CROSS-REFERENCE TO RELATED APPLICATION This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/432,856 filed Dec. 15, 2022. This application is also a continuation in part of U.S. patent application Ser. No. 17/691,271 filed Mar. 10, 2022, which is a continuation in part of U.S. Design Patent Application Ser. No. 29/794,783 filed Jun. 15, 2021 and claims the benefit of U.S. Provisional Patent Application Ser. No. 63/160,549 filed Mar. 12, 2021, and U.S. Provisional Patent Application Ser. No. 63/187,003 filed May 11, 2021, the entireties of which are hereby incorporated herein by reference for all purposes.
TECHNICAL FIELD The present disclosure relates generally to the field of children's toys and accessories, and more particularly to a segmented toy bar for children's toys and accessories.
BACKGROUND Children's toys and accessories such as play gyms and mats often incorporate a toy bar that extends over and above the play area to support toys and entertainment features for interaction and play by a child. Commonly, such toy bars are in the form of an elongate flexible bar or tube, which may include a fiberglass rod or beam at its inner core for structural support, a layer of foam padding around the inner rod, and a fabric or soft goods external cover over the foam padding.
Previously known toy bars typically take the form of a unitary elongate body of 1 meter (m) or more, and up to 1.5 m, 2 m or more, in length. While these toy bars may be flexed or bent to fit within a package for shipping and storage, they typically still require a relatively large packaging envelope, which may increase costs of production and shipping. Also, it can be difficult to retain flexed toy bars in their packaging, as they tend to unexpectedly expand and escape, or spring out of the packaging, causing inconvenience to users and/or increased expense in packaging.
Accordingly, it has been found that needs exist for improvements to toy bars for children's accessories. It is to the provision of improvements to toy bars for children's accessories meeting these and other needs that the present disclosure is primarily directed.
SUMMARY The present disclosure is directed to an improved toy bar for children's accessories. In example embodiments, the toy bar comprises two or more segments of relatively shorter length, configured for coupling together to form a toy bar assembly of relatively longer length. In some examples, the toy bar segments are connected by one or more couplings, including without limitation: hinged coupling elements, elastic coupling elements, threaded coupling elements, living hinge coupling elements, slot-and-flange coupling elements, rod and ferrule coupling elements, rotationally or translationally engaged coupling elements, pivotal coupling elements, twist coupling elements, and/or other coupling means. In example forms and methods of use, the improved toy bar of the present disclosure is configured for stable and secure packaging and storage in a compact configuration within a packaging envelope of smaller or reduced dimension(s) relative to that of previously known toy bars.
In one aspect, the present disclosure relates to a segmented toy bar assembly including a first toy bar segment, a second toy bar segment, and at least one coupling connecting the first toy bar segment to the second toy bar segment. The at least one coupling is preferably configured to allow reconfiguration of the segmented toy bar assembly between an expanded configuration wherein the first and second toy bar segments are extended in axial alignment to define an expanded length, and a compact configuration wherein the first and second toy bars are configured to fit within a packaging envelope having a compact length substantially less than the expanded length.
In another aspect, the disclosure relates to a segmented toy bar assembly including a first toy bar segment, a second toy bar segment, and at least one hinged coupling pivotally connecting proximal ends of the first and second toy bar segments. The assembly preferably further includes first and second support members affixed at distal ends of the first and second toy bar segments respectively. Each of the first and second toy bar segments preferably take the form of a flexible member having a cross-sectional profile having a width and a thickness, the width being at least two times the thickness.
In still another aspect, the disclosure relates to a segmented toy bar assembly including a first toy bar segment, a second toy bar segment, and a third toy bar segment. The assembly preferably also includes a first coupling rotationally connecting the first and second toy bar segments, and a second coupling rotationally connecting the second and third toy bar segments. The assembly preferably also includes first and second support feet affixed at distal ends of the first and second toy bar segments respectively. Each of the first and second toy bar segments preferably take the form of a flexible member having a cross-sectional profile defining a width and a thickness, the width being at least two times the thickness. The first and second couplings preferably allow reconfiguration of the segmented toy bar assembly between an expanded configuration defining an expanded length and a compact configuration having a compact length substantially less than the expanded length.
These and other aspects, features and advantages of the disclosure will be understood with reference to the drawing figures and detailed description herein, and will be realized by means of the various elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following brief description of the drawings and detailed description of example embodiments are explanatory of example embodiments of the invention, and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a children's play yard accessory, including a play mat and a pair of segmented toy bar assemblies according to an example embodiment of the present disclosure.
FIG. 2 is a detailed view, in partial cut-away, showing a section of a segmented toy bar assembly including a hinged coupling portion, according to an example embodiment of the present disclosure.
FIG. 3 is a detailed perspective view of a hinged coupling portion of a segmented toy bar assembly according to an example embodiment of the present disclosure.
FIG. 4 is a detailed perspective view of a support foot portion of a segmented toy bar assembly according to an example embodiment of the present disclosure.
FIGS. 5A, 5B, 5C and 5D (collectively, FIG. 5) show a sequence of operation of a segmented toy bar assembly according to an example embodiment of the present disclosure.
FIGS. 6A and 6B (collectively, FIG. 6) show different variations of hinged segmented toy bar assemblies according to example embodiments of the present disclosure.
FIG. 7 shows a packaged children's play yard accessory, including a play mat, a pair of segmented toy bar assemblies, and hanging toys, in a compact shipping or storage configuration within a package according to an example embodiment of the present disclosure.
FIGS. 8A, 8B, 8C and 8D (collectively, FIG. 8) show an elastically and translationally coupled segmented toy bar assembly according to another example embodiment of the present disclosure.
FIGS. 9A, 9B and 9C (collectively, FIG. 9) show a hinged or pivotally coupled segmented toy bar assembly according to another example embodiment of the present disclosure.
FIGS. 10A, 10B, 10C, 10D, 10E and 10F and (collectively, FIG. 10) show a threaded or twist-connection segmented toy bar assembly according to another example embodiment of the present disclosure.
FIGS. 11A, 11B, 11C, 11D, and 11E (collectively, FIG. 11) show a unitary or living hinge coupled segmented toy bar assembly according to another example embodiment of the present disclosure.
FIGS. 12A, 12B, 12C and 12D (collectively, FIG. 12) show a translationally engaged slot-and-flange coupled segmented toy bar assembly according to another example embodiment of the present disclosure.
FIGS. 13A and 13B (collectively, FIG. 13) show an alternate arrangement of a hinge coupling for a segmented toy bar assembly according to another example embodiment of the present disclosure.
FIG. 14 is a perspective view of a hinged or pivotally coupled segmented toy bar assembly according to another example embodiment of the present disclosure.
FIG. 15 shows the hinged or pivotally coupled segmented toy bar assembly of FIG. 14 in an arched or in-use configuration.
FIG. 16 is an exploded view of the hinged or pivotally coupled segmented toy bar assembly of FIG. 14.
FIG. 17 is a detailed, exploded perspective view of a support foot portion of the hinged or pivotally coupled segmented toy bar assembly of FIG. 14.
FIG. 18 is a cross-sectional view of the support foot portion of FIG. 17.
FIG. 19A shows a hinge of the segmented toy bar assembly in an extended configuration.
FIG. 19B shows the hinge of FIG. 19A in a partially collapsed or folded configuration.
FIG. 20 shows the hinged or pivotally coupled segmented toy bar assembly of FIG. 14 in a collapsed or folded configuration.
FIGS. 21 and 22 show a hinged or pivotal coupling mechanism according to yet another example embodiment of the present disclosure.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS The present invention may be understood more readily by reference to the following detailed description of example embodiments taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated by reference as though fully set forth herein.
Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.
With reference now to the drawing figures, wherein like reference numbers represent corresponding parts throughout the several views, FIG. 1 shows a children's play gym accessory 10, comprising a play mat 20 for supporting a child over a floor or other support surface, and a pair of segmented toy bar assemblies 30 (indicated as 30a and 30b) extending over and above the play mat and supporting toys or entertainment elements 12, 14 suspended therefrom, according to an example embodiment of the present disclosure. In some examples, the play mat 20 is padded, for example comprising a foam or non-woven batting within a fabric or soft goods exterior cover, and may include clips, snaps, buttons or other attachment features for attaching the mat to support feet or end elements 70 of the toy bars 30. The play mat 20 may be square or rectangular as depicted, circular, or otherwise shaped.
As shown in further detail in FIG. 2, some example embodiments of the segmented toy bar assembly 30 include two or more (a plurality of) internal bar or rod segments 40 (indicated as 40a and 40b), formed of or at least partially comprising a flexible and resilient material such as for example fiberglass, nylon, polyvinyl chloride (PVC), polymeric, metal, wood, composite, or other material(s) providing sufficient structural support and rigidity for anticipated loading, and having a sufficient degree of elasticity and internal resilience or shape memory to allow the bar or rod to be repeatedly flexed into an arcuate or curved shape, and released to return to a relatively straight configuration. In some example embodiments, the internal bar or rod segments 40 may have a material thickness or diameter of about 4 mm. The toy bar assembly 30 may also include a layer of padding 42 applied over and around the internal bar or rod segments 40, such as for example a tube or sleeve of flexible polyurethane or polyethylene foam or other resilient cushioning material. In some example embodiments, the padding layer 42 may have an outside diameter of about 25 mm and a padding material thickness of about 5 mm. An outer covering 44 of fabric or other flexible material or coating may be provided over the padding 42. In some example embodiments, the fabric covering 44 may be removable for washing, for example by means of a zipper, hook-and-loop fasteners, or other removable attachment means.
Adjacent ends of the toy bar segments 40 are connected to one another by one or more hinged coupling elements or hinges 50, shown in greater detail in an example form in FIG. 3. In some example embodiments, the hinges 50 or other coupling elements may be formed of or at least partially comprise a flexible and resilient material such as for example acrylonitrile butadiene styrene (ABS), high density polyethylene (HDPE), and/or polypropylene. In the depicted embodiment, hinge 50 comprises oppositely arranged first and second receivers 52, 54 for receiving and engaging respective ends of the bar segments 40. Each receiver 52, 54 further comprises a hinge pin 56, 58, having a medial portion that extends through a hole in the proximal end of each respective bar segment 40 and one or both ends affixed to top and/or bottom flanges of the receiver. The hinge pins 56, 58 define two parallel axes of rotation of the toy bar segments 40a, 40b, and are offset from one another by a distance d in a direction transverse to the axial dimension. The dual-hinge assembly effectively provides for two offset 90° folds that combine to effect a 180° fold of adjacent coupled bar segments 40. In example embodiments, the offset distance d is at least about twice the thickness of the foam padding material 42, to allow the toy bar segments 40a, 40b to be folded into a compact of folded configuration generally parallel to one another (see FIG. 5), to prevent scissoring of the foam material, and/or to reduce or eliminate potential pinch points. In some particular embodiments, the offset distance d is at least about 1 centimeter (cm) to about 5 cm, for example about 2.5 cm. In some examples, the hinge pins 56, 58 may be generally centrally positioned on the receivers 52, 54, or alternatively may be positioned toward a corner or end of the receivers to provide different alignment or support structure arrangement for the adjacent toy bar segments 40a, 40b. The receivers 52, 54 optionally comprises stop members 62, 64 at one side thereof, to restrict the pivotal movement of the toy bar segments 40a, 40b to rotate in only one direction relative to one another (i.e., from 0° to 180°, but not beyond 180°), and optionally further comprise releasable and/or fixed locking elements to retain the toy bar segments 40a, 40b in their extended (180°) positions and/or their folded (0°) positions. In some example embodiments, the hinges are configured for one-time use, to allow the toy bar assembly to be expanded and assembled after delivery to the end user, and thereafter remain fixed in the expanded configuration. In other example embodiments, the hinges are configured for repeated assembly and disassembly, allowing the end user to reconfigure the toy bar assembly between its expanded and compact configurations multiple times.
The toy bar assembly 30 optionally also includes a support foot 70 at each end thereof, shown in further detail in FIG. 4. In example form, the support foot 70 comprises a lower base pad portion 72 having a flat face at one end, optionally comprising a non-slip material for contact with a floor or other support surface; and an opposite upper end defining a channel or opening 74 for receiving and engaging an outer end of a toy bar segment 40. The support foot 70 optionally further comprises a retention slot 76 or other attachment feature for attaching the play mat 20 to the foot. The support foot 70 optionally further comprises a transversely outwardly projecting flange 78 for preventing the padding 42 and outer covering 44 from sliding beyond its intended positioning on the toy bar segments 40. In example embodiments, the support feet 70 are large enough to prevent parts of the toy bar assembly from presenting choking hazards.
FIGS. 5A, 5B, 5C and 5D (collectively, FIG. 5) show a sequence of operation or movement of a three-segmented, two-hinged toy bar assembly 30 according to an example embodiment of the present disclosure (with the padding 42 and outer covering 44 not shown in FIGS. 5A, 5B and 5C, and shown in broken lines in FIG. 5D). The toy bar assembly 30 may be folded into a compact configuration as shown in FIG. 5A, wherein the hinged toy bar segments 40a, 40b, 40c are generally parallel and adjacent to one another, for shipment and storage. The toy bar assembly 30 is unfolded as shown in FIG. 5B (partially unfolded) and FIG. 5C (fully unfolded), into an expanded configuration with the toy bar segments 40a, 40b, 40c generally coaxially aligned with one another and forming a straight or linear bar. The toy bar assembly 30 may then be bent or flexed into an arcuate, curved or semi-circular configuration as shown in FIG. 5D, for positioning over and above the play mat 20 or other play area, to support toys or entertainment features above a child for play (see FIG. 1).
In example embodiments, and with reference to FIG. 3, the toy bar segments 40 have a cross-sectional profile wherein a bar width WB in a width-wise dimension is substantially greater than a bar thickness TB in a thickness-wise dimension, for example having an aspect ratio of WB:TB of at least about 2:1, and in particular example embodiments of at least about 3:1 or 4:1. (Length-wise L, width-wise W, and thickness-wise T dimensions herein refer to mutually orthogonal (90°) directions or axes, corresponding to the X, Y, and Z dimensions or axes, respectively, of a Cartesian coordinate system designation of three-dimensional space). Accordingly, the toy bar segments have a greater degree of stiffness or structural rigidity in their width-wise dimension (Y-axis), and a greater degree of flexibility in their thickness-wise dimension (Z-axis). The hinge axes 56, 58 are aligned generally in the thickness-wise (Z) dimension, allowing the bar segments 40 to fold relative to one another in the width-wise (Y) dimension (in the X-Y plane), as shown in FIG. 5B. In example embodiments, the feet 70 of the toy bar assembly 30 are configured to align the retention slots 76 with the thickness-wise (Z) dimension, so that the bar assembly flexes in the thickness-wise dimension (i.e., about a bending axis in the width-wise (Y) dimension and bending to form an arch in the X-Z plane) when assembled for use, as shown in FIG. 5D and FIG. 1. In this manner, the greater stiffness of the bar assembly 30 in the width-wise dimension (Y-axis, X-Y plane) and the arched configuration (Z-axis, X-Z plane) provides substantial three-dimensional structural strength and resists buckling under load, and the greater flexibility in the thickness-wise dimension (Z-axis, X-Y plane) provides for ease of assembly in use. Alignment of the hinges 50 with the widthwise dimension (Y-axis, X-Y plane) of the toy bar segments 40 avoids stressing the hinges in their fold directions when the toy bar assembly 30 is flexed, thereby avoiding or resisting unintentional folding during use. Alternatively, the bar assembly may be configured to flex in the width-wise dimension (i.e., about a bending axis in the thickness-wise (Z) dimension and bending to form an arch in the X-Y plane) when assembled for use. For example, the toy bar segments may be flexible in the width-wise dimension.
FIGS. 6A and 6B show additional alternate embodiments of toy bar assemblies. FIG. 6A shows a four-segmented (segments 140a, 140b, 140c, 140d), three-hinged (150) toy bar assembly 130. The foam padding 42 and outer covering 44 are not shown in FIGS. 6 and 7 but may be provided in typical form. FIG. 6B shows a two-segmented (segments 240a, 240b), one-hinged (250) toy bar assembly 230. In further alternate embodiments, more segments or differently configured segment and hinge or other coupling arrangements may be provided. In some example embodiments, the toy bar segments comprise rods of circular cross-section, bars of rectangular cross-section, cylindrical tubes, or other configurations. In some example embodiments, the toy bar segments have an axial length LB of no more than about 400 mm and a diameter or transverse dimension of about 15 mm. In example embodiments, the bar segments and/or hinge components may be injection molded, extruded, machined, cut, or otherwise fabricated. In some example embodiments, each of the bar segments of a toy bar assembly are identical components for manufacturing and packaging efficiency. Alternatively, one or more of the bar segments of a toy bar assembly may differ from the other segments, for example having different lengths. In further examples, each of the bar segments of a toy bar assembly is substantially similar in length in order to minimize packaging size for a given overall toy bar assembly length, for example wherein the lengths LB of all of the bar segments of the toy bar assembly differ from one another by no more than about 25%, and in particular example embodiments by no more than about 10%.
With reference to FIG. 7, the segmented toy bar assembly of the present disclosure advantageously allows for more compact and convenient packaging, as for shipping and storage while not in use, than previously known unitary or un-segmented toy bars. In example form as shown, one, two or more toy bar assemblies 30 can be folded into their compact folded configurations, and contained (optionally along with the play mat 20, toys 12, 14, 16, and/or other accessory components) within a box or other package 90 defining a packaging envelope (maximum dimensions of the contained volume) having length LP, width WP and/or height HP dimension(s) that is/are substantially less than one or more corresponding dimension(s) of packaging for previously known toy bars (or packaging for children's accessories including such toy bars). For example, in some embodiments, a folded toy bar assembly 30 according to the present disclosure having an overall length of at least 100 cm to 150 cm in its expanded configuration may be contained within a packaging envelope of less than 55 cm length and/or less than 43 cm width, such as for example within a packaging envelope of about 46 cm length and/or about 25 cm width. In other example embodiments, a toy bar assembly according to the present disclosure having an overall length of about 138 cm in its expanded configuration may be contained in its folded or compact configuration within a packaging envelope of no more than about 35 cm length by about 12 cm width by about 4 cm height. In still further example embodiments, a toy bar according to the present disclosure may be contained in its compact configuration within a packaging envelope of no more than about 46 cm length by about 9 cm width by about 3 cm height. Additionally, the compact folded toy bar assembly 30 according to the present disclosure may be contained within a reduced-size packaging envelope without flexing or bending of the toy bar segments 40, allowing the toy bar assembly to be packaged more stably and securely, without the risk of unexpectedly expanding and escaping, or springing out of the packaging as with previously known packaging of toy bars. The reduced-size packaging envelope enabled by the segmented toy bar assembly of the present disclosure may thereby reduce packaging costs, reduce shipping costs, reduce storage space requirements, and improve the user's experience and convenience.
FIGS. 8A, 8B, 8C and 8D (collectively, FIG. 8) show an elastically-jointed and translationally coupled segmented toy bar assembly 830 according to another example embodiment of the present disclosure. The foam padding sleeve, outer soft goods covering, and support feet are not shown in this and subsequent embodiments, in order to better show the bar segment and coupling arrangements, but it will be understood that such features may be provided in typical fashion for the various embodiments of toy bar assemblies disclosed. This embodiment is substantially similar to the above-described embodiments, with differences as noted. The bar assembly 830 includes a plurality of bar segments 840, coupled to one another by elastic translational couplings 850 to form an extended elongate configuration for use and to allow the assembly to be disassembled or broken down to a more compact or folded configuration for transport and storage. The couplings 850 comprise male projections or pin elements 852 affixed to ends of the bar segments, and female receiver sleeves or ferrules 854 configured to receive and engage the projections or pin elements to couple adjacent bar segments to one another. An elastic member or cord 856 is optionally engaged between the confronting male projections or pin elements 852 of adjacent bar segments. In use, the user assembles the toy bar assembly 830 into its expanded configuration by axially aligning the toy bar segments 840 and inserting opposed male projections or pin elements 852 of adjacent bar segments into opposite ends of the intermediate female receiver sleeve or ferrule 854. The toy bar assembly 830 may be broken down or folded into its compact of folded configuration by pulling the bar segments 840 axially away from one another to retract the male projections or pin elements 852 from the female receiver sleeve or ferrule 854 and folding the bar segments relative to one another as shown in FIG. 8D. The elastic member or cord 856 retains the parts in connection with one another and assists the user in assembly. The toy bar assembly 830 can be packaged in its compact or folded configuration within a box or other package 890. In example embodiments, a folded toy bar assembly 830 having a length of about 138 cm in its expanded configuration may be contained within a packaging envelope of no more than about 40 cm length, no more than about 8 cm width, and/or no more than about 2-3 cm height in its compact or folded configuration.
FIGS. 9A, 9B and 9C (collectively, FIG. 9) show a hinged or pivotally coupled segmented toy bar assembly 930 according to another example embodiment of the present disclosure. This embodiment is substantially similar to the above-described embodiments, with differences as noted. The bar assembly 930 includes a plurality of bar segments 940, coupled to one another by pivotal couplings or hinges 950 to form an extended elongate configuration for use (FIG. 9B) and to allow the assembly to be folded into a more compact or folded configuration (FIG. 9C) for transport and storage. The pivotal couplings 950 comprise a single axis of rotation about a hinge pin 952 that is laterally offset from the lengthwise axes of the bar segments 940, and transversely offset (in the direction of the hinge axis) bar receivers 954, to allow a 180° folding range with sufficient spacing between the bar segments to accommodate the foam sleeve and fabric covering of the toy bar assembly without scissoring, and without presenting pinch points during use. In example embodiments, a folded toy bar assembly 930 having a length of about 138 cm in its expanded configuration may be contained within a packaging envelope of no more than about 38 cm length, no more than about 5 cm width, and/or no more than about 2-3 cm height in its compact or folded configuration.
FIGS. 10A, 10B, 10C, 10D, 10E and 10F and (collectively, FIG. 10) show a threaded or twist-connection segmented toy bar assembly 1030 according to another example embodiment of the present disclosure. This embodiment is substantially similar to the above-described embodiments, with differences as noted. The bar assembly 1030 includes a plurality of bar segments 1040, coupled to one another by threaded or twist-connect couplings 1050 to form an extended elongate configuration for use (FIG. 10A) and to allow the assembly to be disassembled or broken down to a more compact or folded configuration for transport and storage (FIG. 10F). The couplings 1050 comprise a male fitting portion 1052 configured to be received and engaged within a female fitting portion 1054. The couplings 1050 may incorporate inter-engaging helical thread elements 1056, and optionally locking tabs 1058. In use, the user assembles the toy bar assembly 1030 into its expanded configuration by axially aligning the toy bar segments 1040 (FIG. 10B) and engaging the male and female coupling portions 1052, 1054 of adjacent bar segments with one another by twisting in opposite directions about the lengthwise axis of the bar assembly (FIGS. 10C, 10D, 10E). The toy bar assembly 1030 may be disassembled and folded into its compact of folded configuration by twisting in the opposite direction, separating the bar segments 1040 from one another, and folding the bar segments relative to one another as shown in FIG. 10F. The toy bar assembly 1030 can be packaged in its compact or folded configuration within a box or other package 1090. In example embodiments, a folded toy bar assembly 1030 having a length of about 138 cm in its expanded configuration may be contained within a packaging envelope of no more than about 36 cm length, no more than about 10 cm width, and/or no more than about 2-3 cm height in its compact or folded configuration.
FIGS. 11A, 11B, 11C, 11D, and 11E (collectively, FIG. 11) show a unitary or living hinge coupled segmented toy bar assembly 1130 according to another example embodiment of the present disclosure. This embodiment is substantially similar to the above-described embodiments, with differences as noted. The bar assembly 1130 includes a plurality of bar segments 1140, coupled to one another by living hinge couplings 1150 to form an extended elongate configuration for use (FIGS. 11A, 11B) and to allow the assembly to be folded into a more compact or folded configuration (FIG. 11E) for transport and storage. The living hinge couplings 1150 comprise unitary molded bodies comprising first and second bar segment receiver sleeves 1152, 1154, with a flexible interconnecting web of material 1156 extending between the receiver sleeves and forming a hinge segment. The hinge formed by interconnecting web 1156 defines a single axis of rotation that is laterally offset from the lengthwise axes of the bar segments 1140 and their respective coaxial sleeves 1152, 1154, to allow a 180° folding range with sufficient spacing between the bar segments to accommodate the foam sleeve and fabric covering of the toy bar assembly without scissoring, and without presenting pinch points during use, as shown in FIG. 11E.
FIGS. 12A, 12B, 12C and 12D (collectively, FIG. 12) show a translationally engaged slot-and-flange coupled segmented toy bar assembly 1230 according to another example embodiment of the present disclosure. In example embodiments, the assembly 1230 comprises a plurality of leg subassemblies (three are shown, joined together by a central hub connector 1235. Each leg assembly comprises two or more toy bar segments, which in the depicted embodiment include an upper bar segment 1240a having an upper end configured for attachment to the hub 1235, and a lower bar segment 1240b having a lower end configured for supporting the assembly on the ground, a floor, or other support surface. Confronting lower ends of the upper bar segments 1240a and upper ends of the lower bar segments 1240b include interengaging slot and flange coupling features 1250a, 1250b configured to slidingly or translationally engage with one another as shown in FIG. 12C. In some example embodiments, one or both of the upper bar segments 1240a and the lower bar segments 1240b comprise curved or radiused, substantially rigid, arcuate members. In further example embodiments, one or both of the upper bar segments 1240a and the lower bar segments 1240b at least partially comprise a natural or synthetic wood material or veneer. The toy bar assembly 1230 can be packaged in its compact or folded configuration within a box or other package 1290 as shown in FIG. 12D. In example embodiments, the toy bar assembly 1230 may be contained within a packaging envelope of no more than about 17″ (about 43 cm) length, no more than about 7″ width (about 18 cm), and/or no more than about 4″-5″ (about 10-13 cm) height in its compact or folded configuration.
FIGS. 13A and 13B show an alternate arrangement of a hinge coupling 1350 for a segmented toy bar assembly according to another example embodiment of the present disclosure. The hinge coupling 1350 is substantially similar to hinge 50 disclosed above, with differences as noted. The body of the hinge coupling 1350 comprises a hinge body or housing comprising first and second half-housing elements, 1353, 1355. In some example embodiments, both of the half-housing elements, 1353, 1355 comprise identical moldings for manufacturing efficiency. In example embodiments, the half-housing elements, 1353, 1355 each comprise a hinge pin 1357, a hinge pin receiving recess 1359, 180° limit stop abutments 1361, 90° limit stop abutments 1363, and indexing positional lock elements 1365 for releasably retaining toy bar segments 1340 in the 180° and 90° positions. The coupling 1350 is assembled by mounting the first and second half-housing elements 1353, 1355 in mirror-image arrangement confronting one another, with each half-housing's hinge pin received in the other half-housing's receiving recess, and joining the half-housings by ultrasonic welding, adhesive, thermal or solvent bonding, one or more fasteners, or other attachment means.
FIGS. 14-16 show a hinged or rotatably coupled segmented toy bar assembly 1530 according to yet another example embodiment of the present disclosure. This embodiment is substantially similar to the above-described embodiments, with differences as noted. The bar assembly 1530 includes a plurality of bar segments 1540 (indicated as 1540a, 1540b, and 1540c), hingeably or rotatably coupled to one another to form an extended elongate configuration for use (FIG. 14) and to allow the assembly to be disassembled or broken down to a more compact or folded configuration for transport and storage. As shown in FIGS. 14 and 16, the segmented toy bar assembly 1530 includes a middle/center bar segment 1540b, a first outer or end bar segment 1540a pivotally or rotatably coupled to a first end 1542b of the middle bar segment 1540b, and a second end bar segment 1540c pivotally or rotatably coupled to a second outer or end 1544b (opposite the first end 1542b) of the middle bar segment 1540b. In some example embodiments, the segmented toy bar assembly may include two end bar segments rotatably or pivotally coupled to one another. In other example embodiments, the segmented toy bar assembly may include two end bar segments and two or more center bar segments rotatably or pivotally coupled to one another.
As shown in FIGS. 14 and 15, some example embodiments of the segmented toy bar assembly 1530 include two or more (a plurality of) internal bar or rod segments 1540 of or at least partially comprising a flexible and resilient material such as for example fiberglass, nylon, polyvinyl chloride (PVC), polymeric, metal, wood, composite, or other material(s) providing sufficient structural support and rigidity for anticipated loading, and having a sufficient degree of elasticity and internal resilience or shape memory to allow the bar or rod to be repeatedly flexed into an arcuate or curved shape, and released to return to a relatively straight configuration. In other example embodiments, the segments 1540 comprise a cross-sectional profile having a width and a thickness, wherein the width is generally greater than the thickness. For example, the width may be at least two times the thickness. Optionally, the toy bar assembly 1530 may also include a layer of padding or a sleeve 1520 applied over and around the internal bar or rod segments 1540, such as for example a tube or sleeve of flexible polyurethane or polyethylene foam or other resilient cushioning material. Optionally, an outer covering of fabric or other flexible material or coating may be provided over the padding. In some example embodiments, the fabric covering may be removable for washing, for example by means of a zipper, hook-and-loop fasteners, or other removable attachment means.
The toy bar assembly 1530 also includes one or more support feet 1590, or other means for attaching the toy bar assembly 1530 to for example the mat 20, at each end thereof, as shown in FIG. 15. In example form, the support foot 1590 comprises a foot adapter portion 1582 having a first end with a snap lock pin 1586 and a second, opposite end defining a buckle 1584 for receiving and releasably engaging the outer ends 1544a and 1544c of end bar segments 1540a and 1540c, respectively, as shown in FIGS. 17 and 18. In example embodiments, each of the outer ends 1544a and 1544c include a user-operable clip 1546 configured to cooperatively engage a catch or recess 1588 provided on the buckle end 1584. The support foot 1590 further includes a foot base portion having a sleeve portion 1592 including a snap lock pin receiver 1596 configured for receiving and releasably engaging the snap lock pin 1586. The foot base portion 1590 also includes a retention clip 1594 or other attachment feature for attaching the play mat 20 to the foot 1590 and thus the segmented toy bar assembly 1530. In some example embodiments, the toy bar assembly 1530 may be coupled or otherwise connected directly to the mat 20. For example, the play mat 20 may comprise selectively operable retention clips having a buckle portion similar to the buckle end 1584 for receiving and releasably retaining the outer ends 1544a and 1544c.
In the depicted embodiment, as shown in FIG. 16, the inner end 1544a of the first end bar segment 1540a comprises a male coupling which is hingeably coupled to the first end 1542a of the middle bar segment 1540b comprising a reciprocally configured female coupling for engaging the male coupling. Similarly, the inner end 1542c of the second end bar segment 1540c comprises a male coupling which is hingeably coupled to the second end 1544b of the middle bar segment 1540b comprising a reciprocally configured female coupling for engaging the male coupling. The end bar segments 1540a and 1540c are rotatably or hingeably coupled to the center bar segment 1540b to form an extended elongate configuration for use (FIGS. 14 and 15) and to allow the assembly to be folded into a more compact or folded configuration for transport and storage (FIG. 20). In example embodiments, the first end bar segment 1540a and second end bar segment 1540c are identical and/or interchangeable. In some example embodiments where more than one middle bar segments 1540b are provided, each middle bar segment may comprise female end coupling and/or male end coupling as needed to allow the toy bar assembly to fold or collapse from an extended configuration to a more compact folded configuration.
FIGS. 19A and 19B show detailed views of the hinged or pivotal connection between the end bar segment 1540c and the center bar segment 1540b. The female end 1542c of the end bar segment 1540c comprises a channel or spacing defined by a pair of retaining walls or flanges 1550′ and 1550″. The spacing between the retaining walls is configured to receive the male end 1544b of the middle bar segment 1540b. The retaining walls 1550′ and 1550″ include apertures or openings 1552′ and 1552″, respectively, configured to receive and retain hinge pins 1562′ and 1562″ extending from opposing sides of the male end 1544b of the middle bar segment 1540b. Accordingly, the end bar segment 1540c may be pivoted or hinged relative to the middle bar segment 1540b about an axial axis defined by the hinge pins 1562′ and 1562″. The retaining walls 1550′ and 1550″ further include locking holes or catches 1554′ and 1554″ configured to engage locking protrusions or elements 1564′ and 1564″ protruding from the male end 1544b of the middle bar segment 1540b. In example embodiments, the retaining walls 1550′, 1550″ are configured to resiliently deflect, for example outward, as they engage locking protrusions 1564′, 1564″. Conversely, the retaining walls may be deflected to disengage the locking protrusions from the locking catches to unlock the hinge and allow the bar segments to be folded relative to one another.
In example embodiments, the end bar segment 1540c may be pivoted about hinge pins 1562′, 1562″ until locking holes 1554′, 1554″ are aligned with and engaged around locking protrusions 1564′, 1564″. Optionally, the leading or engaging edges and/or surfaces of the retaining walls and/or locking protrusions may be chamfered and/or angled to assist in deflecting the retaining walls away from the locking protrusions during operation. In some example embodiments, both the retaining walls 1550′, 1550″ and the locking protrusions 1564′, 1564″ may be resiliently deformable. In other example embodiments, the locking pins 1564′ and 1564″ are spring-loaded or biased so that the locking pins can be depressed and moved out of the way of the retaining walls 1550′ and 1550″ but re-engage the locking holes 1554′ and 1554″ as the locking holes align with the locking pins when the end bar segment is fully opened or unfolded, for example such that the end bar segment 1540c is colinear to the center bar segment 1540b. In example embodiments, the end bar segment 1540a can be re-folded relative to the center bar segment 1540b by depressing the locking pins 1564′ and 1564″ to disengage the locking holes 1554′ and 1554″. Optionally, there may be more than one locking hole on each of the retaining walls 1550′, 1550″. For example, one set of locking holes may retain the bar segments in a fully open or extended (180°) configuration while a second set of locking holes may retain the bar segments in a closed or folded configuration. In example embodiments, the female end 1544a of the end bar segment 1540a and the male end 1542b of the middle bar segment 1540b are similarly configured and operable as the hinge connection or configuration between the female end 1542c of the end bar segment 1540c and the male end 1544b of the middle bar segment 1540b, respectively, as described herein.
FIGS. 21 and 22 show detailed views of an alternative hinged or pivotal connection configuration between an end bar segment and a center bar segment, for example between the end bar segment 1440a and the center bar segment 1440b. The inner end 1442a includes a channel or spacing defined by a pair of retaining walls or flanges 1450′ and 1450″. The spacing between the retaining walls is configured to receive the first end 1446 of the middle bar segment 1440b. The retaining walls 1450′ and 1450″ include apertures or openings 1452′ and 1452″, respectively, which are configured to receive and retain hinge pins 1462′ and 1462″ extending from opposing sides of the first end 1446 of the middle bar segment 1440b. Accordingly, the end bar segment 1440a may be pivoted or hinged about an axial axis defined by the hinge pins 1462′ and 1462″. The retaining walls 1450′ and 1450″ further include locking fingers or flanges 1454′ and 1454″ configured to engage locking or engagement members 1464′ and 1464″, respectively. In example embodiments, the locking members 1464′ and 1464″ and the locking flanges 1454′ and 1454″ are configured to resiliently deflect away as the locking flanges 1454′ and 1454″ contact and engage the locking members 1464′ and 1464″. Optionally, the leading or engaging edges and/or surfaces of the locking flanges and locking members may be chamfered or angled to assist in deflecting the locking members away from the locking flanges during operation. Optionally, either the locking members or the locking flanges may resiliently deform as they rotate about a common pivot point and engage one another. As shown in FIG. 18, when the end bar segment is fully opened or unfolded, for example such that the end bar segment 1440a is colinear to the center bar segment 1440b, the locking members 1464′ and 1464″ spring back and catch the non-leading edges (opposite the leading edges) of the locking flanges which prevents the end bar segment 1440a from being folded or closed unintentionally. In some example embodiments, the locking members 1464′ and 1464″ restrict the pivotal movement of the bar segments 1440a and 1440b to rotate in only one direction relative to one another (i.e., from 0° to 180°, but not beyond 180°). To re-fold or re-hinge the end bar segment 1440a relative to the center bar segment 1440b, the locking members 1464′ and 1464″ must be deflected or otherwise moved out of the way of the locking flanges 1454′ and 1454″. Optionally, the segmented toy bar assembly 14030 may further comprise releasable and/or fixed locking elements to retain the toy bar segments 1440a, 1440b in their extended (180°) positions and/or their folded positions. In some example embodiments, the hinges are configured for one-time use, to allow the toy bar assembly to be expanded and assembled after delivery to the end user, and thereafter remain fixed in the expanded configuration. In other example embodiments, the hinges are configured for repeated assembly and disassembly, allowing the end user to reconfigure the toy bar assembly between its expanded and compact configurations multiple times.
Preferably, the compact folded toy bar assembly 1530 according to the present disclosure may be contained within a reduced-size packaging envelope without flexing or bending of the toy bar segments 1540, allowing the toy bar assembly to be packaged more stably and securely, without the risk of unexpectedly expanding and escaping, or springing out of the packaging as with previously known packaging of toy bars. The reduced-size packaging envelope enabled by the segmented toy bar assembly of the present disclosure may thereby reduce packaging costs, reduce shipping costs, reduce storage space requirements, and improve the user's experience and convenience.
In example methods of use of toy bar assemblies according to example embodiments of the present disclosure, a toy bar assembly is provided for use in connection with a children's accessory such as a play gym or play mat. The toy bar may be provided to a user such as an adult caregiver of a child in a packaged state, with the toy bar in a compact configuration within a box or other package. The toy bar assembly includes two or more toy bar segments and at least one coupling between two adjacent toy bar segments. The user may remove the assembly from the package and extend the toy bar segments into an expanded configuration, for example with the toy bar segments extended in axial alignment to define an expanded length. The expanded toy bar assembly may be mounted to the mat or other play accessory, for example by flexing it into an arch configuration positioned over the play area and optionally connecting feet of the toy bar assembly to the play mat or other accessory. One or more toys or entertainment features may be suspended from the toy bar for interaction by a child. The coupling(s) between the toy bar segments allow(s) selective and controlled user reconfiguration of the toy bar assembly between the expanded configuration and a compact configuration. In its compact configuration, the toy bar assembly is configured to fit within a packaging envelope defined as the minimum dimension packaging space (not necessarily incorporating a physical package) within which the toy bar can be fit in its compact configuration. In example embodiments, the compact configuration packaging envelope defines a compact length substantially smaller than the expanded length of the toy bar assembly. In example embodiments, the compact length may be at least 25% less than the expanded length, and in particular embodiments at least 40% less, 50% less, or 75% less. Otherwise stated, in example embodiments, the compact length may be less than about 75% of the expanded length, and in particular embodiments less than about 60%, less than about 50%, or less than about 25% of the expanded length. In example embodiments, the toy bar assembly is packaged within a package with an interior space or volume defining the packaging envelope dimensions, with the toy bar segments in their compact configuration and fitting stably and securely within the packaging envelope without flexing, bending or otherwise deforming the toy bar segments. In some embodiments, the toy bar assembly may be set up and remain in its expanded configuration. In other embodiments, the toy bar assembly may be reconfigured repeatedly by setting up in its expanded configuration and taking down to its compact configuration for storage between uses.
While the invention has been described with reference to example embodiments, it will be understood by those skilled in the art that a variety of modifications, additions and deletions are within the scope of the invention, as defined by the following claims.
