Note: Descriptions are shown in the official language in which they were submitted.
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Figure and a Composition for Forming the Figure
Field of the Invention
[0001] 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
[0002] 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.
[0003] 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
[0004] 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 took 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
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characteristics are that the toy figure material is easily paintable and
significantly more
resistant to dyes(color migration).
[0005] 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.
[0006] 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
[0007] FIG. I illustrates a perspective view of an embodiment of a figure
according to the
invention.
[0008] FIG. 2 illustrates a cross-sectional plan view of a portion of a
component of the
figure illustrated in FIG. I taken along the line "2-2."
[0009] FIG. 3 illustrates a cross-sectional plan view of another portion of
the component of
the figure illustrated in FIG. I taken along the line "3-3."
[0010] Like reference numerals have been used to identify like elements
throughout this
disclosure.
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Detailed Description of the Invention
[0011] 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.
[0012] Referring to FIG. 1, an exemplary embodiment of a toy figure is
illustrated. In this
embodiment, the toy figure 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 figure 10
are solid
pieces of material. As illustrated in FIG. 1, the thickness of the different
parts or components
of the toy figure 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
figure 10 often present molding challenges. The components of the toy figure
10 can be
referred to alternatively as thick-walled components.
[0013] Referring to FIG. 2, a cross-sectional view of leg 18 of toy figure 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 "d l" and "d2" at this location of the leg 18 can vary.
[00141 Referring to FIG. 3, another cross-sectional view of leg 18 of toy
figure 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 "d 1." In
addition, the leg
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18 has a fourth dimension "d4" extending along the same direction as dimension
"d2." In
this embodiment, dimension "d3" is shorter than dimension "dl" and dimension
"d4" is
shorter than dimension "d2." Notable however is the fact that the leg 18 is
solid at both
cross-sectional locations.
[0015] 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.
[0016] Typically, molding involves forming parts that have an even wall
thickness, which
the parts of the toy figure 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.
[0017] 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
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"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.
[0018] To minimize this effect, there are several techniques available. One
technique is
that large flow channels, including the sprue, the tanner 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.
[0019] In one embodiment, the toy figure 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 figure 10 is based on the particular
material that is used
to form the toy figure 10.
[0020] According to the invention, the toy figure 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.
[0021] Another characteristic or feature of the toy figure 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.
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[0022] Another characteristic or feature of the toy figure 10 is the relative
weight of the toy
figure 10. In one embodiment, the toy figure 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 figure 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 figure 10 with a stronger, more substantial feeling which is
characteristic of
porcelain material. Thus, the molded material has a desired range of specific
gravity.
[0023] Another alternative characteristic or feature of the toy figure 10 is
that the toy figure
be paintable. In other words, for toy figure 10, it is desired that the molded
material be
easily paintable so that color can be added to the toy figure 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 figure 10 can be
painted
directly, which results in cost and time savings.
[0024] While several of the desired characteristics described above are based
on the toy
figure 10 appearing to be made of porcelain, the composition of the molded
portions of the
toy figure 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
figure 10.
[0025] The toy figure 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
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acrylonitrile, about 5 - 30 percent weight butadiene, and about 40 - 60
percent weight styrene.
Molded materials that include ABS are easily paintable.
[0026] 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
figure 10 does
not include any glass filler material. The lack of glass filler material is
acceptable for toy
figure 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 figure 10 as
discussed in greater detail below.
[0027] 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 figure 10.
[0028] In one exemplary method of making the toy figure 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 figure 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.
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[0029] 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 figure 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.
[0030] The main components of the material used to form the body of the toy
figure 10 are
ABS and barium sulfate. In addition or alternatively, the material can also be
used to form
the eyes of the doll or toy figure 10 or a different figure as well. 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.
[0031] 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.
[0032] In a preferred embodiment, the composition includes about 40 - 45
weight percent
barium sulfate, about 50 weight percent ABS, and the remainder is viscosity
modifiers, flow
agents, and pigments.
[0033] As mentioned above, the specific gravity of the toy figure 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
figure 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
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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 figure 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.
[0034] 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.
[0035] In an alternative embodiment, the toy figure can be a single piece of
material and
formed using a single molded piece of material.
[0036] 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
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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.
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