FLEXIBLE TOY FIGURE WITH ARMATURE

• US 20130052911A1
• Filed: 07/20/2012
• Published: 02/28/2013
• Est. Priority Date: 07/20/2011
• Status: Active Grant

• Current Assignee: Mattel Incorporated
• Original Assignee: Mattel Incorporated
• Inventors: Benecke, Bill, Sun, Steed, Chen, Thai Cheng
• Granted Patent: US 9,028,292 B2
• Time in Patent Office: Days
• US Class Current: 446/375
• CPC Class Codes: A63H 3/04 with deformable framework
• CPC Class Codes: A63H 3/16 made of parts that can be put together facial parts only A63H3/365
• CPC Class Codes: A63H 3/46 Connections for limbs
• CPC Class Codes: A63H 9/00 Special methods or compositions for the manufacture of dolls, toy animals, toy figures, or parts thereof
• CPC Class Codes: B29C 48/0012 combined with shaping by internal pressure generated in the material, e.g. foaming
• CPC Class Codes: B29C 69/00 Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore B29C48/001 takes precedence
• CPC Class Codes: Y10T 29/4984 Retaining clearance for motion between assembled parts

Abstract

A toy figure is provided that incorporates an articulated armature, the armature including a torso member and multiple limbs, where each limb may be the same or different, and each limb includes at least one limb segment. Each limb segment includes two longitudinal primary plates that intersect approximately orthogonally, and a plurality of substantially parallel secondary plates that intersect with and are approximately orthogonal to both primary plates. The outer edges of the primary and secondary plates of each limb segment substantially define a shape and a volume for that limb portion of the toy figure. The articulated armature is surrounded by a resilient body material to simulate flesh.

Claims

1. A toy figure, comprising:

an articulated armature including a torso member and multiple limbs, where each limb may be the same or different, and each limb includes at least one limb segment; and

a resilient body surrounding the articulated armature;

wherein each limb segment includes two longitudinal primary plates that intersect approximately orthogonally; and

a plurality of substantially parallel secondary plates that intersect with and are approximately orthogonal to both primary plates;

wherein the outer edges of the primary and secondary plates of each limb segment substantially define a shape and a volume for a corresponding limb portion of the toy figure.

2. The toy figure of claim 1, wherein each limb of the armature includes at least two limb segments connected by an articulated joint.

3. The toy figure of claim 1, wherein the torso member of the armature is rigid or semi-rigid;

and each limb is connected to the torso member by an articulated joint.

4. The toy figure of claim 3, wherein each limb of the armature includes a distal hand segment or a distal foot segment that is connected to the limb by an articulated joint.

5. The toy figure of claim 1, wherein the armature includes a head segment that is connected to the torso member by an articulated joint.

6. The toy figure of claim 1, wherein each armature limb segment is substantially rigid.

7. The toy figure of claim 1, wherein the secondary plates are substantially equally spaced along at least one of the limb segments.

8. The toy figure of claim 1, wherein a plurality of the secondary plates have a nonuniform plate thickness.

9. The toy figure of claim 8, wherein the nonuniform plate thickness varies along one dimension of the secondary plates.

10. The toy figure of claim 9, wherein for a plurality of the secondary plates the nonuniform plate thickness increases at an outer edge of the secondary plate.

11. The toy figure of claim 9, wherein for a plurality of the secondary plates, the nonuniform plate thickness increases with a distance from an intersection with a primary plate.

12. The toy figure of claim 10, wherein the increased plate thickness of the secondary plates enhances a retention of the surrounding resilient body.

13. The toy figure of claim 1, where for a plurality of the secondary plates, a ratio of secondary plate thickness to a separation width between adjacent secondary plates is about 1:

1 to about 1;

5.

14. The toy figure of claim 1, wherein the primary and secondary plates include circumferential plate edges that in combination define an outer shape and volume appropriate for an upper arm segment, a lower arm segment, an upper leg segment, or a lower leg segment of the toy figure.

15. An armature limb segment for a toy figure, comprising:

two intersecting primary plates, each primary plate extending longitudinally along the limb segment and intersecting at an approximately right angle; and

a plurality of secondary plates, disposed along and intersecting with primary plates so that the secondary plates are substantially parallel to one another, and at approximate right angles to each of the intersecting primary plates.

16. The armature limb segment of claim 15, wherein the primary and secondary plates include circumferential plate edges that in combination define an outer shape and volume appropriate for an upper arm segment, a lower arm segment, an upper leg segment, or a lower leg segment of the toy figure.

17. A limb for a toy figure, comprising:

an armature limb segment that includes a plurality of plates disposed transverse to a long axis of the limb segment and generally parallel to one another, so that the plates are spaced along the long axis with a spacing between adjacent plates that is less than five times an average thickness of the plates;

and a plastic material disposed upon and encasing the armature limb segment to simulate flesh of the toy figure.

18. The limb for a toy figure of claim 17, further comprising a second armature limb segment that may be the same or different than the first armature limb segment, that includes a plurality of plates disposed transverse to a long axis of the second limb segment and generally parallel to one another, so that the plates are spaced along the long axis with a spacing between adjacent plates that is less than five times an average thickness of the plates;

wherein the first and second armature limb segments are coupled by an articulated joint;

the plastic material is disposed upon and encases both the first and second armature limb segments; and

the plastic material is sufficiently resilient to permit the limb to be flexed at the articulated joint.

19. A method of manufacturing a toy figure, comprising:

injection molding a plurality of rigid polymer armature limb segments;

wherein each armature limb segment includes two longitudinal primary plates that intersect approximately orthogonally, and a plurality of substantially parallel secondary plates that intersect with and are approximately orthogonal to both primary plates;

assembling a plurality of armature limb members by connecting a plurality of articulated limb segments via articulated joints;

assembling an articulated armature that includes a torso member and multiple articulated limb members connected to the torso member by articulated joints; and

insert molding a flexible polymer skin onto the assembled articulated armature such that the flexible polymer skin encapsulates the articulated armature, and the shape and volume of each resulting limb is substantially defined by the outer edges of the primary and secondary plates of the limb segments incorporated in that limb.

20. The method of manufacturing of claim 19 wherein assembling a plurality of armature limb members includes assembling at least one arm member by connecting an upper arm segment and a lower arm segment via an articulated joint, and assembling at least one leg member by connecting an upper leg segment and a lower leg segment via an articulated joint.