its interior, the fracture paths364having a decreased shell thickness relative to the surrounding portions of the egg shell360. A wedge access aperture368in the egg shell360permits the pass-through of an end of the wedge340so as to permit a user to grasp the wedge340and remove it to activate the breakout mechanism300.

FIG.24illustrates a breakout mechanism400in accordance with another embodiment. The breakout mechanism400includes a base member404being formed of two base member portions404a,404b, and a plunger member408formed of two plunger member portions408a,408b. The base member404has a tubular side wall412with a generally hollow interior in which the plunger member408is received, and an interior lip416along the top of the side wall412. The plunger member408has a tubular side wall420, and an exterior ridge424along the bottom of the side wall420that cooperates with the interior lip416of the base member404to inhibit full exit of the plunger member408from the base member404. The plunger member408also has a set of internal walls428that define a channel. A screw drive432is secured inside of the base member404and includes a motor436that turns a threaded shaft440(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 battery444for powering the motor436. A traveler448having an internally threaded portion receives the threaded shaft440. The traveler448is generally tubular and has a rectangular exterior profile dimensioned to prevent rotation in the channel defined by the internal walls428of the plunger member408. A lip450on the exterior of the traveler338limits insertion into the channel defined by the internal walls428as it abuts against the lower edge of the internal walls428. A biasing element452(which is shown as a helical compression spring and which, for convenience may be referred to as a spring452) is fitted inside the end of the traveler448opposite the threaded shaft440. A magnetic switch453is provided in the breakout mechanism400and controls power to the motor436from the battery444. The magnetic switch453is actuatable (i.e. closed) by the presence of a magnet454proximate to the housing, as shown inFIG.24, thereby powering the screw drive432.

FIG.25shows the breakout mechanism400in a compacted state positioned inside a housing. In the illustrated embodiment, the housing is an egg shell460. The egg shell460includes a fracturable shell portion464secured to an annular shell portion468. The annular shell portion468snap-fits to a base shell portion472. The traveler448is positioned inside the channel created by the internal walls428of the plunger member408and is positioned at a lower end of the threaded shaft440. The spring452is compressed between a shoulder in the interior of the traveler448and an end surface in the channel. The motor436is used to drive the screw drive432to drive progressively increasing flexure of the spring452so as to increase a biasing force exerted by the spring452urging the plunger member408outward from the base member404.

FIG.26shows the breakout mechanism400in an expanded state after activation of the screw drive432via placement of a magnet proximate to the egg shell460adjacent the motor436. The screw drive432operably exerts a separating force urging the plunger member408and the base member404apart. Upon sufficient fracturing of the egg shell460, the spring452expands from a compressed state to push apart the broken egg shell460abruptly to heighten the realism of the hatching action.

FIG.27shows a toy character500that includes a breakout mechanism similar to the breakout mechanism400shown inFIGS.24to26. The breakout mechanism shown inFIG.27has a base member504and a plunger member508shown in an expanded state. The toy character500includes a swiveling wheel assembly512that has a pair of wheels516that are driven, optionally by the same motor that drives the base member504and the plunger member508apart. A pair of non-swivelling wheels520is attached to the base member504. The swivelling wheel assembly may be connected to the motor in such a way that the wheel assembly512is intermittently rotated by some angle by the motor. This provides somewhat erratic movement to the breakout mechanism500. 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.

FIGS.28to30illustrate a housing fracturing mechanism600according to an embodiment. The housing fracturing mechanism600has a base frame member604that includes an outer bowl608secured to an inner bowl612. The outer bowl608has an inner lip616about its top periphery. An upper frame member620is rotatably coupled to the base frame member604about the top periphery of the outer bowl608. An inner lip624of the upper frame member620securely receives the inner lip616of the outer bowl608. Three cutting elements628are pivotally coupled at a first end thereof to the base frame member604via a fastener such as a partially threaded screw632. A second end636of the cutting elements628is slidably coupled to the upper frame member620via their protrusion through openings640in a side wall of the upper frame member620. The cutting elements628are somewhat arcuate in shape and define an aperture644into which a housing648to be fractured may be positioned.

As will be understood, rotation of the upper frame member620in a counter-clockwise direction relative to the base frame member604causes the cutting elements628to pivot and intersect/constrict the aperture644like an analog camera aperture. Sharp protrusions652along the cutting elements628project towards the aperture644and act to puncture and/or crack the housing648. In this manner, the housing648placed in the housing fracturing mechanism600may 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.

FIGS.31A and31Billustrate a housing fracturing mechanism700in accordance with another embodiment. The housing fracturing mechanism700includes a pair of cutting elements704that are pivotally coupled via a fastener708, such as a bolt or rivet. One or both of the cutting elements704has a recess712in a cutting edge716thereof. A housing to be broken can be placed in the one or more recesses712and can be broken via pivoting of the cutting elements704, as shown inFIG.31B, thereby permitting access to the toy character provided in the housing.

Toy characters employing the breakout mechanisms described above, particularly those illustrated inFIGS.20to23and24to27, can be used in conjunction with companion toy characters that may or may not be placed inside a housing with the toy characters.

FIG.32Ashows a breakout mechanism800for a toy character similar to that ofFIG.27in an expanded state. The breakout mechanism800has a base member804that nests within a plunger member808in a compacted state and is urged away from the plunger member808via a screw drive having a motor to the expanded state shown. Movement of the toy character on a surface is provided by wheels812that have a cam profile on them with at least one lobe on each wheel, similar to those shown inFIG.6). The wheels812are driven by the motor.

FIG.32Bshows a companion mechanism820for a companion toy character that is placed in a housing with the toy character (employing the breakout mechanism800ofFIG.32A). The companion mechanism820has a main body824and a wheel base828that nests within the main body824, but is biased outwards via an internal helical metal coil spring to an expanded state as shown. The wheel base828has a set of wheels832enabling movement of the companion mechanism820along a surface with minimal pushing.

FIG.33shows the breakout mechanism800ofFIG.32Aand the companion mechanism820ofFIG.32Bin a stacked compacted state. In the compacted state, the screw drive of the breakout mechanism800has not yet been activated to drive the plunger member808away from the base member804. The companion mechanism820is also in a compacted state, with the wheel base828being held under compression within the main body824against the force of the helical metal coil spring. The companion mechanism820is atop the plunger member808of the breakout mechanism800.

FIG.34is a sectional view of a housing in the form of an egg shell840having two toy characters positioned inside. A primary toy character844employs the breakout mechanism800, which is in a compacted state. A ancillary toy character848employs the companion mechanism820, which is also in a compacted state. Upon activation of the motor and attached screw drive of the breakout mechanism800within the primary toy character844, such as via a magnet to draw two contacts together to close a circuit, the screw drive urges the plunger member808away from the base member804, causing the breakout mechanism800to expand and push the ancillary toy character848through the egg shell840to fracture it. At the same time, the wheels812commence to rotate, and their lobes help push against the interior of the egg shell840to fracture it.

Upon its fracturing, the companion mechanism820within the toy character848is no longer held in compression and the wheel base828is urged away from the main body824by the helical metal coil spring.

Once the primary toy character844is freed from the egg shell840, the wheels812cause the primary toy character844to move across a surface upon which it is placed.

The breakout mechanism800and the companion mechanism820can include electronic components that are activated upon expansion. In the case of the breakout mechanism800, the electronic components can be placed on the same circuit as the motor and be activated upon closing of the circuit. For the companion mechanism820, its electronic components may be activated upon the closing of a circuit once the main body824and the wheel base828are urged apart by the helical metal coil spring.

The electronic components can enable the primary toy character844and the ancillary toy character848to make audible noises such as bird chirps, display lights, etc. Further, the primary toy character844and the ancillary toy character848can “interact” through sensing the other. For example, the primary toy character844can be equipped with an audio speaker for generating a bird chirping noise, and the ancillary toy character848can 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 character844and the ancillary toy character848can 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 character844and the ancillary toy character848can 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.35shows another companion mechanism900for a smaller ancillary toy character similar to the companion mechanism820ofFIG.32Bin accordance with another embodiment. The companion mechanism900has a main body904and a wheel base908that nests within the main body904, and that is biased outwards via an internal helical metal coil spring to an expanded state as shown. The wheel base908has a set of wheels912enabling movement of the companion mechanism900along a surface with minimal pushing.

FIG.36shows a breakout mechanism920similar to that ofFIG.32Aand two of the companion mechanisms900ofFIG.35in a stacked compacted state. The breakout mechanism920has a base member924that nests within a plunger member928in a compacted state as shown, and is urged away from the plunger member928to an expanded state via a screw drive. Movement of the breakout mechanism920on a surface is provided by wheels932that have a cam profile on them with at least one lobe on each wheel, similar to those shown inFIG.6).

Each of the two companion mechanisms900has its wheel base908being held under compression within the main body904against the force of the helical metal coil spring. One of the companion mechanisms900is positioned atop of the other companion mechanism900, which is, in turn, positioned atop the plunger member928of the breakout mechanism920.

FIG.37is a sectional view of a housing in the form of an egg shell940having three toy characters positioned inside. A primary toy character944employs the breakout mechanism920, which is in a compacted state. Each of two ancillary toy characters948employ the companion mechanism900, which is also in a compacted state. Upon activation of the screw drive of the breakout mechanism920within the primary toy character944, such as via a magnet to draw two contacts together to close a circuit, the screw drive urges the plunger member928away from the base member924, causing the breakout mechanism920of the primary toy character944to expand and push the toy characters948positioned on top through the egg shell940to fracture it. Upon its fracturing, the companion mechanism900within each of the ancillary toy characters948is no longer held in compression and the wheel base908is urged away from the main body904by the helical metal coil spring.

The primary toy character944and the ancillary toy characters948can include electronic componentry to provide additional functionality as described above with regards to the primary toy character844and the ancillary toy character848.

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.38shows an exemplary breakout mechanism1000that is configured with additional behaviors when placed in a housing. The housing is an egg shell1004that has a raised inner ring1008. A small magnet1012magnetizes a metal rod1016that protrudes from the centre of the bottom inside surface of the egg shell1004. An adapter disk1020is positioned atop of the raised inner ring1008of the egg shell1004. The adapter disk1020snaps onto the breakout mechanism1000and enables movement of the breakout mechanism1000relative to the egg shell1004as part of an additional behavior. A frustoconical metal disk1024is secured to the bottom of the breakout mechanism1000to guide placement of the metal rod1016to a Hall sensor1028inside of the breakout mechanism1000. The Hall sensor1028senses the magnetism of the metal rod1016to detect when the breakout mechanism1000is positioned inside of the egg shell1004.

FIG.39shows a bottom portion of the egg shell1004with the raised inner ring1008along its inside surface. A crenelated ring1032protrudes from the interior surface of the bottom of the egg shell1004within the raised inner ring1008. A post anchor1036inside of the crenelated ring1032has an aperture in which the metal rod1016is secured.

FIGS.40A and40Bshow the adapter disk1020having an annular plate1040with a peripheral lip1044extending downwards. A pair of wheel recesses1048a,1048bare dimensioned to receive wheels of the breakout mechanism1000. One of the wheel recesses,1048a, is deeper than required to receive a wheel of the breakout mechanism1000. A disk grip1052projects from a bottom surface of the annular plate1040. Together, the wheel recess1048aand the disk grip1052enable a person to pull the adapter disk1020off of the breakout mechanism1000onto which it snaps so that the wheels of the breakout mechanism1000may be exposed and used to mobilize the breakout mechanism1000on a surface. A central gear disk1056is rotatably coupled to the annular plate1040and has a number of gear teeth on its upper surface. Two arcuate walls1060extend from a lower surface of the central gear disk1056. The arcuate walls1060have thickened vertical edges1064. A through-hole1068enables passage of the metal rod1016through the adapter disk1020. A pair of securement posts1072extend from the upper surface of the annular plate1040to releasably engage corresponding holes in the bottom surface of the breakout mechanism1000.

The breakout mechanism1000is configured such that, prior to its triggering to fracture the egg shell1004, detection of the magnetism of the metal rod1016does not trigger the motor of the breakout mechanism1000. To trigger the additional behaviors of the breakout mechanism1000thereafter, the adapter disk1020is secured to the bottom of the breakout mechanism1000via the securement posts1072, and the combined breakout mechanism1000and adapter disk1020are placed into the bottom portion of the egg shell1004. The arcuate walls1060of the adapter disk1020fit within the crenelated ring1032of the egg shell1004, and the thickened vertical edges1064engage the crenelated ring1032to inhibit rotation of the central gear disk1056relative to the egg shell1004.

During placement of the breakout mechanism1000and the adapter disk1020, the metal rod1016inserts into the breakout mechanism1000guided by the frustoconical metal disk1024so that the metal rod1016engages the Hall sensor1028. The magnetism of the metal rod1016is sensed by the Hall sensor1028and triggers the motor of the breakout mechanism1000to start up.

The breakout mechanism1000includes 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 mechanism1000and 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 disk1056to rotate the breakout mechanism1000and annular plate1040secured thereto relative to the central gear disk1056. On the upward stroke of the angled piston arm, the breakout mechanism1000and the annular plate1040secured to it remain stationary relative to the egg shell1004. As will be understood, continued operation of the motor of the breakout mechanism1000causes it to intermittently rotate within the egg shell1004.

The motor of the breakout mechanism1000can also drive other mechanisms, such as the rotation of extending wing members, providing the illusion that the breakout mechanism1000is flapping its wings.

In addition, the Hall sensor1028may trigger other elements of the breakout mechanism1000. For example, the breakout mechanism1000can include one or more of lights, an audio speaker emitting a bird chirp, etc. that can be triggered by the Hall sensor1028.

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.

Persons skilled in the art will appreciate that there are yet more alternative implementations and modifications possible, and that the above examples are only illustrations of one or more implementations. The scope, therefore, is only to be limited by the claims appended hereto.