1. Field of the Invention
The present invention is directed to the field of stuffed toys, in particular, a method, apparatus and kit for stuffing plush toys.
2. Description of the Related Art
Retail shops at which customers can make customized stuffed toys such as teddy bears are extremely popular. Such toys are also known in the toy trade as “plush.” At such retail shops customers choose from a variety of pre-made animal or character “skins,” which are the outer fabric casings of the plush toy comprised of fabric panels sewn together into the form of the animal or character and act as the container, which is formed into the full shape of the animal or character by being stuffed full of a soft, fluffy stuffing material. In essence, the skin is the plush toy absent the stuffing and decorative detailing. The customer also selects from a variety of facial features to be attached to the skin in the appropriate location after the skin is stuffed and choose from a variety of clothing and other accessories to complete the plush toy.
The focal point of the in-store manufacturing process is the stuffing machine. It is a large piece of heavy equipment that typically measures several feet in length, width, and height, and weighs hundreds of pounds. It is powered by a/c current that runs large motors, blowers and air compressors which, together, generate and direct significant air velocity and pressure needed to feed the stuffing from the machine, through an injection tube, and into the skin through a hole in the fabric of the skin. Once filled with stuffing, the skin is removed from the injection tube and the store employee closes the skin fill hole by tying shut laces around the hole, or by some other method of closure, which requires the skill of the store employees.
Due to the size and costs of the machine required for this method of stuffing a plush toy, it is too dangerous to be handled by customers, especially young children. Therefore, the customer merely passively watches, while the employee performs the entire manufacturing process.
Attempts have been made to reduce the size and cost of these stuffing machines to make them more portable and more suitable for the mass market, but the degree to which they can be reduced is restricted by the requirements of the large motors and compressors needed to generate sufficient pressure to fill the skins. Such machines also require skill and dexterity not possessed by young children.
There remained a need for a toy stuffing apparatus to be reduced to a size, price, and level of skill and safety that would allow them to be used at home by small children as an activity toy, or craft kit. The inventors' prior U.S. Pat. No. 7,377,841, the contents of which are hereby incorporated by reference, sets forth a mechanical apparatus for stuffing plush toys which can be used at home. This patent includes an apparatus having a top drum within which arms and paddles are rotated to fluff the plush toy stuffing and push the stuffing down into a chamber in which a simultaneously rotated auger, transports the stuffing along the auger shaft and out to an exit, and, in turn into the plush toy casing.
However, this apparatus has numerous parts and their configuration requires a certain size and internal volume to operate properly. Accordingly, there remained a need to have a simpler mechanical toy stuffing apparatus which has less parts and is smaller than the prior art apparatus and, therefore, easier and less expensive to manufacture. There also remained a need to have a mechanical toy stuffing apparatus that was simpler and easier to operate and eliminated the need to hold the plush casing onto the fill nozzle.
The prior art discloses different types of stuffing apparatus. However, so far as is known, none of the prior art devices resolve all of these problems in a simple, effective and yet highly advantageous manner as in the present invention discussed herein.
It is therefore an object of the invention to provide a novel toy stuffing apparatus.
It is also an object of the invention to provide a toy stuffing apparatus which is simpler and easier to use.
It is a further object of the invention to provide a toy stuffing apparatus wherein the user does not have to hold the stuffed toy casing on the end thereof, when stuffing.
It is yet another object of the invention to provide a toy stuffing apparatus which is simple, easy and inexpensive to manufacture and is comprised of fewer parts than the prior art devices.
Certain of the foregoing and related objects are readily attained according to the present invention by the provision of an apparatus for inserting stuffing into a casing, comprising a stuffing hopper defining an interior chamber therein, having an inlet for receiving stuffing and an outlet for discharging stuffing; an auger housing located below said stuffing hopper and defining an interior chamber therein, which is in communication with said interior chamber of said stuffing hopper, said auger housing having an inlet located adjacent to and in communication with said outlet of said stuffing hopper, and a discharge outlet to discharge the stuffing from said apparatus; means for feeding stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing, which means are located within said stuffing hopper; a rotatable auger located within said interior chamber of said auger housing to drive the stuffing in said interior chamber of said auger housing towards and to said discharge outlet thereof, where it, in turn, exits said auger housing into the casing; and drive means for rotating said auger.
Preferably, the apparatus further comprises an externally threaded nozzle connected to said auger housing adjacent said discharge outlet. In a preferred embodiment, said means for feeding stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing is a resilient bellows movable between a compressed configuration and an expanded configuration, received within said interior chamber of said stuffing hopper. It is also preferable that at least one of said stuffing hopper and said auger housing includes a transparent portion. In one embodiment, said stuffing hopper is transparent. Advantageously, the apparatus further comprises at least one transparent window in said auger housing.
It is preferred that the apparatus further comprises a removable lid receivable over said inlet of said stuffing hopper. Advantageously, said drive means is a manually-operable handle.
Certain of the foregoing and related objects are also readily attained according to the present invention by the provision of a kit for making a stuffed toy at home, comprising a casing having an opening therein; stuffing to be inserted into said casing; closure means for closing said opening in said casing; and an apparatus for inserting stuffing into said casing, comprising a stuffing hopper defining an interior chamber therein, having an inlet for receiving said stuffing and an outlet for discharging said stuffing; an auger housing located below said stuffing hopper and defining an interior chamber therein, which is in communication with said interior chamber of said stuffing hopper, said auger housing having an inlet located adjacent to and in communication with said outlet of said stuffing hopper, and a discharge outlet to discharge said stuffing from said apparatus; means for feeding said stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing, which means are located within said stuffing hopper; a rotatable auger located within said interior chamber of said auger housing to drive said stuffing in said interior chamber of said auger housing towards and to said discharge outlet thereof, where it in turn, exits said auger housing into said casing and drive means for rotating said auger.
Preferably, the apparatus further comprises an externally threaded nozzle connected to said auger housing adjacent said discharge outlet. Advantageously, said means for feeding stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing is a resilient bellows movable between a compressed configuration and an expanded configuration, received within said interior chamber of said stuffing hopper. It is preferable that at least one of said stuffing hopper and said auger housing includes a transparent portion. It is also preferred that a removable lid is receivable over said inlet of said stuffing hopper. Desirably, said drive means is a manually-operable handle.
In addition, certain of the foregoing and related objects are also readily attained according to the present invention by the provision of a method for making a stuffed toy comprising a casing having an opening therein, stuffing to be inserted into said casing, closure means for closing said opening in said casing and an apparatus for inserting stuffing into said casing, comprising a stuffing hopper defining an interior chamber therein, having with an inlet for receiving said stuffing and an outlet for discharging said stuffing; an auger housing located below said stuffing hopper and defining an interior chamber therein, which is in communication with said interior chamber of said stuffing hopper, said auger housing having an inlet located adjacent to and in communication with said outlet of said stuffing hopper, and a discharge outlet to discharge said stuffing from said apparatus; means for feeding said stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing, which means are located within said stuffing hopper; a rotatable auger located within said interior chamber of said auger housing to drive said stuffing in said interior chamber of said auger housing towards and to said discharge outlet, thereof, where it in turn, exits said auger housing into said casing; and drive means for rotating said auger; removing said means for feeding said stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing, from said stuffing hopper; inserting said stuffing into said interior chamber of said stuffing hopper; placing said means for feeding said stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing into said stuffing housing; affixing said opening of casing onto said discharge outlet of said auger housing; rotating said drive means to, in turn, rotate said auger, to feed said stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing and towards and out of said discharge outlet of said auger housing and into said casing; removing said casing from said apparatus; and closing said opening of said casing via said closure means.
It is preferred that the apparatus include an externally threaded nozzle connected to said auger housing adjacent said discharge outlet. It is also preferable that said means for feeding stuffing from said interior chamber of said stuffing hopper into said interior chamber of said auger housing is a resilient bellows movable between a compressed configuration and an expanded configuration, received within said interior chamber of said stuffing hopper. Desirably, the apparatus further comprises a removable lid receivable over said inlet of said stuffing hopper. It is also advantageous that said drive means is a manually-operable handle.
Other objects and features of the present invention will become apparent from the detailed description considered in connection with the accompanying drawings, which disclose several embodiments of the invention. It is to be understood that the drawings are to be used for the purpose of illustration only and not as a definition of the limits of the invention.
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It is preferred that bellows 40 has a diameter slightly less than the diameter of the cylindrically-shaped interior chamber of stuffing hopper 14, to allow for it to expand downwardly to its open and expanded configuration due to its resilient nature and, conversely, be resiliently compressed when in contact with stuffing 200. It is also preferred that plunger 42 has a diameter which is less than the diameter of bellows 40 and is tapered on its lower end thereof, to feed stuffing 200 downwardly in the interior chamber of stuffing hopper 14 and subsequently into auger housing 16.
Lid 38 is removably affixed to inlet 36 of stuffing hopper 14, such as by corresponding screw threads (not shown). However, other means to affix cap 38 can be utilized such as by a snap or press fit. As an alternative to the preferred embodiment, bellows 40 and lid 38 are separate unattached components.
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Auger housing 16 also encloses a corkscrew-like, rotatable auger 24. Auger 24 is centrally positioned within the interior chamber of auger housing 16 in order to, when rotated, move stuffing 200 in the interior chamber of auger housing 16, towards discharge outlet 26 and, subsequently, into toy casing 100, as shown in
Auger 24 is attached to drive means for rotating auger 24. As seen in
In the preferred embodiment, auger housing 16 also includes a nozzle 28, as seen in FIGS. 1 and 3-6. Nozzle 28 is preferably tapered on its outer end and has external screw threads 29. However, other suitable nozzle configurations and shapes can be utilized, such as one having an arrow shape or one having a larger-sized outer end and a narrower inner neck portion, to allow the casing 100 to be placed over the larger end and held to the narrower neck in order to prevent the casing from easily coming off during stuffing.
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While there have been shown and described novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the method steps described, the devices illustrated, and the operation thereof, 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. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.
Particularly, while the stuffed toy casing has been illustrated in the shape of a rabbit, it can assume any other shape such as, for example a teddy bear or dog. Moreover, although the window and stuffing hopper have been illustrated as being transparent, they can be fully or partially transparent or opaque. Additionally, the number and location of the windows can be altered. Furthermore, the shape of the nozzle can be modified and the device may include other mechanical means for securing the casing to the nozzle.
This application claims benefit from U.S. Provisional Patent Application Ser. No. 61/519,988, filed Jun. 3, 2011, the contents of which are hereby incorporated by reference.
Number | Date | Country | |
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61519988 | Jun 2011 | US |