US20050191936A1 - Doll - Google Patents

Abstract

A toy doll is described having a first member and a second member coupled to said first member. The said second member can slidably and/or rotatably move relative to said first member, said second member comprising an armature, an element coupled to said armature, said element being more compliant than said armature, and a molded form around at least said armature and element to simulate a body part with a bendable joint. In another embodiment, the doll includes a body member, where the body member has electronics configured to selectively energize a light emitting source exposed through said body member and a platform configured to enable removable coupling of an accessory to said body member, where said source illuminates at least portions of said accessory.

Description

• The present application claims priority to provisional application Ser. No. 60/534,887 filed Jan. 7, 2004 and provisional application Ser. No. 60/557,033 filed Mar. 25, 2004, the entire contents of each of which is incorporated by reference for all purposes.
BACKGROUND
• Examples of known bendable dolls are found in U.S. Pat. Nos. 593,592; 1,189,585; 3,325,939; 3,624,691; 3,955,309; 4,233,775; and 5,516,314; and in publications JP49-18956 A; JP50 037068 B2; JP62-164092U; JP63-103685 A; EP1108454; GB2354456. Examples of known dolls with magnetic attachments are found in U.S. Pat. Nos. 4,038,775, 4,118,888, 4,170,840, 4,176,492, 4,183,173, 4,186,515, 4,206,564, 5,277,643, 5,295,889, 5,380,233, 5,727,717, and 6,171,169. The disclosures the patents and publications listed in this paragraph are incorporated herein by reference.
SUMMARY
• The present disclosure relates generally to toy dolls with a bendable armature, and in one example, to dolls in which the armature includes a combination of bendable limbs and articulated joints. In another example, it further relates to such dolls in which a torso of the doll houses electronics, and provides an attachment platform for accessories such as simulated wings. In another example, electronics power an LED in the torso, and the wings are attached to the torso by aligning magnets in the wings with corresponding magnets in the torso. Still further, the wings can be translucent to transmit light within the wings.
• The advantages of the present disclosure will be understood more readily after a consideration of the drawings and the Detailed Description of Example Embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a drawing of a doll in accordance with the present disclosure.
• FIG. 2 is a drawing of an opposite side of the doll shown inFIG. 1, showing the attachment of simulated wings to the back of the doll.
• FIGS. 3-4 are drawings of example sets of wings that may be attached to the doll ofFIGS. 1 and 2, for example.
• FIG. 5 is a rear view of an alternative doll torso configuration.
• FIGS. 6A and 6B are drawings of the torso of the doll ofFIG. 5 coupled to the wings ofFIG. 4.
• FIG. 7 is a front elevation view of an armature that could be used for an alternative embodiment of a doll.
• FIG. 8 is a magnified view of a portion of the armature ofFIG. 7, showing details of the twisted wire structure of the armature.
• FIG. 9 is a front view of a head portion of an armature for a posable figure, according to another embodiment of the disclosure.
• FIG. 10A is a front elevation view of a partially formed posable figure, after one step of insert molding.
• FIG. 10B is a rear elevation view of the partially formed posable figure ofFIG. 10A.
• FIG. 11A is a magnified view of a portion of the partially formed posable figure ofFIGS. 10A and 10B, showing details of upper arm connecting pegs.
• FIG. 11B is a magnified view of a portion of the partially formed posable figure ofFIGS. 10A and 10B, showing details of upper leg locating pegs.
• FIG. 11C is a magnified view of a portion of the partially formed posable figure ofFIGS. 10A and 10B, showing details of lower leg locating pegs.
• FIG. 12 is a front and rear elevation view of a posable figure after two steps of insert molding, according to an embodiment of the disclosure.
• FIG. 13 is a semi-transparent front elevation view of the posable figure ofFIG. 12, showing an armature and a molded body enclosing the armature.
• FIG. 14 is a semi-transparent side elevational view of the posable figure ofFIG. 13.
• FIG. 15 is a detailed drawing of an alternative partially formed arm insert of the doll ofFIGS. 1 and 2.
• FIG. 16 is a detailed drawing of an alternative arm using the insert ofFIG. 15.
• FIGS. 17-18 are detailed drawings of an alternative leg insert.
• FIG. 19 is a detailed drawing of an alternative leg using the insert ofFIGS. 17-18.
• FIG. 20 shows alternative embodiments of arms, legs, arm inserts, and leg inserts.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
• In thedoll1000 shown inFIG. 1, thelegs1010 andarms1020 are formed of rigid plastic, and the shoulder andhip joints1022 and1024, respectively, are simulated through the use of pins that interconnect the arms and legs to the torso. In one embodiment, the shoulder joint is an insert-molded swivel and hinge joint, of the type shown in FIG. 4 of U.S. Pat. No. 4,673,374, the disclosures of which are incorporated herein by reference. Still further, the arm-portion of the joint, identified as reference character 34 in U.S. Pat. No. 4,673,374, is molded from a rigid plastic, and is sized and shaped so as to define less than the entire desired outer shape of the complete arm. This rigid element is then encased in a soft, flesh-like material such as Kraton or soft PVC. An example structure is shown below, wherein the resulting shoulder joints may have two degrees of freedom. A similar joint may be used at the hip, or a simpler mushroom joint may be used.
• In one embodiment, a pair of twisted wires is trapped within the arm portion of the joint, and extends approximately to a wrist portion of the arm.
• It is believed that twisted wire may improve cyclic life for the limb, allowing the doll to be manipulated further, and more often, while maintaining acceptable durability. Furthermore, by using twisted wire, this can be achieved with simple manufacturing processes to generate the twisted wire either during the doll assembly, or before the raw material is shipped to the plant. Also, the use of twisted wire trapped within the arm can achieve other synergistic effects. For example, in some cases with untwisted wire, a different modulus of elasticity can be encountered depending on the bend angle. As such, by using twisted wire, a more uniform effect can be achieved, if desired. Not also that the twisted wire can include three strands of wire twisted together, or other multiples higher than 2.
• A second rigid plastic member may be used to trap the ends of the twisted wires, safely encasing those ends in protective plastic. A further alternative includes legs with a similar insert-molded joint and armature, as described below herein.
• Due to the shape of thelegs1010, in which anarrow isthmus1026 is defined at the knee of the leg, as shown inFIGS. 1 and 2, bending action naturally occurs at or about the knee area, even if only short rigid elements are molded on the wires embedded within the legs. In this way, it is possible to reduce manufacturing and part costs, yet maintain functionality desired by users. More specifically, by reducing the cross-sectional area of the knee, relative to the upper andlower leg portions1028 and1030, respectively, it is possible to enable bending action to occur at or about the knee area. However, in an alternative embodiment, rigid elements can also be used in the legs, similar to the example embodiment of the arms.
• Accessories for the various embodiments described above include removable wings, such as thewings1300 ofFIG. 3, however various other accessories could be used, such as, for example: capes, backpacks, equipment, or weapons. Magnets may be used to attach the wings to the torso, such asmagnets1310 and1312, by including mating magnets, one in the torso, and another in the wings. If desired, multiple mating pairs of magnets may be used, such as shown inFIG. 3. Alternatively, only one pair need be used, and additional structural support may be provided by mating posts and holes, with the post formed in one of the torso or the wing, and a corresponding hole formed in the other of the torso and wing. Still other structure may be used, such as matting bends or other surface contours between the torso and wing.
• Note that, in one example, the magnets not only can be used to maintain a connection between the doll and the accessory, but also can be used to locate the accessory to the doll during connection. In other words, the magnets can also be used to align the accessory, such as the wings, to the doll, thereby allowing easier attachment and detachment of accessories to a doll. This is due in part to the self-centering action of magnets, caused by the shape of the magnetic field. Further, since this easier attachment/detachment may require less dexterity than other attachment approaches, it can be easier for children playing with the doll to attach and detach the accessories, without degrading or breaking the parts.
• Another aspect of the present doll is electronics contained within the torso, and/or within other locations of the doll body. An LED (such as LED1314) may be powered by the electronics, and may be aligned with the wings so that light from the LED shines through the wings. Note that other LEDs can be added at various portions of the body as an alternative, or in addition to, the LED used to shine through the wings. By making the wings of translucent or clear plastic, light may be transmitted throughout the wings, creating a magical glow effect. For example, totally and/or partially internally reflective surfaces may be used to direct light through the wings, before being reflected outward to a viewer. In this way, certain portions of the wings may appear illuminated, even though the entire structure is translucent (or transparent).
• Thedetachable wings1300 can be of various forms. The figures show example wing configurations, however, others can also be used. In one example, the wings are formed of translucent material, such as polymeric material, to allow transmission of light from a light source, such as an LED as described above. Further, the wings can be fabricated with integrally molded recesses for receiving and holding a magnet. In the example ofFIG. 3, the wings have multiple sections, and may include sticker decorations.
• FIG. 4 shows an alternative pair ofwings1400 for mating todoll1500 ofFIG. 5. In this example, the wings utilizemagnets1410 and1412 for attachment to mating magnets in doll1500 (such asmagnets1510 and1512 ofFIG. 5). Further, hold1414 is shown that aligns with a protruding LED indoll1500, such asLED1514 ofFIG. 5.Wings1400 further contain etched forms, such asstars1420 and/orsections1422. In one example, the etches areas reflect internal light outward to a viewer from the LED, so that when viewing the front of the doll, light in the wings can be seen, even though the LED is in the doll's back. FIGS.6A-B shows thewings1400 attached to thedoll1500 from a rear and side perspective. In particular,FIG. 6B shows abend angle1430 ofwings1400, which enable a more contoured fit between the wings and the dolls back, thereby providing a more life-like appearance.
• Returning toFIG. 5, it also shows access panel1516 (held closed by screw1518, which enables access to internal electronics for powering theLED1514, as well as the ability to change batteries. Further,FIG. 5 showsbutton1520, which activatesLED1514. In one example, a single actuation ofbutton1520 creates flashing of the LED, whereas in other examples, the LED is lighted continuously during depression ofbutton1520.
• FIGS. 7-14 show an alternative embodiment of a posable figure, in which no hinged or pivoted articulations are included. However, the features described below, or selected groups of features, can be incorporated in the limbs described above.
• Referring toFIG. 7, anarmature10 for a posable figure is shown. Although it is anticipated thatarmature10 will eventually be enclosed by and bonded to an outer covering, such as an injection-molded body of a posable figure,FIG. 7 shows the inner core of the armature in isolation for clarity.Armature10 may include a plurality of twisted strands ofwire12, best seen inFIG. 8, which may be joined together to form an articulated structure. As depicted inFIG. 8,strands12 may be constructed from three pliable metal wires twisted together, although other suitable numbers of wires and/or materials may be used to construct the inner armature.
• As depicted inFIG. 7,armature10 may include alower strand14, amiddle strand16, and anupper strand18.Lower strand14 may extend from afirst foot portion20ato asecond foot portion20b, andmiddle strand16 may extend from afirst hand portion22ato asecond hand portion22b.Upper strand18 may extend from anupper portion24 of the lower strand, to ahead portion26.
• The strands of wire in the armature may be connected atjunctures28 and30 to form a unitary structure. As indicated,juncture28 may connectlower strand14 toupper strand18 at a point at or near a lower end of the upper strand, so that the upper strand may not extend appreciably below its intersection with the lower strand atjuncture28.Juncture30 may connect the middle strand to the upper strand at a point betweenjuncture28 andhead portion26.Junctures28 and30 may be formed, for example, by spot welding, although other forms of adhesion such as gluing, crimping, or the like may also be suitable for forming connections between the strands of wire.
• As depicted inFIG. 7,armature10 may be formed into an articulating structure that includeslower leg portions32aand32b,upper leg portions34aand34b,lower arm portions36aand36b,upper arm portions38aand38b, and aneck portion40. For simplicity, symmetric pairs of parts such as the leg and arm portions, among numerous others, may hereinafter be referred to by a single reference number. Thus, “lower leg portions32” will be understood to meanlower leg portions32aand32b, and so forth.
• The strands of wire may be chosen to have any diameter that permits a desired amount of flexibility in the various regions of the armature. For example,lower strand14 andupper strand18 may be formed from twisted wires that are approximately 0.030-inches in diameter, andmiddle strand16 may be formed from a twisted wire that is approximately 0.025-inches in diameter. However, it will be appreciated that wires of other diameters may be equally suitable or more suitable for various designs, depending on the overall size of the posable figure and its intended use.
• In the embodiment depicted inFIG. 7, a distal end ofupper strand18 forms headportion26 in the shape of a substantiallycircular loop42 that is spot welded toneck portion40 at anupper juncture44. However, it should be appreciated that the head portion may be suitably formed in various other ways. For example,FIG. 9 shows an embodiment in which ahead portion126 is formed in the shape of a curved hook orsemi-loop46.
• InFIGS. 7-9, thevarious wire strands14,16, and18 that are included inarmature10 are shown before any injection molding steps involving the toy figure have been performed. Such injection molding may typically be performed in a two-step process. In the first injection molding step, a plurality of structures may be injection molded around the inner wire, to form a more rigid and substantial inner skeleton. In the second injection molding step, a flesh-like outer covering may be molded around the skeleton to form a surrounding body, which may enclose both the inner wire armature and portions of rigid structures that were added in the first step. These two injection molding steps are described below in greater detail.
• FIGS. 10A and 10B show front and rear elevation views, respectively, of a partially formed posablefigure 110, after a first injection molding step has been performed. After the first injection molding step, partially formed figure110 may includewire armature10 as described above, as well as a plurality of support members. These support members may include surrounding members48,50, and52, end caps54 and56, and sprues58,60, and62, among others. The support members may extend outward from the strands of wire, adding structure and stability toarmature10. As described below, some of the support members may also allow partially formed figure110 to be located accurately and conveniently in a mold, prior to a second injection molding step.
• The support members may be constructed from any suitable material, such as a resin material that may be conveniently molded aroundwire armature10 in molten form. The support member material may, for example, be a relatively flexible polymer material such as polypropylene, or it may be a more rigid polymer such as polyethylene. The support member material may also be a thermoplastic elastomer material such as polyvinylchloride (PVC), or a styrene-based elastomer such as a Kraton material manufactured by Kraton Polymers of Houston, Tex. In some embodiments, this material may be chosen to bond and/or be otherwise compatible with a material used for the outer covering of the toy figure.
• Surrounding members48,50, and52 each may be configured to surround a portion of the wire ofarmature10, and each may include a plurality of locating pegs extending substantially radially outward from the wire. For example, surrounding member48 may include upper arm pegs64 and66, surrounding member50 may include upper leg pegs68 and70, and surrounding member52 may include lower leg pegs72,74, and76. The locating pegs may be substantially cylindrical as depicted inFIGS. 10 and 11, or they may have any other suitable shape. For example, the locating pegs may be substantially conical or frustoconical. The locating pegs may also have rounded ends.
• FIG. 11 shows details of the structure of surrounding members48,50, and52, and their associated locating pegs. The locating pegs may be configured to assist in locating partially formed figure110 in a mold, in preparation for a second injection molding step. As indicated, upper arm pegs64, upper leg pegs68, and lower leg pegs72 may extend forward and away from the armature, upper arm pegs66 and upper leg pegs70 may extend backward and away from the armature, lower leg pegs74 may extend laterally and away from the armature, and lower leg pegs76 may extend medially and away from the armature.
• Providing locating pegs of the type just described may help to position partially formed figure110 in a desired location within a mold. For example, a particular locating peg may be configured to substantially span a radius of the mold, thereby holding a wire strand of the armature spaced away from the walls of the mold. This may allow material to be injected into the mold to form a continuous molded body, encasing and bonded to the armature, with the wires of the armature spaced away from the surface of the body.
• As depicted inFIGS. 10A and 10B, end caps54 and56 may be disposed to cover free ends oflower strand14 and/ormiddle strand16. In other words, the end caps may be disposed to cover foot portions20 and/or hand portions22 of the inner wire armature. End caps54 and56 may hold loose ends of the wires together, and may reduce the chances that an end of one of the wires will break through the body of the toy.
• Sprues58,60, and62, which may be substantially cylindrical, may serve to further locate partially formed figure110 in a mold during a second injection molding step. For example, the sprues may be placed in corresponding cylindrical depressions or recesses in the mold, to hold the armature in position while a surrounding body is injection molded around partially formedfigure 110.
• As depicted inFIGS. 10A and 10B, sprues58 and60 may be disposed near end caps54, and attached to the end caps by connecting shafts78. In addition, sprues60 may be attached to surrounding members80 by shafts82, and surrounding members80 may be attached to each other by a connectingshaft84. In this manner, sprues58 and60, connectingshafts78,82 and84, and surrounding members80 all form a substantially continuous structure for locating the partially formed figure in a mold, and supporting it there during a second injection molding step. Similarly, sprues62 may be connected to end caps56 by connecting shafts86, and end caps56 may be connected to each other by a connectingshaft88, as indicated.
• Aside from the aforementioned structures, a moldedhead portion90 may also be added during the first injection molding step. Moldedhead portion90 may include arear section92 extending in slight relief from the remainder of the molded head portion.Rear section92 may include a substantiallyrectangular aperture94, and two smallercircular apertures96. Apertures94 and/or96 may be used for additional secure positioning of partially formed figure110 in a second mold, for instance using shafts, pins, or the like to extend from the mold into the apertures.
• Achest portion98 may also be added during the first injection molding step. Furthermore, portions of the inner wires may be covered with a relatively thin coating of material, generally indicated at100. The additional structure ofchest portion98 andwire coating100 may serve to selectively increase the rigidity of portions of the toy figure, and to provide greater stability to the partially formed figure prior to a second injection molding step.
• FIGS. 12-14 show a toy figure, generally indicated at210, after two steps of injection molding. As is best seen inFIGS. 13-14, toy figure210 may include partially formed figure110 (including armature10), and also a surrounding and continuously moldedbody212.Body212 may be constructed from any resilient, flexible material, such a highly elastic thermoplastic material such as a soft polyvinyl chloride (PVC) material having a Shore hardness of approximately 65. The body material may be colored to match the desired finished color of the posable figure, but the body material is depicted as transparent inFIGS. 13-14, so that partially formed figure110 may be seen disposed within it.
• Although in general, any suitable material may be used to construct the body of the toy figure, in some embodiments the body material may be chosen to bond to and/or be otherwise compatible with the material used for the support members of the armature of the toy figure. For example, the body material and the support member material may both be constructed from styrene-based elastomers such as a Kraton material, with either similar or different Shore hardnesses. Such similar elastomers may tend to bond particularly securely to each other during injection molding of the body around the armature.
• FIG. 12 shows front and rear views, respectively, of toy figure210 after a second step of injection molding but before final finishing of the toy figure is complete. Sprues58,60, and62 may still be attached externally to figure210 after the second molding step. Similarly, portions of connecting shafts78,82,86, and/or88 may remain outside ofbody212 after the second molding step. The protruding sprues and/or shafts, if any, may be cut or broken off of toy figure210 as part of final finishing steps.
• Further,FIG. 12 also showselectronic chip230, which can include analog or digital circuitry for powering electronic actuators in the body, such asLED236. Also, a battery (or batteries)238 is shown coupled to the electronic chip for providing a power source. However, alternative power sources can be used, such as an electromagnetic generator that is powered by motion (e.g., motion caused by someone playing with the doll) of the doll.
• Electronic chip230 is housed within the molded body of the doll. In this particular example,chip230 is located intorso region228. However, the chip, or its circuitry, could be located in other regions (such as the legs), or distributed about various regions of the body. Also, in this example, the light source (in this case LED236) is located at the surface of the body so that light can be emitted out to the accessory (not shown) coupled viamagnets232 and234.
• Electronic chip230 is also coupled to aswitch240 for actuatingLED236. In this case, a contact switch is utilized in which the user depresses a button to activateLED236. The LED is activated whileswitch240 is depressed, and the LED is deactivated whileswitch240 is not depressed. Note however that alternative switches could be used. For example, a heat sensor could be used to sense heat from the user's body contacting the doll. Other alternative sensors could also be used that sense when the doll is held, or contacted in a certain way by the user. Such sensor could further be integrally molded in the doll, which may also provide improved appearance of the doll body.
• Continuing withFIG. 12, the rear view showsmagnets232 and234 that can be used to locate and attach the wings (or other accessories), described above. In this case, themagnets232 and234 are located within the body mold, such that the surface of the back is smooth, with the magnets exposed. However, the magnets can be internally integrally molded and covered with a smooth layer of body material, if desired. This may provide an improved appearance in some applications.
• FIG. 13 shows a front view of toy figure210 after some final finishing steps, with the material of moldedbody212 depicted as transparent so thatarmature10 may be seen within the figure. As depicted inFIG. 13, locating pegs74 and76 may extend to lateral andmedial surfaces214 and216 of the body, respectively. Also as depicted inFIG. 13, various finishing steps may be applied to the toy figure after the second injection molding step. For example, sprues and/or connecting shafts that remain external to moldedbody212 may be removed, possibly leaving portions of shafts82 extending to surfaces of the body. Facial features, generally indicated at218, may be added by, for example, etching and/or painting.Hair220 may be attached to the figure by, for example, heat sealing or gluing. In some embodiments, clothing and/or other accessories may be added to the figure.
• FIG. 14 shows a right side view of toyfigure 210, with the material of moldedbody212 depicted as transparent as inFIG. 13. As depicted inFIG. 14, locating pegs64,68, and76 may extend to ananterior surface222 of the body, and locating pegs66 and70 may extend to aposterior surface224 of the body. End portions of the various locating pegs extending to surfaces of the body may be sanded or otherwise smoothed as desired, as a final finishing step.
• FIG. 15 shows a detailed approximately 1:1 scale drawing of anarm insert300 which can be used in the doll described above. The drawing shows the arm insert, which can be used for both the left and right arms, after two molding steps, where the molding can be insert molding as described herein.
• Specifically,FIG. 15 showsarm insert300 having a first insert molded pivot at310 and a pair ofparallel disks312 used to form a shoulder joint captured by the doll torso. The following molding steps can be used to forminsert300, although alternative approaches may also be used. First,wire314, which spans from approximatelyhole320 tohole322 is placed in a mold and held or located by the pins of the mold (not shown), where the pins formholes320 and322 ininsert300.Wire314 can be a twisted pair of two or more wires, or a single wire. Then, the insert is partially molded, forming thelower structure324, andmiddle structure326. Included inlower structure324 are locatingpegs330, which are used to locate the piece after the first molding operation in later molds. After forming the lower andmiddle structure324 and326, a second molding operation is performed which formsupper structure328 aroundmiddle structure326, thereby formingrotary pivot310. Further, the second molding operation, which formsupper structure328, also formsdisks332 and334 (which are later captured by the doll body to form a second pivot at the shoulder in addition to pivot310). Alternatively, these two molding operations could be combined into a single molding operation.
• After the second molding operation, the piece is placed in another mold and located bypegs330 to form either a right arm or left arm as described in more detail below. By structuringinsert300 in this way, it is possible to have a single insert design that can be used to form both the left and right arms, thereby saving cost.
• Lower structure324 is shown with two locatingpegs330, however only a single peg, or more than 2 pegs, could be used, if desired. Further,lower structure324 has a stepped outer form which can improve the strength of the piece and thereby improve durability, while still properly capturingwire314. Likewise,middle structure326 is also formed in a step manner, for similar reasons. Also, lower andmiddle structures324 and326 have reinforced structure around holes320 and322, respectively to compensate for the lack of material in the hole. Again, this improves strength and durability of the finished arm, thereby allowing repeated use by a doll user.
• FIG. 15 includes a top and side views in conventional drawing format. Further, an isometric view is also shown, illustrating various features of the insert.
• Referring now toFIG. 16, aright arm400 is shown, which is formed usinginsert300.FIG. 16 includes an isometric view and details ofright arm400.
• As shown inFIG. 16,insert300 is used in a third molding operation to form theright arm400 overinsert300. The view illustrates the shape of the hand and arm, including joint418 anddisks412 later used to form a two degree of freedom rotary shoulder joint.FIG. 16 also shows locatingpins430 which were used to locateinsert300 in the mold forming thearm400. After this molding operation, pins430 can be cut off, thereby leaving a finished arm for assembly to the doll body.
• Arm400 is thus formed to provide improved durability and desired flexibility, as well as a more realistic simulation of human parts, while still enabling the desired degrees of freedom and motion for effective play by the user. Therefore, the combination of rotary shoulder joints with bendable elbow joints thus provides an advantageous result.
• While the above example shows a right arm, it is also possible to form a left arm in a substantially similar way.
• Referring now toFIGS. 17-19, detailed drawings of the left leg insert (FIGS. 17-18) and finished right leg (700 ofFIG. 19) are shown, withFIG. 19 at approximately 1:1 scale. The legs are formed in a manner similar to the arms discussed above with respect toFIGS. 15-16. However, there are various differences.
• First, as shown inFIGS. 17-19, theleg insert600 includes a single degree of freedom insert moldedhip joint610, which is angled relative to theupper leg section612. Thehip joint610 is captured by the doll torso.
• The following molding steps can be used to forminsert600, although alterative approaches may also be used. First,wire614, which spans from approximatelyhole620 tohole622 is placed in a mold and held or located by the pins of the mold (not shown), where the pins formholes620 and620 ininsert600.Wire614 can be twisted pair of two or more wires, or a single wire. Then, the insert is partially molded, forming thelower structure624, and themiddle structures626. Included inlower structure624 are locatingpegs630, which are used to locate the piece after the first molding operation in later molds. After forming the lower andmiddle structure624 and626, a second molding operation is performed which formsupper structure628, thereby forming rotary pivot610 (which is later captured by the doll body to form a pivot at the hip). Alternatively, these two molding operations could be combined in a single molding operation.
• After the second molding operation, the piece is placed in another mold and located bypegs630 to form a left leg as described in more detail below. While the different left and right leg inserts are described, they could be reused as described above with regard toFIGS. 17-19.
• Lower structure624 is shown with two locatingpegs630, however only a single peg, or more than 2 pegs, could be used, if desired. Further,lower structure624 has a stepped outer form which can improve the strength of the piece and thereby improve durability, while still properly capturingwire614. Likewise,upper structure628 is also formed in a step manner, for similar reasons. Also, lower andupper structures624 and628 have reinforced structure around holes620 and622, respectively to compensate for the lack of material in the hole. Again, this improves strength and durability of the finished leg, thereby allowing repeated use by a doll user.
• Referring now toFIG. 19, aleft leg700 is shown in an approximately 1:1 scale drawing, which is formed usinginsert600.
• As shown inFIG. 19,insert600 is used in a third molding operation to form theleft leg700 overinsert600. The various views illustrate the shape of the leg and foot, including joint610 later used to form a single degree of freedom rotary hip joint.FIG. 19 also shows locatingpins630 which were used to locateinsert600 in the mold forming theleg700. After this molding operation, pins630 can be cut off, thereby leaving a finished leg for assembly to the doll body.
• Leg700 is thus formed to provide improved durability and desired flexibility, as well as a more realistic simulation of human parts, while still enabling the desired degrees of freedom and motion for effective play by the user. Therefore, the combination of rotary hip joints with bendable elbow knees thus provides an advantageous result. Furthermore, the shape formed by this third molding operation provides a thinnedportion720 to form the knee. Thus, even thoughwire614 spans an area much larger than the knee joint, the knee bends aboutthin area720 due to the shape formed in this third molding operation. As such, less manufacturing complexity can be used while still achieving repeatable bending at a desired location. Again, a right leg may be formed in a similar fashion.
• Referring now toFIG. 20, several alternative embodiments are described. The two right side drawings inFIG. 20 show alternative arm and arm insert designs, in whichsection326 is modified to includesmall dimples810 and812 to inner and outer parts of theupper arm section326. In this way, it is possible to provide improved location of the insert in the third molding operation which forms the arm around the insert. In other words, these dimples (or a single dimple, or more than 2 dimples) can help prevent, or reduce, location errors of the skeleton in arm mold.
• Continuing withFIG. 20, the left side drawings show an alternative leg insert and leg. First, asmall dimple814 is added tosection628 of the leg insert at the upper inner thigh area of the leg, again to prevent or reduce location errors of the leg skeleton in leg mold, as described above with regard todimples810 and812. While asingle dimple814 is used, more than one could also be used.
• Second, the barrel diameter in the location neardimple814 has been reduced, and asupport rib816 has been added to increase the strength of theleg section628, thereby providing improved durability.
• It is believed that the disclosure set forth above encompasses multiple distinct examples with independent utility. While each of these examples has been disclosed in example form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the disclosure includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. Similarly, where any claim recites “a” or “a first” element or the equivalent thereof, such claim should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements.
• Inventions embodied in various combinations and subcombinations of features, functions, elements, and/or properties may be claimed through presentation of claims in a related application. Such new claims, whether they are directed to a different invention or directed to the same invention, whether different, broader, narrower or equal in scope to the original claims, are also regarded as included within the subject matter of the inventions of the present disclosure.

Claims (20)

1. A toy doll, comprising

a first member;

a second member coupled to said first member, where said second member can slidably rotatably move relative to said first member, said second member comprising an armature, an element coupled to said armature, said element being more compliant than said armature, and a molded form around at least said armature and element to simulate a body part with a bendable joint.

2. The doll ofclaim 1 wherein said first member is a plastic body member.

3. The doll ofclaim 1 wherein said first member is a plastic torso member.

4. The doll ofclaim 1 wherein said second member is a limb.

5. The doll ofclaim 4 wherein said limb is an arm.

6. The doll ofclaim 4 wherein said limb is an leg.

7. The doll ofclaim 1 wherein said relative movement includes rotating movement.

8. The doll ofclaim 1 wherein said armature is plastic and insert molded to said first member to form said coupling.

9. The doll ofclaim 1 wherein said element comprises twisted wire.

10. The doll ofclaim 1 wherein said coupling is configured to form an articulated shoulder joint.

11. The doll ofclaim 1 wherein said coupling is configured to form an articulated hip joint.

12. A doll, comprising:

a body member, the body member comprising:

electronics configured to selectively energize a light emitting source exposed through said body member;

a platform configured to enable removable coupling of an accessory to said body member, where said source illuminates at least portions of said accessory.

13. The doll ofclaim 12 wherein said source is a light emitting diode.

14. The doll ofclaim 12 wherein said platform includes a magnet configured to be coupled to a magnet in said accessory.

15. The doll ofclaim 14 wherein said platform includes at least two magnets configured to be coupled to at least two magnets in said accessory.

16. The doll ofclaim 12 wherein said accessory is at least partially translucent to transmit light from said source through said accessory and create a visual glowing effect.

17. The doll ofclaim 12 wherein said accessory includes wings.

18. A toy doll, comprising

an accessory;

a first member, said first member comprising:

electronics configured to selectively energize a light emitting source exposed through said body member;

a platform configured to enable removable coupling of said accessory to said body member, where said source illuminates at least portions of said accessory; a second member coupled to said first member, where said second member can rotatably move relative to said first member, said second member comprising an armature, an element coupled to said armature, said element being more compliant than said armature, and a molded form around at least said armature and element to simulate a body part with a bendable joint.

19. The doll ofclaim 18 wherein said platform includes at least two magnets configured to be coupled to at least two magnets in said accessory.

20. The doll ofclaim 18 wherein said accessory is at least partially translucent.

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