Smoke generator with combined spacer and wetting wire and toy smoke-ring gun using same

[0002] This application is a continuation-in-part of U.S. application Ser. No. 09/732,508 filed on Dec. 7, 2000 now U.S. Pat. No. 6,421,502.

[0003] The invention generally relates to apparatus for producing smoke, steam or fog, and more particularly, to a toy gun that produces one or more traveling smoke rings when fired.

[0004] Various toys are known that utilize smoke, steam, and fog (herein, collectively, “smoke”) generators, and a variety of generators for producing smoke for toys, theatrical productions, and the like are also known. See, e.g., U.S. Pat. No. 3,891,826. Liquid mixtures specifically designed for use in such generators are also known. See, e.g., U.S. Pat. No. 3,342,746.

[0005] Toy guns have captured the popular imagination for many years. Metcalf, E. W. and Maresca, F., Ray Gun(1999) Fotofolio, Inc., New York, N.Y. is devoted to one type of toy gun, a ray gun. In particular, smoke-producing toy guns are known. U.S. Pat. No. 2,855,714 describes a toy gun that produces smoke rings through the detonation of percussive caps within the gun casing.

[0006] While the visual effects and realism of smoke-producing toy guns are significant advantages, a number of drawbacks have limited their commercialization. For example, many prior smoke generators for toys employ mixtures that are not always completely safe. In particular, many oils and oil-based mixtures for making smoke have not been approved for human use. Children may be especially prone to injury from exposure to or mishandling of such fluids, or to heaters used to vaporize liquids to make smoke.

[0007] Many prior generators, such as those employed in model railroads, have an open smoke producing device, usually a chimney on an engine, that operates continuously. This arrangement is not conducive to producing smoke rings. It also can be sensitive to orientation—a smoke generator for a fixed, upright smokestack on a model train may not function, or function well, when used in a toy that may assume orientation other than upright. Further, continuous smoke production and the power requirements of such production also militate against the portability of the toy or other device using smoke.

[0008] Prior toy guns have used detonation of percussion caps to make smoke. This arrangement is portable and does not require electrical power, but it clearly may not be suitable for use by or near children because of the harmful percussion cap explosions. Percussion caps also produce the noise of a cap explosion, which may be a negative attribute to many.

[0009] U.S. Pat. No. 3,342,746 to Seuthe discloses oil-based fluids and a generator for producing smoke. As noted above, such fluids may not be completely without adverse health reactions, particularly when used in closed rooms. In particular, exposure to such fluids in aerosol form can produce significant eye, nose and throat discomfort.

[0010] A later Seuthe patent, U.S. Pat. No. 3,891,826, describes a smoke generator that relies on a capillary action to draw the liquid from a central, open-top reservior to a heated region where it vaporizes to provide a smoke or fog. Such generators require an upright orientation for optimal use (due to the effect of gravity on a capillary action that feeds fluid to a resistance heater) and to avoid fluid loss, e.g., due to an outflow from the fluid reservoir. Also, use of electrical resistance wires or coiled wires in many prior generators to vaporize a fluid has presented unacceptable power requirements for portable devices operated with batteries. With model railroads, in contrast, power is typically supplied by household electrical current through a step-down transformer. Further, the narrow clearances and related manufacturing requirements make the Seuthe generator comparatively difficult to manufacture.

[0011] It is therefore a principal object of this invention to provide a smoke generator that is portable, safe, fast-acting for non-continuous operation, has comparatively low power requirements, and is substantially orientation insensitive.

[0012] Another principal object of this invention is to provide a portable, battery-powered smoke-ring gun that uses electrical resistance heating to produce the smoke and a mechanical heater accessory that significantly enhances the efficiency and volume of the smoke production.

[0013] A further object is to provide a smoke ring gun with the foregoing advantages of the smoke generator of the present invention that also has a favorable cost of manufacture.

[0014] A still further object is to provide a smoke ring gun with the foregoing advantages that can generate smoke from a water-based liquid.

[0015] The present invention provides apparatus for producing smoke and a toy gun that fires to produce smoke in a traveling ring shape, and in particular is capable of producing a succession of smoke rings traveling from the gun in its direction of aim. A particular toy gun includes a smoke chamber fed by an electrical resistance smoke producing generator. The chamber has an elastic, edge-mounted diaphragm, or equivalent moveable member, that co-acts with the chamber and an outlet orifice formed in a front wall of the chamber to produce the smoke rings. The smoke generator used in the gun is preferably the smoke generator of the present invention. The generator and toy gun can operate with water-based smoke-producing liquids.

[0016] The invention includes a smoke generator that includes:

[0017] a) a supply tank that holds the liquid,

[0018] b) a source of variable fluid pressure (e.g. air) in sealed fluid communciation with the supply tank for increasing and decreasing fluid pressure in the tank to feed the liquid to and from a heating unit;

[0019] c) a first tube with a first end entering into the supply tank, and a second smoke outlet end;

[0020] d) a heater positioned at least partially within the first tube for vaporizing the pressurized liquid driven by an increase in the pressure into a narrow annular region between the heating element and the surrounding tube; and

[0021] e) a spacer that secures a generally uniform radial spacing along the annular region between the outer-surface of the heater and the inner surface of the first tube.

[0022] The spacing is such that the pressure increase feeds the fluid to a region adjacent the heater on rapid vaporization, but does not usually overflow the tube, or have a sufficient thermal mass that rapid vaporization of the liquid is difficult. Typically, the heater is an electrical resistance wire that is coiled. When used in a toy gun of the present invention, the variable fluid pressure source is preferably a bulb made from a pliable material, such as rubber, or the like.

[0023] The resistance coil is preferably sealed within a heat conductive tube, e.g., a glass tube. In most invention embodiments, the heating element will be suspended in the first tube, usually by means of one or more lead wires to the electrical resistance wire. Also in the preferred form, a second metal tube concentrically surrounds the first tube for mechanical protection and insulation. Overflow and condensate that flow to the bottom of the generator are drained to a closed collection compartment.

[0024] A spacer, preferably in the form of a wire that is spiral wrapped around the glass envelope of the heater, maintains a generally uniform, circumferential spacing between the glass envelope and the surrounding first tube. The diameter of the wire is in the range of about 25 to about 75% of the width of the annular gap when the heater is centered in the first tube. For a circumferentially uniform gap of about 0.004 inch (measured radially), the wire preferably has a diameter of about 0.002 inch. The width should also be sufficient not only to control the uniformity of the spacing, but also to force the fluid flowing over the heater to follow a generally helical, or upwardly swirling, flow path. The combination of even radial spacing, an increased flow path over the heater, and it is believed, the turbulence in the fluid flow created by the presence of the wire in the flow path, all combine to increase the efficiency and volume of smoke production, other factors being constant.

[0025] The wire provides some degree of lateral position control through its physical presence in the gap and, in part, through a degree of movement due to the inherent spring action of the wire. The wire is formed of a material that is non-corrosive in the smoke generation environment. Stainless steel is preferred. The wire preferably has a circular cross-section.

[0026] This “wetting wire” preferably has from 2 to 36 turns with a diameter of a few mils wrapped over an axial length of about one inch, e.g., for a smoke ring gun application. Preferably there are 12 to 14 turns with the wire diameter about half the radial spacing. The wetting wire is secured axially by any convenient mechanical expedient to surround the heater coil within the envelope, and preferably extending for a distance below it. Preferably, the upper end of the wire is directed down over the outer surface of the first tube and clamped by an O-ring. The lower end of the wetting wire is wrapped onto the lower electrical lead for the heating coil.

[0027] The glass envelope of the heater is preferably formed of a cylinder of glass sealed at its ends with a high-temperature epoxy plug. Lead wires to the heater coil pass through, and are secured by, the plugs.

[0028] In a preferred embodiment, the smoke generator is positioned below and in fluid communication with the first smoke chamber of a toy smoke ring gun. Also, the smoke generator is actuated by 1) an electrical on-off switch that controls the flow of current from a battery or batteries, preferably secured in a handle or grip portion of the gun body, to the electrical resistance wire, and 2) a variable pressure liquid supplier, e.g. a flexible rubber bulb that is squeezed by the user to create a positive air pressure in a liquid supply tank, thereby forcing smoke liquid to the heater. Typically, this produces an instant burst of smoke filling the smoke chamber. When the pressurized fluid supplier is disengaged (released), negative pressure is delivered to the tank, which in turn clears all, or most, of the smoke liquid from the generator.

[0029] The invention also provides a toy gun that includes at least one and preferably all of the following components:

[0030] a) gun body,

[0031] b) a smoke chamber at one end of the gun body and having spaced apart front and rear walls and a side wall,

[0032] c) a member movable axially to form pressure waves within the smoke chamber forming at least a portion of said rear wall,

[0033] d) an orifice in said front wall,

[0034] e) a smoke generator operably coupled to the smoke chamber of the type described in summary form above; and

[0035] f) an actuator, preferably an elongated member mounted in the gun body for an axial sliding movement and spring-driven toward a forward position where it strikes the diaphragm to create a pressure wave inside the smoke chamber that interacts with the orifice to produce a traveling smoke ring.

[0036] The smoke generator is battery-powered and has an electrical resistance heater that vaporizes a portion of a liquid from a supply of the liquid carried in the gun. The movable member is preferably a latex rubber sheet of generally circular configuration, but is edge-mounted, preferably with a low tension across the sheet. The actuator head is preferably rigid. The drive-spring is preferably adjustable to vary the strike force of the actuator on the diaphragm. The actuator is operatively coupled to a trigger that cocks, and then releases, the actuator to move under the forces of the compressed spring. The smoke generator preferably uses a flexible bulb, activated by a second trigger as a hand grip, to produce smoke for the smoke chamber. A light source is provided in the smoke chamber. It can be actuated by the same switch that powers the smoke generator, although in other embodiments the light source may be controlled by a separate switch.

[0037] Still other features, advantages and aspects of the present invention will become more apparent from a description of illustrative embodiments hereinafter, when read in conjunction with the drawings of which:

[0038] FIG. 1 is a view in side elevation, showing a toy smoke-ring gun according to the present invention, and a succession of traveling smoke rings produced by the gun;.

[0039] FIG. 2 is a view in vertical cross-section of a preferred embodiment of a smoke-ring gun according to the present invention;

[0040] FIG. 3 is an enlarged view in vertical cross-section of the smoke generator shown in FIG. 2;

[0041] FIG. 4 is a detailed view in vertical section corresponding to FIG. 3 showing an alternative form of a smoke-generator according to the present invention; and

[0042] FIG. 5 is a detailed view in vertical section of a portion of an alternative improved smoke generator of the type shown in FIGS. 2-4 and including a spacer and wetting wire wrapped on the heater envelope.

[0043] FIGS. 1-3 show a toy smoke-ring gun 10 according to the present invention and a succession of smoke rings 12 produced by the gun 10. The rings 12 are ejected from a smoke collection chamber 14 located at the front of the gun 10 and secured, e.g. by a set of struts 11, on a gun body 16. The rings travel axially in the direction of arrow 18. In the preferred form shown, the gun 10 is in the form of a pistol with a hand grip 20 and a trigger 22. As will be described below, the form, number and speed of the smoke rings are all adjustable. Smoke is produced by a user of the gun on demand to fill the chamber 14. Rings can be generated automatically, but preferably one ring is produced with each pull of the trigger 22 provided that there is sufficient smoke accumulated in the chamber 14. The gun 10 is preferably powered by batteries 24. The operation of the gun 10 is invariant to its orientation. It can be placed on its side when not in use without spilling a liquid supply held in a tank 32 and vaporized in small volumes to create the smoke. However, when not in use, in its presently preferred form shown in FIGS. 2 and 3, the gun 10 rests on a flat-bottomed base 28 found at the bottom of the hand grip 20 and serving as a holding compartment for multiple batteries 24. The weight of the batteries, and the configuration of the base, provide a stable support for the gun 10 when it is not in use.

[0044] A central feature of the present invention is an on-demand, battery-powered, orientation-insenstiive, smoke generator 30 shown in detail in FIG. 3, and in an alternative form, in FIG. 4 (like parts being marked with the same reference number in both figures). The smoke-ring generator 30 includes the tank 32 that holds a supply of a liquid 34 to be vaporized, an air-filled rubber bulb 36 to pump the liquid to a heating region, and a heater 38, preferably one using an electrical resistance heating wire. The wire is preferably coiled, and will be referred to herein as a “coil”, but the term “coil” is not limited to a resistance heater element that is actually in a helical or coiled form. As shown, the generator is in its preferred orientation, with arrow 31 indicating the vertical.

[0045] A tube 40 is mounted generally vertically through the upper wall of the tank 32 so that the bottom of the tube 40 ends slightly above the bottom of the tank. A high temperature glass tube 42 of the heater 38 is mounted coaxilly inside the metal tube 40, with a narrow annular space 43 therebetween. The bottom of the glass tube is above the top of the liquid 34 in the tank 32. The top of the glass tube 42 extends above the top of the metal tube 40. Inside the glass tube 42 an electrical resistance wire or coil 44 is positioned so that the top of the coil is just below the top of the metal tube 40, and the bottom of the coil is well above where the metal tube 40 goes through the tank 32. The position of the coil limits heat transmission principally to the area of connection between the metal tube 40 and the tank housing 32. The glass tube 42 extends above the metal tube 40 so that an electrical lead 46 cannot touch the metal tube 40. Both ends of the glass tube 42 are fused so that the tube and leads are sealed and impervious to moisture. Air is preferably not evacuated from the glass tube 42 for better heat conduction to the outer surface, but operation with some degree of a vacuum in the tube is possible. A bottom lead 48 extends through the glass tube 42 and out the end of the metal tube 40 so that it can be easily connected to the bottom outside of the metal tube 40. A durable electrical connection 47 is connected to the outside of the metal tube 40 and extended outside the tank 32 .

[0046] A larger metal tube 50, preferably formed of brass, is mounted coaxially outside of the metal tube 40 so that the top of the metal tube 50 extends above the top of the glass tube 42, and the bottom of this metal tube 50 extends just above the bottom of the glass tube 42. This outer metal tube 50 acts as an insulator, protects the inner, relatively delicate, tubes 40,42 from damage, and protects against human contact with any components at the high heat of the coil 44. Also, the tube 50 becomes an electrical conductor so that the lead 46 from the top of the coil 44 so that a durable electrical lead 52 can be connected to the tube 50.

[0047] The liquid 34 is loaded through the tank filler hole 34a. A rubber stopper 54 seals the tank 32 so that no air or fluid can escape. The rubber bulb 36 is mounted on an air delivery tube 56 that extends to an air-tight connection 58 to the tank 32. Because the only vent to atmosphere from the heater is the tube 40, the liquid 34 does not flow out of the heater when the gun 10 is laid on its side, or even when it is held upside down, just as olive oil will not pour easily from a can that has only one small hole punched in its upper end. This characteristic of the smoke generator is referred to herein as “closed”.

[0048] Although the close fit between the glass tube 42 and the metal tube 40 could be considered a capillary space, the opposite effect is desired. When the rubber bulb 36 is squeezed, air is delivered to the tank 32 which in turn exerts positive fluid pressure on the liquid 34. This liquid is pumped up into the metal tube 40 and over the glass tube 42 where it is vaporized rapidly by the high heat produced by the coil 44. When the rubber bulb 36 is released, negative pressure is delivered to the tank 32. This allows the coil 44 to rapidly heat to its highest temperature without loss of heat to the liquid. Also, the evacuation of the fluid from the region around the coil 44 in response to a decrease from the increased (pumping) fluid pressure conserves power through an increase in electrical resistance produced by the increased heat of the coil when the heat sink of the surrounding liquid is withdrawn. This conservation of power is important in that the heater 38 is powered by battery.

[0049] In addition, when fluid is delivered to the metal tube 40 by squeezing the rubber bulb 36, not all the fluid is vaporized, particularly if the squeezing is strong, or rapidly repeated before vaporization occurs. This excess fluid overflows the tube 40, runs down the outside of the tube 40 to the bottom of an annular catch well 90 between the tubes 50 and 40. This liquid, if allowed to build up, would rob heat from the metal tube 40. A drainage hole 60 at the bottom of the well 90 allows the excess fluid to drain into a separate tank 62. Another drain line 63 empties condensate from the smoke chamber 14 to the tank 62. The liquid collected in the tank 62 can then be removed through an access hole 64 and rubber stopper 66.

[0050] FIG. 5 shows another alternative, presently preferred, embodiment of the smoke generator 30′ (like parts in the FIG. 4 and FIG. 5 embodiments being identified with the same part number, but distinguished by a prime). A key feature of the generator 30′ is a spacer 92 disposed in the annular gap 43 between the glass envelope 42′ of the electrical resistance heater 38′ and the surrounding metal tube 40. The spacer 92 is shown in its presently preferred form, that is, as a wire that is spiral-wrapped around the glass envelope 42′.

[0051] The wire 92 is formed of any suitable non-corrosive material. Stainless steel is preferred. The wire 92 has a diameter that radially fills a significant portion (e.g. about 25 to about 75%) of the gap 43. The exact width can vary, but the functional result is that the wire 92 maintains a generally uniform spacing circumferentially across the gap 43 without plugging or significantly impeding the flow of the liquid 34 to the region adjacent the heater. The spiral wrap of the wire 92 ensures that this radial spacing is also maintained axially (in the direction of arrow 93).

[0052] The spacer wire 92 also creates a helical flow path 94 for the fluid 34 that is forced by fluid pressure (applied via the bulb 36 and air delivery tube 56) upwardly through the gap 43 where the electrical resistance coil 44 vaporizes it. The helical flow path is longer than a linear path straight up the gap 43, and thus increases the surface area, and interaction time, for the transfer of heat from the coil 44, through the glass envelope 42′, to the fluid. This increased surface area effect is reflected in the characterization of the spacer wire 92 also as a “wetting” wire.

[0053] The circumferentially even radial spacing, and this increased flow path and the resultant surface area for heat transfer, produces a greatly increased efficiency of operation as compared to the generator 40 described with reference to FIGS. 2-4. Turbulence produced by the presence of the wire 92 in the gap 43 is also believed to assist the heat transfer. In operation, with other factors the same, the generator 40′ using the spacer and wetting wire 92 produces roughly twice as much smoke, evaluated by subjective visual comparison, than a generator 40.

[0054] The generator 40′ also secures the wire 92 in a selected axial location with respect to the heating coil 44. The wire 92 is anchored principally by bending its upper end over the upper edge of the metal tube 40, directing it down the outside of the tube 40, and then clamping it under an O-ring 96 (which may be the O-ring shown in FIG. 4 as sealing the tube 40 within the upper wall of the tank 32). The O-ring 96 is readily replaceable to facilitate disassembly for repair or maintenance. However, any equivalent such as an adhering, clamping under a screw, or simply wrapping around a post or other projection, can work. The wire 97 is also preferably secured at its lower end 92b. As shown, a simple wrapping of the end 92baround the lower heater coil lead wire is a simple and effective lower anchor for the wetting wire 92. However, many other known mechanical securing arrangements can be used.

[0055] The wire 92 is held by this mounting in an axial position such that the spiral turns are co-extensive with the heating coil 44, and preferably extend below it to the bottom end of the glass envelope 42′. In generators used in toys, the wire 92 has between 2 and 36 turns to provide a reliable, uniform spacing around and along the gap 43, while increasing the path length by creating a helical flow path. For a generator with the illustrative dimensions given above, and a 0.001 to 0.005 inch gap clearance, the wire 32 preferably has a diameter of 0.001 to 0.004 inch. With a 0.004 inch radial-measure gap, the wire has a preferred diameter of 0.002 inch (50%), and 12 to 14 turns over the approximately one-inch axial length of the turns. The slight clearance between the wrapped wire and the adjacent surfaces permits a sliding insertion of the wire wrapped on the glass envelope 42′ into the tube 40, while still adequately controlling the mutual spacing of those components and creating the extended spiral flow path after the wire “relaxes” into the gap 43.

[0056] In manufacture, the lower end 92bof the wire 92 is first wrapped on the lead wire 49 as shown. The lead wires 46 and 49 are centered in, and adhered within, plugs 98a, 98bthat seal the ends of the glass envelope. The plugs are preferably a suitable high-temperature epoxy such as the product sold by Duralco under the trade designation “4525”. The plugs each extend into the cylindrical glass envelope 42′ about ⅛ to {fraction (3/16)} inch to ensure a reliable seal.

[0057] The wire 92, once anchored at its lower end, is wrapped over the outside of the envelope 42. When the wrapped heater 38′ is slid into position within the tube 40, the upper end 92ais then directed down the outside of the tube 40 and secured by the O-ring 96.

[0058] FIG. 2 shows the heat generator 30 installed in a toy gun 10, in this case, a pistol styled like a fanciful “ray gun”. The body 16 of this gun includes a hollow casing of plastic or other suitable material. The gun body 16 is preferably molded from a suitable plastic in two mirror-image halves with the hand grip 20 and battery compartment 28. The smoke chamber 14 can be formed integrally therewith, but preferably is molded separately and then secured to the front end of the gun body 16 (e.g., with a snap-on action) after the two halves are mated in clam-shell fashion. Rearward depression of the trigger 22 operates to engage an axially extending actuator (or “striker”) 68 through a pivoted, spring-loaded dog 70, causing a like rearward movement of the actuator from a forward position adjacent the diaphragm 74 to an extreme rear position against the action of a coiled compression spring 80. The dog 70 is mounted in a recess 68rformed in the lower side of the actuator 68. At the rear limit position, a corner 72 of the body 16 cams the dog 70 to pivot against its spring 71 until it releases from the trigger 22. This release allows the actuator to slide forward propelled by the compressed spring 80 to strike an elastic diaphragm 74. It also defines the rear limit position of the movement of the actuator 68.

[0059] With reference to FIG. 2, the smoke chamber 14 is defined by the diaphragm 74 (forming a generally planar rear wall 14b), a front wall 14ain generally parallel, spaced relation with the rear wall, and a generally cylindrical side wall 14cextending between walls 14aand 14b. The diaphragm 74 is preferably replaceably sandwiched between the smoke chamber 14 and the gun body 16, and it can be mounted in a separate circular frame 76 that is so secured. A generally circular orifice 14dis formed in the front wall as an exit port for the smoke rings 12. The orifice 14dis preferably positioned coaxially with the diaphragm 74. In the preferred form shown for a hand-held toy gun 10, the diameter of the orifice is in the range of about 1 to 3 inches, with about 1.25 inches being generally preferred.

[0060] The upper outlet end of tube 50 of the smoke generator 30 passes through a lower portion of the chamber side wall 14cto feed smoke produced by the generator 30 to the smoke chamber. (The generator 30′ is preferably used.) An optional light 78 is attached inside the chamber wall 14cto facilitate visual inspection of the smoke in the chamber 14 and, in particular embodiments, to add illumination to the smoke inside the smoke chamber and/or to the rings eminating from it, particularly in darkened rooms. The chamber 40 can be made (whole or in part) from a transparent or translucent material such as a suitable plastic, such as polypropylene.

[0061] The ratio of the diameter of the orifice 14dto the internal diameter of the smoke chamber 14 is adjustable to maximize smoke ring quality and output by holding smoke in the chamber after it is produced, and then producing a well formed ring after the gun is “fired”. Typically, that ratio is as low as about 1:4, but preferably in a range of about 1:2 to 2:3. By way of illustration, but not of limitation, the orifice 14d, as noted above, has a diameter of about 1.25 inches, and the internal diameter of the smoke chamber 40 is about 2.5 inches. The chamber diameter ranges from 2 to 5 inches for the preferred gun 10 shown in FIGS. 2 and 3.

[0062] The gun is “fired” to eject at least one smoke ring by the actuator 68 striking the diaphragm 74. The actuator in the preferred form illustrated is mounted in the body 16 at at least two axially separate bearing surfaces 16aand 16b. The actuator 68 reciprocates freely along its lengthwise axis in the direction of the axial arrow 18. As shown in FIGS. 2 and 3, the actuator is approaching its forward position where the actuator head 82 strikes the diaphragm 74. The resilience of the diaphragm material (and ribs 74a) returns the diaphragm to its original shape and returns the actuator 68 to a point where the trigger 22 when in its forward or unsprung position can engage the dog 70 and the gun can be fired again. There is no limiting forward position to the actuator other than the diaphragm. If the actuator stopped abruptly (or snaps) at a limit position, it is found that the ensuing pressure wave is not conducive to well-formed smoke rings. In the preferred form, the actuator is also generally centered on the diaphragm 74 and the orifice 14d. The coil spring 80 held in a cavity 16cformed at the center rear of the gun body urges the actuator forward, toward the diaphragm. The spring, when compressed, provides a motive force that propels the actuator to strike the diaphragm with its head 82 to deflect the diaphragm forwardly to thereby produce a pressure wave in the fluid in the smoke chamber 14. In the preferred form shown, the spring 80 is captured at its front end on an end boss 68aof the actuator, and at its rear end the spring 80 abuts an adjustable stop member 84. The stop 84 pivots freely about a pivot pin 84ain response to a manual movement of projecting lever 84b. The pivot is not centered in the main body 84cof the stop 84 so that rotation (in the clockwise direction as shown) produces a camming action that compresses the spring 80. The force of the spring 80 on the stop, and friction with the pin 84aand the surrounding body 16, secures it against further rotation once it is manually set. This manual rotation of the stop allows a convenient adjustment of the actuator striking force, and thereby the speed of the smoke rings ejected by the gun 10 when it is fired.

[0063] The actuator head 82 is preferably circular with a diameter near in size to that of the orifice 14d. The striking face 82ais preferably flat. The impact of the face 82aon the diaphragm 74 deflects the diaphragm forward a short distance, one sufficient to create a pressure wave within the smoke chamber that in turn creates a smoke ring that ejects from the gun 10 and travels forward, in an axial direction with respect to the gun. The quality, speed and number of smoke rings created depends on an interplay of factors such as the material, thickness, tension and mounting of the diaphragm, the rigidity of the striking face 82a, the mass and velocity of the actuator, and the absolute and relative sizes of the areas of the diaphragm and the striking face that interreact. In one form, as illustrated and as noted above, the diaphragm is an edge-mounted piece of latex rubber about 10 mils thick held so that it is flat before it is struck, but not stretched to any significant degree. If the diaphragm is tensioned, the actuator impact can produce a bouncing leading to the formation of multiple surges per firing (which may be desirable under certain circumstances). However, to produce a quality traveling ring with one impact, and use a taut diaphragm, the actuator head 82apreferably mounts a layer of foam rubber or like energy absorbing or “lossy” material to cushion the blow.

[0064] While the preferred embodiment uses an elastic diaphragm, it will be recognized that there are many ways to move a member to produce a wavefront in an adjacent fluid. For example, a rigid or resilient member can be mounted to move in the manner of a piston within a cylinder (e.g., the smoke chamber side wall), or the diaphragm can be coupled to a solenoid in the manner of a diaphragm in a telephone or loudspeaker, or a diaphragm can itself be formed of materials, or layers of materials, that deform in response, e.g., to applied voltages in manner that produces the desired pressure wave. These variations are intended to fall within the scope of the appended claims.

[0065] It is also contemplated, and it is presently preferred, to use an elastic diaphragm 74′ that is bowed or curved slightly in cross section, e.g., ⅛ to ¼ inch measured at the center at a maximum. The direction of this curvature is convex with respect to the actuator head 82 (shown in dashed lines in FIG. 2.). To restore this curved shape after being impacted by the actuator and driven toward a flat or concave configuration, a set of radial ribs 74amutually-spaced may be formed integrally in the diaphragm material.

[0066] Similarly, while the actuator is described as a spring-loaded, linearly reciprocating “plunger”, an equivalent striking member can be formed in a wide variety of ways well known to those skilled in the art. Some examples are pivoting strikers (using a hammer-like pivoting action), solenoid-driven, pneumatically, and hydraulically-driven strikers, as well as direct drives for a rigid, piston-like diaphragm or diaphragm mountings.

[0067] In the preferred, hand-gun form illustrated herein, the tube 40 is preferably made from a metal or alloy thereof such as stainless steel. The envelope 42, 42′ of the heater, made from a high temperature silicate such as borosilicate glass, extends vertically so that its bottom end is above the top of the liquid 24 in the tank 32, and its upper end extends above the upper end of the metal tube 40. The metal tube 40 for a hand-gun 10 has an outer diameter of preferably 0.05 to about 0.07 inch, more preferably about 0.0546 to about 0.066 inch. Typically, the glass tube 42 preferably has an outer diameter of between about 0.049 to 0.055 inch, more preferably about 0.049 inch. A preferred radial spacing of the glass tube 42 to the inner wall of the tube 40 is between from about 0.001 to about 0.005 inch, preferably about 0.004 inch. This spacing has been found to promote the pumped movement of a suitable volume of liquid 34 to a region adjacent the heater in response to a pressure increase that can be produced manually, but not so much liquid that it strongly gushes up and out of the tube 40, or requires a significant time delay for vaporization. In the preferred form, the heater reaches its operating temperature in about 5 seconds, and smoke can then be made repeatedly, on demand, in about ½ second.

[0068] By way of illustration, but not of limitation, when used in a toy smoke ring gun as shown in FIGS. 1-4, or a like application, the generator 40′ is formed of a metal tube that is about 1.9 inches long, and a glass envelope about 1.5 inches long that extends above the tube 40 by about ⅜ inch. The heating coil 44 is about ¾ inch in axial length, terminating at its top end near the upper end of the tube 40, as shown. The glass envelope has an outside diameter of about 0.049 inch and the average radial width of the gap 43 is, as noted above, about 0.004 inch. The wetting wire 92 is a 0.002-inch diameter stainless steel wire wrapped with 12 to 14 turns per inch.

[0069] The invention is compatible with a wide range of suitable smoke precursor liquids. However as discussed, it is an object of this invention to provide smoke that is essentially safe for use in settings in which humans are present. Preferably, that smoke is made from liquid that is approved by the U.S. Food and Drug Administration (FDA). A preferred liquid is water having a smoke producing amount of propylene glycol and less than about 5 ppm mineral impurities. Such liquid can be obtained from a variety of commercial sources including “Fog fluid FJ1Q, unscented” from Visual Effects Inc. of Bronx, N.Y. (USA).

[0070] The resistance coil 44 has a resistance of from between about 4 ohms to about 10 ohms when cold (room temperature), and draws about 400 to about 600 milliamps in normal use to produce smoke. In the absence of liquid, the coil heat continues to draw current, but its resistance increases without the liquid acting as a heat sink. In this “liquid-withdrawn” state, it draws preferably about 300 to 450 milliamps, a conservation of about ⅓ of the current drawn when vaporizing (assuming a fixed voltage). The resistance coil can be made from a wide range of suitable materials, but nickel or alloys of nickel are preferred. Nickel that is at least about 99.9% pure is preferred for use in the hand-gun 10 shown in FIG. 2. The preferred coil has an outer diameter (O.D.) of about 0.02 inch.

[0071] A user of the toy gun 10 closes an electrical switch 86 to power the resistance coil 44 and energize the light 78. Power can be supplied by any suitable means including the batteries 24, or a cord extension to a household electrical socket or transformer. In the preferred toy gun embodiment using batteries for maximum portability, a battery compartment in the base 28 houses 6 AA batteries in series to provide about 9.0 volts with fresh batteries. After use, the voltage drops to about 7.5 volts, and after about 3 hours of use, to about 6.0 volts.

[0072] A second “trigger” 88 mounted in the hand grip 20, when depressed against a spring force by the user, contacts and compresses the bulb 36 to increase fluid pressure in the tank 32. This spring force acting on the trigger 88 is preferably provided by the resiliency of the bulb 36 itself. This increase in fluid pressure causes a rise in level of the liquid 34 into the annular space 43 between the heater and the tube 40, toward the resistance coil 44. The small volume of liquid in this narrow annular space 43 vaporizes very quickly (about ½ second) to produce smoke. That smoke rises into and fills the smoke chamber 14. If the trigger 88 is pulled too strongly, or too often, the pumped liquid can overflow the tube 40. If so, it runs into the well 90 at the bottom of the annular space between the tubes 40 and 50 where it is drained away so that it does not interfere with the vaporization process. Release of the trigger 88 lowers the fluid pressure as the resilient bulb 36 expands back toward its pre-compressed configuration. This decrease from the increased fluid pressure level immediately causes the liquid 34 to withdraw from the space 43 adjacent the heater 38. Smoke generation then, in most cases, ceases promptly.

[0073] The toy gun thus has a readily available supply of liquid 34 in tank 32, for repeated fast production of batches of smoke “on demand”. Of course, the smoke generator 30 can be operated continuously or semi-continuously, not “on-demand”. However, continuous or semi-continuous operation requires a greater power and liquid usage, and a likely waste of smoke that is produced, fills the chamber 14, and flows, unstructured, out of the orifice 14d, not as rings. As discussed above, the toy gun 10 can operate generally independently of orientation so that smoke rings can be produced with, e.g., a sideway or even upside down orientation, or the gun can be placed on its side when not in use. As also discussed above, the smoke generator 30, 30′ and gun 10 of the present invention can operate with water-based smoke precursor liquids (usually water with polyglycol, or the like, and a low level of mineral impurities). Smoke formed from such liquids are less likely to be irritating, or to have other health hazards, than known oil-based; liquids. It will also be appreciated that the spacer and wetting wire 92 is a simple and low cost enhancement to the efficiency and volume production of fog as compared to a like generator with a “straight-through” flow path and no arrangement to establish and maintain a uniform spacing around the heater.

[0074] Although the invention has been shown and described with respect to its preferred embodiments, it will be appreciated from the foregoing that various other changes, omissions and additions will occur to those skilled in the art without departing from the spirit and scope of the invention.

[0075] For example, while the invention has been described with respect to an air-filled, deformable bulb as a source of a variable pressure acting as the liquid 34 in the tank 32, a wide variety of other arrangements can achieve the same end effect. The liquid can be held in a deformable tank. A piston and cylinder arrangement can vary the pressure hydraulically. A compressed air supply or gas from a CO₂cartridge can be applied to the tank. Further, while the heater has been described as an electrical resistance wire in a glass envelope, a wide variety of resistance and other heaters are known that can be adapted to vaporize the liquid, whether continuously or on demand. Further, while a hand gun is described as the preferred application of the present invention, it will be recognized that the invention can be readily adapted to other toys (toy rifles, bazookas, and cannons, and model trains and boats) and to other smoke applications (theatrical productions).

[0076] While the spacer 92 has been described as a spiral-wrapped wire, it can assume other forms, e.g. projections from the tube 40 or the envelope 42′, or separate annular rings or axial ribs or wires or arrays of ribs or wires, or blocks of solid materials adhered or secured to set the gap spacing. Likewise, the enhanced “wetting” function produced by the spiral wrap and its resultant spiral path can be created by a wide variety of structures that direct the fluid flow in a path that is increased as compared to a generally linear axial flow along the gap 43. The wire 92 can have a non-circular cross-section. And as noted above, a variety of mechanical arrangements can secure the wetting wire, or equivalent components, in position, whether permanently or replaceably.

[0077] These and other modifications and variations disclosed herein are intended to fall within the scope of the appended claims.