Figure and a Composition for Forming the Figure

Abstract

A toy figure having at least one solid, molded part with a varying thickness is disclosed. The toy figure is a collector or fashion doll that has particular characteristics or properties. The toy figure is formed using a composition of ABS and barium sulfate, which provides several desired characteristics, including at least the aesthetics, feel, weight, and paintability of the toy figure.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of PCT Application Ser. No. PCT/US2011/023260, entitled “Figure and a Composition for Forming the Figure”, filed Feb. 1, 2011, Attorney Docket No. 1389.0197i, which was published as International Publication No. WO 2011/094726A3 on Aug. 4, 2011, which claims priority to U.S. patent application Ser. No. 61/300,327, filed Feb. 1, 2010, the disclosure of which is incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present invention relates to a figure, and in particular, to a material or composition that can be used to form the figure. The present invention also relates to method of making the figure.

BACKGROUND OF THE INVENTION

Conventional figures are formed of a thermoplastic material, such as resin, that is molded into shaped objects. These figures usually have multiple components or body parts that are molded using the thermoplastic material. Typically, the body parts are hollow and not solid. The molding of such parts results in the walls of a body part having a uniform thickness. In addition, due to the hollow structure of the body parts, the parts are generally lightweight. Moreover, such conventional figures and body parts typically lack any pleasing aesthetic features.

Thus, there is a need for a material that can be used to form molded figures or other objects and that is easy to mold. In addition, there is a need for a figure that is aesthetically pleasing and that is formed by a material that has desired properties.

SUMMARY OF THE INVENTION

In one embodiment, a toy figure has at least one solid, molded part with a varying thickness. The toy figure is a collector or fashion doll that has particular characteristics or properties. One characteristic is the feel or touch of the material of the toy figure. The material has a cool feel or touch, resembling that of a porcelain material. Another characteristic is that the toy figure material aesthetically resembles or appears to look like porcelain. Another characteristic is that the toy figure material has a specific gravity in a particular range which gives the toy figure a heavier or weighted feel. Additional characteristics are that the toy figure material is easily paintable and resistant to staining.

The molded part is formed using a mixture of ABS and barium sulfate. The mixture of ABS and barium sulfate can be about 20-80 weight percent barium sulfate and about 20-80 weight percent ABS. In another embodiment, the mixture includes about 30-70 weight percent barium sulfate and about 30-70 weight percent ABS. In yet another embodiment, the mixture includes about 40-60 weight percent barium sulfate and about 40-60 weight percent ABS. Alternatively, the mixture may include about 35-55 weight percent barium sulfate and about 45-65 weight percent ABS.

In an alternative embodiment, a colorant is added to the mixture of ABS and barium sulfate. In another embodiment, a flow additive is added to the mixture of ABS and barium sulfate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of an embodiment of a figure according to the invention.

FIG. 2 illustrates a cross-sectional plan view of a portion of a component of the figure illustrated in FIG. 1 taken along the line “2-2.”

FIG. 3 illustrates a cross-sectional plan view of another portion of the component of the figure illustrated in FIG. 1 taken along the line “3-3.”

Like reference numerals have been used to identify like elements throughout this disclosure.

DETAILED DESCRIPTION OF THE INVENTION

The term “figure” as used herein includes all types of toy figures and dolls. In particular, one type of figure or doll is a collector or fashion doll which, as described below, typically has different properties than conventional toy figures or dolls. The terms “characteristics,” “properties,” and “features” are used interchangeably herein in reference to molded articles.

Referring to FIG. 1, an exemplary embodiment of a toy figure is illustrated. In this embodiment, the toy FIG. 10 includes a torso 12, arms 14 and 16, legs 18 and 20, and a head 22. In one embodiment, one or more of the components of the toy FIG. 10 are solid pieces of material. As illustrated in FIG. 1, the thickness of the different parts or components of the toy FIG. 10 vary. For example, the torso has a thickness that varies along the length of the torso. In addition, each of the arms 14 and 16 and each of the legs 18 and 20 can vary in thickness as well. The solid construction and the varying thickness of the parts of the toy FIG. 10 often present molding challenges. The components of the toy FIG. 10 can be referred to alternatively as thick-walled components.

Referring to FIG. 2, a cross-sectional view of leg 18 of toy FIG. 10 is illustrated. In this view, the leg 18 has a first dimension “dl” extending from the front of the leg 18 to the back of the leg 18. In addition, the leg 18 has a second dimension “d2” extending from one side of the leg 18 to the other side of the leg 18. In different embodiments, the particular dimensions “d1” and “d2” at this location of the leg 18 can vary.

Referring to FIG. 3, another cross-sectional view of leg 18 of toy FIG. 10 is illustrated. The cross-section illustrated in FIG. 3 is taken at a location that is lower on the leg 18 than the cross-section illustrated in FIG. 2. As shown in FIG. 3, the leg 18 has a third dimension “d3” extending along the same direction as dimension “d1.” In addition, the leg 18 has a fourth dimension “d4” extending along the same direction as dimension “d2.” In this embodiment, dimension “d3” is shorter than dimension “d1” and dimension “d4” is shorter than dimension “d2.” Notable however is the fact that the leg 18 is solid at both cross-sectional locations.

In this embodiment, the leg 18 is a solid, molded piece of material. Leg 20 and arms 14 and 16 are also solid, molded pieces of material. In one method, one or more parts of the figure are molded using an injection molding technique. The material to be molded needs to have a viscosity that enables it to fill all of the cavities of the mold.

Typically, molding involves forming parts that have an even wall thickness, which the parts of the toy FIG. 10 do not have. Polymers are not good thermal conductors and are materials with high rates of shrinkage and coefficients of thermal expansion. These characteristics mean that when there are large differences in wall thickness within the component being molded, then some parts of the component will cool more and less quickly than other areas of different thickness. This effect will lead to sink/distortion and certainly different temperatures within the component at the point of ejection from the mold. One solution to control the sink/distortion is called “packing” which involves the injection of material after the mold is full. This solution requires that the gate point be large enough to prevent premature freezing while the “packing” continues.

When the molding material is a mixture of two materials, one viscoelastic and the other essentially solid particles suspended in the viscoelastic material, there is a tendency for the mixture to separate due to high stresses required to make the material flow when the mixture is force through channels. Since the stress is highest at the boundary between the material and the wall of the mold channels, combined with the fact that the mold is cooler than the melt mixture, the tendency is to cause the surface of the melt to fracture. This is then “frozen” at the surface since the melt is in contact with a cooled mold. This causes aesthetic defects to appear on the surface of the molded part, particularly at high stress points.

To minimize this effect, there are several techniques available. One technique is that large flow channels, including the sprue, the runner system, and the gate, can be used. Another technique is that a slow and profiled injection speed can be used to control shear rates as the melt front passes restrictions/high stress areas. Alternatively, melt viscosity can be reduced by using high MFI grade resins and raising melt temperature as much as possible. Also, heated molds can be used to reduce the rate of cooling and to slightly reduce the stress at the boundary layer.

In one embodiment, the toy FIG. 10 is a collector-type doll in that it is intended to have characteristics and features that are not normally found in dolls or figures with molded parts. The difference in characteristics and features between conventional dolls formed of basic molded plastic parts and the toy FIG. 10 is based on the particular material that is used to form the toy FIG. 10.

According to the invention, the toy FIG. 10 has several characteristics or features that are desirable. One characteristic or feature is the aesthetic appearance of the figure. It is desirable that the figure has a “porcelain-like” aesthetic in that the figure appears to look like it is made of porcelain. This porcelain aesthetic is neither expected nor obtained from conventional molded plastic parts.

Another characteristic or feature of the toy FIG. 10 is how the surface of the figure feels to a user. It is desirable that the figure has a surface that feels cold to the touch, which is another similarity to porcelain material. This cold sensation is also not expected from toy figures that are made using conventional molded plastic parts.

Another characteristic or feature of the toy FIG. 10 is the relative weight of the toy FIG. 10. In one embodiment, the toy FIG. 10 weighs more than a toy figure that is formed of conventional plastic parts, which as noted above, are often hollow and relatively light in weight. In particular, the specific gravity of the molded components of the toy FIG. 10 is greater than the specific gravity of a conventional plastic figure. It is desirable that the figure has a weight that is slightly heavier than a conventional doll figure. This increased weight provides the toy FIG. 10 with a stronger, more substantial feeling which is characteristic of porcelain material. Thus, the molded material has a desired range of specific gravity.

Another alternative characteristic or feature of the toy FIG. 10 is that the toy FIG. 10 be paintable. In other words, for toy FIG. 10, it is desired that the molded material be easily paintable so that color can be added to the toy FIG. 10. Often a primer material is needed to be applied initially to a toy figure to facilitate the painting of the toy figure with the desired colors. In one embodiment, the material used for toy FIG. 10 can be painted directly, which results in cost and time savings.

While several of the desired characteristics described above are based on the toy FIG. 10 appearing to be made of porcelain, the composition of the molded portions of the toy FIG. 10 has better properties, such as strength and durability, than an actual porcelain material. The improved properties allow for a more versatile usage of the toy FIG. 10.

The toy FIG. 10 is formed using a composition that includes a resin. In one embodiment, the resin is acrylonitrile butadiene styrene, referred to herein as ABS, which is a thermoplastic material. ABS is a copolymer and is comprised of polymerized styrene and acrylonitrile with polybutadiene. The relative proportions of the components of ABS can vary depending on the particular application or use. In one exemplary implementation, the proportions of the components of ABS can range from about 15-35 percent weight acrylonitrile, about 5-30 percent weight butadiene, and about 40-60 percent weight styrene. Molded materials that include ABS are easily paintable.

Typically, the use of a resin such as ABS in a molded component requires a glass fiber or filler in the resin compound due to the fragility and brittleness of molded ABS material. However, the composition that is used to mold the parts of the toy FIG. 10 does not include any glass filler material. The lack of glass filler material is acceptable for toy FIG. 10 because structural, machineable, and high tensile strength are not needed as other characteristics and features, such as aesthetic and feel, are desired for the toy FIG. 10 as discussed in greater detail below.

In forming the mixture of the composition to be molded, barium sulfate (BaSO₄) is added to the ABS resin as a filler. The quantity of barium sulfate that is added to the ABS material changes the properties of the overall mixture. For example, as the quantity of barium sulfate added to ABS increases, the resulting composition becomes drier. As mentioned above, the composition to be molded needs to be able to adequately fill the cavities of the mold. Accordingly, if the mixture is too dry, then the mixture will likely not adequately flow throughout the mold, thereby resulting in defects in the molded toy FIG. 10.

In one exemplary method of making the toy FIG. 10, ABS was loaded with 30-70 weight percent barium sulfate. Depending on the dryness of the resulting mixture, additional ABS can be added to the initial mixture of ABS and barium sulfate. For example, if the initial mixture is too dry for properly molding the toy FIG. 10, additional ABS can be added, thereby changing the percentage of the mixture that is barium sulfate. Thus, for example, the resulting mixture can have about 30-50 weight percent barium sulfate and 50-70 weight percent ABS.

In an alternative embodiment, the initial mixture can be formed of 20-80 weight percent barium sulfate added to 20-80 weight percent ABS. Alternatively, the initial mixture for the toy FIG. 10 may include about 40-60 weight percent barium sulfate and about 40-60 weight percent ABS. Alternatively, the composition may include about 35-55 weight percent barium sulfate and about 45-65 weight percent ABS.

The main components of the material used to form the toy FIG. 10 are ABS and barium sulfate. However, in one embodiment, a colorant can be added to the main component mixture. The mixture may include about 0.5-5.0 percent weight of the colorant. The colorant can be a standard colorant that is selected from a standard color reference chart or samples and that can be obtained from available plastic colorant systems.

In another embodiment, a flow modifier is added to the main component mixture. The flow modifier is added to reduce gate blush and flow marks from the molded components. The mixture may include about 0.5-5.0 percent weight of the flow modifier as well.

As mentioned above, the specific gravity of the toy FIG. 10 can vary depending on the particular composition that is molded. In one embodiment, the specific gravity of the toy figure is about 1.50-1.60. The higher the specific gravity represents a relatively heavier toy FIG. 10. Initially, ABS has a specific gravity of about 1.50-1.52. The specific gravity of the composition increases as the amount of barium sulfate is increased. However, as mentioned above, the amount of barium sulfate in the mixture affects the moldability of the mixture and the characteristics of the molded pieces. Regarding the moldability, increased amounts of the filler results in a drier product, which is more difficult to mold. If too much barium sulfate is added to the composition, the mixture is not easily molded or processed. However, regarding the characteristics of the molded pieces, decreased amounts of barium sulfate results in the molded product feeling less and less like porcelain. Thus, variations in the barium sulfate amount in the composition affect the molding process and the characteristics of the toy FIG. 10. In an alternative embodiment, the specific gravity of the toy figure can be lowered such that a specific gravity of about 1.44 is obtained.

Regarding the molding process, the desired mixture of ABS and barium sulfate (and, if included, a colorant and/or a flow agent) is molded using an injection molding process. Once the component is molded, the molded component can be painted. This molded component can be painted without a primer due to the ABS being used. In addition, this molded component allows solvent bonding using common industrial solvents such as MEK (also known as butanone) and methylene chloride. Also, this molded component has significantly improved color migration absorption properties as compared to conventional materials. Conventional materials, such as polybutylene terephthalate (PBT), absorb colorants used in polyester based fabrics. This absorption results in the staining of the conventional molded components. However, molded components including ABS do not have any color transfer from dyes used in polyester fabrics or other materials.

In an alternative embodiment, the toy figure can be a single piece of material and formed using a single molded piece of material.

Therefore, although the disclosed inventions are illustrated and described herein as embodied in one or more specific examples, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the scope of the inventions and within the scope and range of equivalents of the claims. Further, various features from one of the embodiments may be incorporated into another of the embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure as set forth in the following claims.

Claims

1. A toy figure, comprising:

a body including at least one molded component, the at least one molded component being formed from a composition comprising barium sulfate and ABS.

2. The toy figure of claim 1, wherein the composition includes about 20-80 weight percent barium sulfate and about 20-80 weight percent ABS.

3. The toy figure of claim 2, wherein the composition includes about 30-70 weight percent barium sulfate and about 30-70 weight percent ABS.

4. The toy figure of claim 3, wherein the composition includes about 40-60 weight percent barium sulfate and about 40-60 weight percent ABS.

5. The toy figure of claim 3, wherein the composition includes about 35-55 weight percent barium sulfate and about 45-65 weight percent ABS.

6. The toy figure of claim 1, wherein the toy figure includes a torso, a pair of legs, and a pair of arms, the at least one molded component being one of the legs.

7. The toy figure of claim 6, wherein each of the legs and the arms is molded from a composition of barium sulfate and ABS.

8. The toy figure of claim 1, wherein the composition includes a colorant.

9. The toy figure of claim 1, wherein the composition includes a flow agent.

10. A toy figure included a molded portion, the molded portion consisting essentially of:

barium sulfate; and

ABS.

11. The toy figure of claim 10, wherein the molded portion includes about 20-80 weight percent barium sulfate and about 20-80 weight percent ABS.

12. The toy figure of claim 11, wherein the molded portion includes about 30-70 weight percent barium sulfate and about 30-70 weight percent ABS.

13. The toy figure of claim 12, wherein the molded portion includes about 40-60 weight percent barium sulfate and about 40-60 weight percent ABS.

14. The toy figure of claim 12, wherein the molded portion includes about 35-55 weight percent barium sulfate and about 45-65 weight percent ABS.

15. The toy figure of claim 10, wherein the toy figure includes a torso, a pair of legs, and a pair of arms, the molded portion including one of the legs.

16. The toy figure of claim 15, wherein each of the legs and the arms is molded from a composition of barium sulfate and ABS.

17. The toy figure of claim 10, wherein the composition includes a colorant.

18. The toy figure of claim 10, wherein the composition includes a flow agent.

19. A method of manufacturing a figure, the method comprising the steps of:

mixing a composition comprising about 35-60 weight percent barium sulfate and about 40-65 weight percent ABS; and

molding the composition to form the portion of the figure.

20. The method of claim 19, wherein the portion of the figure is a leg of the figure and the leg has a non-uniform thickness.