WO1998004360A1

WO1998004360A1 - Process for manufacturing a flocked toy

Info

Publication number: WO1998004360A1
Application number: PCT/IB1997/001036
Authority: WO
Inventors: Kwang Dong Yoon
Original assignee: Lanka Novelties (Pvt) Ltd.
Priority date: 1996-07-29
Filing date: 1997-07-29
Publication date: 1998-02-05
Also published as: AU3860097A

Abstract

A process for manufacturing a plush toy animal having a realistic texture and appearance. The process includes forming a component of the plush toy animal in a mold and applying an adhesive thereto. A flocking agent is then applied so that the flocking material adheres to the component. The flocked component is thereafter painted and may be attached to a corresponding plush animal body.

Description

PROCESS FOR MANUFACTURING A FLOCKED TOY

BACKGROUND OF THE INVENTION

I. Field of the Invention

This invention broadly relates to plush toys and to a process for manufacturing the same. More particularly, the present invention pertains to a process of manufacturing a flocked plush toy having a realistic feel and appearance. Most particularly this invention relates to a technique for manufacturing flocked components or portions of stuffed toy animals and for incorporating the flocked components on plush toy animal bodies to provide for a plush toy animal having an unusually realistic feel and appearance.

II. Description of the Related Art

Stuffed toys and, in particular, stuffed toy animals have existed for many years and are often loved, adored and, in many circumstances, considered as friends, "pals" and playmates by their owners who, in most instances, are children. Child owners will typically cuddle and sleep with such toys and use them in a variety of imaginative or "make-believe" games. Due to the traditional beloved nature of such stuffed toy animals in the minds and hearts of their child owners, such toys are typically manufactured of a plush or furry-like skin, which is then filled with a stuffing agent to add fullness to the plush toy animal so that the resulting toy is "cuddly" and soft, thus making it more desirable to children. The heads and faces as well as extremities of known existing plush toy animals are typically constructed of the same material as the body and the facial features are then held or attached together by sewing or glue.

A significant deficiency of existing plush toy animals is that they do not appear or feel realistic; that is, they do not resemble, visually and/or texturally, the actual animals on which they are modelled. For example, in many species of animals the majority of the animals' bodies are covered with thick fur whereas other regions are covered with a fuzzy or fine-hair layer which. in many instances, are skin-like in both texture and appearance. Fine-hair covered regions are typically found on the face, hands/feet and perhaps chest of a gorilla, with the remainder of the animal being covered with a thick hair or fur. Likewise, the head of an elephant is fine-haired compared to the rest of its body, which may be fur covered. Fine-haired faces are also present in a variety of other animals such, for example, as various species of dogs, etc.

A "fine-haired" layer which is realistic in both texture and appearance, however, has heretofore been technologically and economically difficult to achieve. Nevertheless, there exists a need for such a fine-haired surface in plush toy animals because oftentimes consumers desire plush toys that are as realistic as possible. For example, consumers may wish to purchase a plush toy elephant that looks and feels like the "real thing", i.e. a real elephant.

Although there exist a few plush toy animals in the market that have a somewhat realistic appearance, such appearance is typically derived or accomplished by manufacturing the animals' faces and other extremities (i.e. paws) from a hard plastic or the like and then incorporating these elements onto a plush toy body. As can be appreciated, the use of hard components on such plush toys decreases their desirability in the minds of children because the plush toys are not as cuddly as other toy animals that have a complete soft or plush composition.

Accordingly, it is an object of the present invention to provide a process for manufacturing soft plush toy animals which are unusually realistic in appearance and texture.

It is also an object of the present invention to provide a method of manufacturing traditionally fine-haired components of plush toy animals that are realistic in texture and appearance and that can be easily incorporated in plush toy animal bodies.

It is a further object of the present invention to provide a plush toy animal having flocked components or features that closely resemble, in both texture and appearance, the fine- haired regions or areas of the real life animal on which the toy animal is modelled. SϋMMARY OF THE INVENTION

The present invention is directed to a process for manufacturing stuffed toys and, in particular, fine-haired component parts of stuffed toy animals that are realistic in both texture and appearance with respect to the corresponding component parts of the actual animals on which the stuffed toy animals are based or modelled. The inventive process begins with the molding of a component portion of the toy animal, i.e. the head or face, by applying a moldable material to a mold. Select portions of the molded component are then covered with an adhesive agent, and a flocking agent is next applied thereto so that the select portions of the molded component are covered with the flocking agent. Once the adhesive dries, thereby firmly attaching the flocking agent to the select portions of the molded component, the finished component is painted, filled with a stuffing agent and attached to a stuffed toy animal body.

In a preferred embodiment, other features or elements are attached to the component. Also in the preferred embodiment, the finished component is attached to a plush toy animal body.

The present invention is also directed to a process for manufacturing a stuffed toy skin having a realistically fuzzy and soft texture. The process includes the steps of (a) molding a skin of the stuffed toy by applying a moldable material to a mold, (b) applying an adhesive to select portions of the molded skin,

(c) applying a flocking agent to the adhesive covered skin, and

(d) painting the flocked, covered skin.

Other objects and features of the present invention will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for purposes of illustration and not as a definition of the limits of the invention, for which reference should be made to the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings, wherein like reference numerals denote similar elements throughout the several views:

FIG. 1 is a flow chart depicting the various steps of a process for manufacturing a realistic plush animal toy in accordance with the present invention;

FIG. 2 depicts a first step of the inventive process;

FIG. 3 depicts a second step in accordance with the present invention;

FIG. 4 depicts a third step in accordance with the present inventive process;

FIG. 5 depicts a fourth step in accordance with the present invention;

FIG. 6 depicts an optional additional step in accordance with the present invention; and FIG. 7 depicts the final step in accordance with the inventive process.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

With reference now to the drawings, and initially to FIG. 1 thereof, a flow chart or schematic representation of a process 10 for manufacturing a plush toy animal having a realistic feel and appearance is there shown. The process is described herein in the context of manufacturing a plush toy animal and, specifically, component portions of plush toy animals that are typically "fine-haired" so that a realistic appearance and "fuzzy" texture results. As used herein, the terms "fine-hair" and "fine- haired" are intended to describe or denote a component or area or region of an animal body which is not typically covered with thick hair or fur but, rather, with a very fine or short hair layer that has a fuzzy texture, similar to the surface of a peach, such, for example, as the face and hands of a gorilla or the head of an elephant. Although the inventive process is described herein in the context of manufacturing a plush toy animal, it will be readily appreciated by those having ordinary skill in the art that the process may likewise be employed in the manufacture of plush toys simulating or consisting of other and inanimate objects such as cars, balls, etc.

Step one of the inventive process 10, which corresponds to block 12 in FIG. 1, consists of molding a particular component part corresponding to a fine-haired area of an actual animal from which a toy animal is modelled. In the context of a plush toy animal, the component part may comprise, for example, an animal's head or face, and/or the animal's extremities such as its paws, hands, feet, tail, tusks, etc. The mold is preferably constructed of a plaster-type material, although other molding materials such as metals may be used without departing from the scope or spirit of the present invention. Step one of the process is performed by pouring into or otherwise filling the mold with a soft, resilient and moldable type of material which, in the preferred embodiment, is latex rubber. The resulting molded component may, as is currently performed, have the form of a relatively thin, flexible and contoured skin or shell.

After step one of the process is performed and the molded component has set and, preferably, been removed from the mold, an adhesive material is applied to the component, as shown at block 14 of FIG. 1. In the preferred embodiment, suitable adhesives are various glues and epoxies which react well with the molded material, e.g. latex rubber. The adhesive agent can be brushed on or, in the preferred embodiment, sprayed on using an air powered spray gun or the like, so as to ensure a uniform application (as is generally desired) of the adhesive to the molded component. Although it is generally contemplated that the adhesive will be substantially uniformly applied over the entire surface of the molded component, particular plush simulations may be more realistic if the adhesive is applied to only selected portions or areas of the molded component and/or in a non-uniform manner.

After the adhesive has been applied to the molded component, a flocking material or agent is sprinkled thereover. The flocking agent may be a fur or dust powder that is preferably hypoallergenic and which, most preferably, is non-flammable. Suitable materials for the flocking agent are nylon powder and synthesis powder. The application of the flocking agent is depicted at block 16 in FIG. 1. After the flocking agent has been applied to the adhesive-covered, molded component, the component is preferably set aside for a short or otherwise sufficient time to allow the adhesive and flocking agent to dry or set. The resulting component has a very thin fine-haired layer with a fuzzy texture that is unusually closely simulative of the fine-haired surface portions of real-life animals.

The next step of the process is then performed (block 18) in which the fine-haired layer component is generally painted, preferably with paint (s) having a color or combination of colors commonly associated with a particular animal. For enhanced realism, the painting may be effected using an airbrush. Of course, it is also contemplated that, in some situations, it may be desirable or sufficient to employ flocking agents of various colors that do not require subsequent painting to impart a realistic appearance; in such cases, the painting step may be omitted. In any event, once the component has been appropriately painted it may then be attached to a plush toy body (block 20 of FIG. 1) by sewing or other suitable attachment techniques as are known to those having ordinary skill in the art. The resulting component has a fine-haired and skin-like textured surface which is significantly more realistic in both appearance and texture than heretofore known plush toys.

FIGS. 2-7 further illustrate the inventive method described in conjunction with FIG. 1 for forming the head of a plush toy animal and, specifically, an elephant head. As shown in FIG. 2, a mold 22 having a cavity 24 formed therein in the shape and contoured in the manner of an elephant's head is prepared. Mold 22 may, as pointed out above, be formed from a plaster type material although other known materials such as various metals, etc. can be readily substituted by those having ordinary skill in the art. A mouth or opening 26 is formed in mold 22 through which the moldable material, e.g. latex rubber, is poured into the cavity 24. With reference now to FIG. 3, after an appropriate time sufficient to permit setting of the molding material, the component 30, in the shape of a toy elephant's head, is removed from mold 22 and an adhesive material 32, such as a glue, epoxy. etc. , is applied to the surface of component 30. The adhesive may for example be applied through a hose or nozzle 32 and may, depending upon the animal or object being simulated and as a matter of design choice, cover the entire surface or only select portions of the component 30. Thus, the article 30 can be sprayed or lightly doused or coated, via brushing or spraying, with the adhesive material 32 so long as at least the portion intended to be provided with the fine-haired texture and appearance in accordance with the invention is substantially covered with the adhesive.

Once so covered, and with reference to FIG. 4, the article 30 is then doused with a flocking agent 36 which is preferably sprinkled or dispensed from a shaker element 38 such as a can or other container having holes through which the particular flocking agent can pass. As will be appreciated, the flocking agent — which, as described above, is preferably a furlike powder material — readily adheres to and is retained by the adhesive coated component 30. The resulting component 30 carries on its surface a fine-hair layer 39 having a fuzzy texture which is significantly skin-like in both texture and appearance and, thus, is closely simulative of the appearance and texture of the fine-hair area of the actual animal on which the particular component is modelled. When the component 30 is thus complete, and as shown in FIG. 5, paint 41 may be applied thereto using any known technique, such as by brushing and/or spraying (i.e. airbrushing) from a nozzle 40.

With reference now to FIG. 6, although the component 30 is now complete it may be further enhanced through the addition of various features and elements which may by way of example be similarly manufactured using the above-described process. For example, in the disclosed plush toy in which the component 30 is an elephant's head, tusks 42 may be separately formed in a differently-configured mold 22 using the same process described in FIG. 1, and then attached to the finished component 30 via sewing or glue, etc.

The painted component 30 (with or without additional attachments) can then be filled with a stuffing agent (not shown) such as polystyrene pellets or other commonly used stuffing material and, either before or after or concurrently with such stuffing, attached to a stuffed plush toy body 44 which, in the present instance, is in the general form of an elephant's body. The finished article 30 may be attached to body 44 in any appropriate manner known to those of ordinary skill in the art but such attachment is preferably effected by sewing the component 30 to the body. Additional bodily extremities such as a tail 46 and feet 48 may be likewise secured to the body. As with tusk 42, the tail and feet can be formed using the inventive process described in conjunction with FIG. 1, thereby resulting in an unusually realistic plush toy elephant having furry, fine-haired or skin- textured components, i.e. head and feet (and, optionally other extremities) . The plush toy thus prepared is a notable improvement over the prior art in that its fine-haired components are far more realistic and life-like in both appearance and texture.

Although the above described inventive process and the article resulting therefrom are described in conjunction with a specific method in which a component part 30 is separately or individually formed and then attached to the remainder of a toy animal, e.g. a toy animal body, it will be readily appreciated by those of ordinary skill in the art that the inventive process may likewise be employed to manufacture a unitary and complete plush toy in lieu of only a component, and that the process is moreover not limited to plush toy animals but may be used to manufacture inanimate toys such, for example, as cars, balls, etc.

Thus, while there have shown and described and pointed out fundamental novel features of the invention as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of the method and devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.

Claims

CLAIMS I claim:

1. A process for manufacturing a fine-hair component portion of a plush toy animal having a substantially realistic appearance and texture closely simulative of the appearance and texture of a corresponding component portion of an actual animal on which the plush toy is modelled, comprising the steps of:

(a) molding the component portion by applying a moldable material to a mold; (b) applying an adhesive to select surface areas of the molded component; and

(c) applying a flocking agent to the select surface areas to which the adhesive has been applied to provide a flocked, fine-hair component bearing a surface having a substantially fuzzy texture and an appearance closely and realistically simulating the corresponding component portion of the actual animal on which the plush toy is modelled.

2. The process of claim 1, further comprising the step of painting the flocked, fine-hair component to further enhance its fuzzy texture and realistic appearance.

3. The process of claim 2, further comprising the step of filling the painted, flocked, fine-hair component with a stuffing agent and attaching it to a plush toy animal body.

4. The process of claim 1, further comprising the step of filling the flocked, fine-hair component with a stuffing agent and attaching it to a plush toy animal body.

5. The process of claim 1, wherein the moldable material is latex rubber.

6. The process of claim 5, wherein the mold is constructed of a plaster material.

7. The process of claim 1, wherein the mold is constructed of a plaster material.

8. The process of claim 1, wherein said adhesive applying step further comprises substantially covering the component with said adhesive and wherein said flocking applying step further comprises substantially covering the adhesive covered component with the flocking agent.

9. The process of claim 8, further comprising the step of filling the flocked, fine-hair component with a stuffing agent and attaching it to a plush toy animal body.

10. The process of claim 1, wherein said flocking applying step is performed by showering the flocking agent from a shaker onto the adhesive covered select surface areas of the component.

11. The process of claim 9, wherein said flocking applying step is performed by showering the flocking agent from a shaker onto the adhesive covered select surface areas of the component.

12. The process of claim 1 , further comprising the step of attaching features commonly associated with the plush toy animal to the component.

13. A process for manufacturing a stuffed toy skin having a fine-hair and soft texture, comprising the steps of:

(a) molding a skin of the stuffed toy by applying a moldable material to a mold;

(b) applying an adhesive to select surface areas of the molded skin; and

(c) applying a flocking agent to the select surface areas to which the adhesive has been applied to provide a flocked, fine-haired component bearing a surface having a substantially fuzzy texture and appearance.

14. The process of claim 13, further comprising the step of painting the flocked, covered skin to further enhance its fuzzy texture and appearance.

15. The process of claim 13, wherein the moldable material is latex rubber.

16. The process of claim 13, wherein the mold is constructed of a plaster material.

17. The process of claim 13, further comprising the step of filling the flocked skin with a stuffing agent.

18. The process of claim 13, wherein said adhesive applying step further comprises substantially covering the skin with said adhesive and wherein said flocking applying step further comprises substantially covering the adhesive covered skin with the flocking agent.