EXERCISE OR TOY FOAM SWORD AND METHOD OF MAKING SAME

Abstract

A foam sword having a sword blade made from a flexible, soft foam material is provided. The blade includes a reinforcing rod that extends partially therethrough to provide some rigidity and to which the sword handle and hilt guard are connected.

Description

BRIEF DESCRIPTION OF THE DRAWING(S)

The foregoing summary, as well as the following detailed description of the preferred embodiment of the present invention will be better understood when read in conjunction with the appended drawings. For the purposes of illustrating the invention, there is shown in the drawings an embodiment which is currently preferred. It should be understood, however, that the invention is not limited to the precise arrangement shown.

FIG. 1 is a side view of a foam sword according to the invention.

FIG. 2 is an exploded assembly view of the sword of FIG. 1.

FIG. 3 is a cross-sectional view through the sword blade of the foam sword taken along lines 3-3 in FIG. 2.

FIG. 4 is an enlarged view of a portion of the hilt guard that extends around the handle of the sword shown in FIGS. 1 and 2.

FIG. 5 is a perspective view of one embodiment of a hilt guard used in the sword of FIGS. 1 and 2.

FIG. 6 is a perspective view of an alternate embodiment of a hilt guard that is usable in connection with the sword of FIGS. 1 and 2.

Claims

1. A foam sword comprising: a sword blade formed from a foam material and having first and second ends, and a longitudinally extending opening extends from the first end at least partially therethrough;a reinforcing rod located in the opening and extending for at least a portion of a length of the blade, and having a handle connection portion extending out from the first end of the blade;a handle having an opening defined at least partially therethrough located on the handle connection portion of the reinforcing rod; anda hilt guard extending from a first end of the handle.

2. The foam sword of claim 1, wherein the hilt guard has a first hole defined at a first end thereof and a second hole defined at a second end thereof, and the first end of the hilt guard is located between the handle and the foam blade, with the reinforcing rod extending through the first hole, and the second end of the hilt guard being connected to a second end of the handle.

3. The foam sword of claim 1, wherein the handle is formed from a foam material.

4. The foam sword of claim 1, wherein the reinforcing rod is a tube formed from a polymeric material.

5. The foam sword of claim 4, further comprising a plug inserted in a first end of the tubular reinforcing rod and a cap is connected to a second end of the tubular reinforcing rod.

6. The foam sword of claim 5, wherein the plug and the cap are connected to the tubular reinforcing rod via cross pins.

7. The foam sword of claim 1, wherein the sword blade is an extruded foam tube, and the opening extends completely therethrough, and a plug is located in the opening at the second end of the sword blade.

8. The foam sword of claim 7, wherein the sword blade comprises polyethylene foam.

9. The foam sword of claim 7, wherein the extruded foam tube has a cross-section with a major dimension and a minor dimension to form a blade-shaped cross-section.

10. The foam sword of claim 7, wherein the second end of the sword blade is chamfered on at least two sides.

11. The foam sword of claim 1, wherein the handle and the hilt guard comprise ethylene vinyl acetate foam.

12. A method of making a foam sword, comprising: cutting a length of extruded tubular foam material to form a foam sword blade;positioning a hilt guard on a portion of a reinforcing rod;positioning a handle on the reinforcing rod with a first end of the handle adjacent to the first end of the foam hilt guard; andinserting a second portion of the reinforcing rod that extends from the handle and hilt guard at least partially into a first end of the tubular foam material blade.

13. The method of claim 12, further comprising: connecting a second end of the foam hilt guard to a second end of the handle.

14. The method of claim 12, further comprising: inserting a plug into a second end of the tubular foam material blade.

15. The method of claim 12, further comprising: applying an adhesive to at least one of the handle, the foam hilt guard or the tubular foam material blade.

16. The method of claim 12, wherein the reinforcing rod is a tube.

17. The method of claim 15, further comprising: inserting plugs into the ends of the reinforcing rod tube.

18. The method of claim 12, further comprising forming the handle and hilt guard from a foam material.