Patent Application
20100136881
The present invention is directed to a toy or exercise implement, in particular to a light and colorful foam sword which can be used as a toy or in connection with exercise, and is therefore suitable for a variety of users without any age limit. With economic growth and increased living standards, more and more adults are paying attention to their health. One way of improving health is to engage in more exercise with one known exercise being engaging in sword play or practicing sword dance. This is generally done with a wooden sword or plastic sword.
In addition, children often engage in toy sword play using sticks, rigid plastic swords or the like. The existing plastic swords are generally rigid or made of non-environmentally PVC blow molded material. Based on the rigid formation of the toy sword blades, it is easy for children to become injured making such items a safety hazard. In particular, children can be poked in the eyes or have bruises on their hands or arms when they get carried away with toy sword play.
It would be desirable to provide an exercise or toy sword which overcomes the difficulties and problems with the prior designs, which is light weight and soft, making it desirable for use with exercise and also for use as a children's play toy.
Briefly stated, the present invention provides a foam sword having a sword blade formed from a flexible, soft foam material having first and second ends.
A longitudinally extending opening extends from the first end at least partially there-through. A reinforcing rod is located in the opening and extends for at least a portion of a length of the blade. The handle connection portion of the reinforcing rod extends out from the first end of the blade. The handle has an opening defined at least partially there through and is located on the handle connection portion of the reinforcing rod. A foam hilt guard extends from a first end of the handle to a second end of the handle.
In another aspect, the present invention provides a method of making a form sword. The method includes:
Cutting a length of extruded tubular foam material to form a foam sword blade;
Positioning a first end of a foam hilt guard on a portion of a support rod;
Positioning a handle on the support rod with a first end of the handle adjacent to the first end of the foam hilt guard;
Connecting a second end of the foam hilt guard to a second end of the handle; and
Inserting a second portion of the support rod that extends from the handle and the foam hilt guard at least partially into the first end of the tubular foam material blade.
Preferably, the foam blade is made from a PE (polyethylene) foam and the handle and hilt guard are made from EVA (ethylene vinyl acetate) closed cell foam.
In a preferred embodiment, the reinforcing rod is a tube, preferably made from PP (polypropylene). This arrangement provides a foam sword having a soft blade with a flexible core formed by the reinforcing rod which extends at least partially therethrough, and in a preferred embodiment more than halfway through the length of the blade.
In a preferred embodiment, the sword can be economically and easily manufactured by using an extruded PE foam tube in order to form the sword blade and a plug can be inserted at the end of the sword blade, in order to cover the remaining opening.
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.
Certain terminology is used in the following description for convenience only and is not considered limiting. The words “left”, “right”, “lower” and “upper” designate directions in the drawings to which reference is made. Additionally, the terms “a” and “one” are defined as including one or more of the referenced item unless specifically noted.
Referring now to
A reinforcing rod 14 is preferably located in the opening 20 in the sword blade 16, and extends through at least a portion of a length of the blade 16. The reinforcing rod 14 has a portion which extends out from the first end of the blade 16 which provides a handle connection portion. The reinforcing rod 14 is more rigid than the foam sword blade 16, providing internal support, but is still flexible so that the sword blade 16 can elastically bend upon contacting an object. The rod 14 is preferably a tube formed from a polymeric material, such as PE (polyethylene).
Preferably, the reinforcing rod 14 only extends along a partial length of the blade 16, so that an end portion of the blade 16 is less rigid and more easily deflects when contacting an object.
In a preferred embodiment, a plug 11 is inserted in a first end of the tubular reinforcing rod 14 and a cap 13 is inserted in the second end of the tubular reinforcing rod 14. Preferably, the plug 11 and cap 13 are connected to the tubular reinforcing rod by having the ends inserted into the tubular openings of the rod, and cross holes are provided through the tubular reinforcing rod 14 as well as the cap 11 and plug 13 into which cross pins 12 are inserted.
A handle 17 having an opening defined at least partially there-through is located on the handle connection portion of the reinforcing rod 14. The handle is preferably formed from an EVA (ethylene vinyl acetate) foam material. However, any other suitable materials could be utilized. In a preferred embodiment, the opening extents through the handle.
A hilt guard 18, preferably made of a flexible foam material, extends from the first end of the handle 17 to a second end of the handle 17. As shown in detail in
As shown in
Referring to
Preferably, the sword 10 is assembled by applying an adhesive to at least one of the handle 17, the foam hilt guard 18 and the sword blade 16 and/or to the reinforcing rod that extends therethrough. The adhesive can be any suitable adhesive, for example an acrylic resin adhesive, contact cement or chloroprene.
Referring to
In order to make the foam sword 10 according to the invention, first an extruded tubular foam material, preferably having a flattened shape, such as that shown in
While the preferred embodiment of the invention has been described in detail, the invention is not limited to the specific embodiments described above, which should be considered as merely exemplary. Further modifications and extensions of the present invention may be developed, and all such modifications are deemed to be within the scope of the present invention as defined above and by the appended claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 200620056099.8 | Mar 2006 | CN | national |
This application is a continuation of U.S. patent application Ser. No. 11/685,813, filed Mar. 14, 2007, which claims the benefit of Chinese Application No. 200620056099.8, filed Mar. 14, 2006, both of which are incorporated herein by reference as if fully set forth.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11685813 | Mar 2007 | US |
| Child | 12701988 | US |
