Saber Apparatus With Deployable, Illuminated Blade

Information

  • Patent Application
  • 20250153068
  • Publication Number
    20250153068
  • Date Filed
    November 12, 2024
    6 months ago
  • Date Published
    May 15, 2025
    4 days ago
  • Inventors
    • Fischio; Matthew Channing (Charleston, SC, US)
  • Original Assignees
    • Reel Saber, LLC (Mount Pleasant, SC, US)
Abstract
A saber apparatus comprises a hilt assembly having a hilt body and a drive assembly. The saber apparatus further comprises a blade member connected to the drive assembly to selectively deploy and retract the blade member. The blade member is deployed in an arc shape and is stored in a flat shape wound up in a reel form within the hilt body. The drive assembly operates to deploy the blade member outward from the hilt body and retract the blade member into the hilt body. The blade member comprises a blade cap at a distal end of the blade member, and the hilt assembly comprises a light source within the hilt body. The light from the light source is directed through a lens axially outward towards the blade cap at the distal end of the blade member.
Description
TECHNICAL FIELD

In general, the present description relates to theatrical props and toys simulating laser swords or other fictional swords. More particularly the present description relates to a swords or sabers that lights up and can be used as a toy, theatrical prop, or collector's item, and that may accurately simulate fictional operations of swords found in many popular films.


BACKGROUND

In the world of cinema and theatre there are many fictional characters whose weapon of choice is a sword, which can take many forms. In such fictional settings, such swords often take on various fantastical or futuristic forms, such as a lighted saber or laser sword (including the LIGHTSABER® sword of a well-known space canon), as well as any number of other swords or sabers emitting light or otherwise simulating energy blades, beams, and the like, all of which various forms may be collectively termed “laser swords” or “saber apparatus” in the present disclosure, both of which terms share the same meaning and scope. Many films have been produced depicting these fictional characters doing battle with their fantastical laser swords. Typically, a laser sword includes a metal or a plastic hilt that allows the laser sword to be a handheld weapon. The hilt includes a switch which is activated by the character in the film to project a brightly lit energy blade. The energy blade length is usually two to four or more feet long, and it can be used by the fictional character to make a cut, burn, and melt through most substances with little to no resistance in the movie. Furthermore, an active laser sword may make a distinctive humming, which rises in pitch and volume as the blade of the laser sword is moved rapidly through the air and produces a loud noise when the energy blade of the laser sword has a contact with another laser sword's energy blade.


Typically, in films many postproduction techniques are used to provide the laser sword. Computer-Generated Imagery (CGI) is a prominently used technique to realistically deploy and retract the energy blade from the hilt of the laser sword, which can be a physical prop in the character's hand. Laser swords have transcended their on-screen origins to become symbols of adventure, heroism, and personal empowerment. In films, their vibrant colors and unique sounds evoke a sense of wonder and excitement, making them not just tools of combat but also instruments of storytelling. This allure has fuelled a thriving market for replicas and collectibles, appealing to both casual fans and dedicated collectors. The combination of their rich lore, striking aesthetics, and the fantasy of wielding such a powerful artifact has made laser swords highly desirable, embodying a connection to the beloved saga and its themes of good versus evil. However, producing a toy, a collector's item, or a theatrical prop for live theatre or shows that effectively simulates the laser sword has proven much more challenging.


There are many commercially available laser sword products, but most have only been effective at simulating a portion of the unique features of the fictional laser swords seen in films. For example, many laser sword products focus on combat durability but fall far short on providing realistic appearance. Others provide very realistic appearing and brightly lit blades along with effective sound effects. However, very few laser sword products have even attempted to recreate the deploying and retracting capabilities of the energy blades of the laser sword shown in films, and these products have typically failed in other aspects. For example, laser sword products of the current art suffer from drawbacks and disadvantages relative to deploying and retracting of the energy blade, and have required mechanisms or features which detracted from the desired laser sword appearance approximating the ones used by fictional characters.


In light of the foregoing, there exists a need for a technical and reliable solution that overcomes the above-mentioned problems, challenges, and short-comings.


SUMMARY

The present description provides a saber having a hilt section and a translucent blade member. The hilt section houses a light source for producing a beam of light directed into the blade member. Furthermore, the hilt section houses a drive assembly which is used to selectively deploy or retract the blade member from an opening in the hilt section.


In one embodiment of the present description, a saber apparatus is provided. The saber apparatus comprises a hilt assembly further comprising a hilt body, wherein the hilt body comprises a drive assembly. The saber apparatus also comprises a blade member that is operatively connected to the drive assembly to selectively deploy and retract the blade member from an opening in the hilt body. The blade member is flexible and is deployed in an arc shape, whereas the blade member is stored in a flat shape wound up in a reel form on a spool gear, within the hilt body. The drive assembly operates in a first operating state to deploy the blade member outward from the opening in the hilt body. The blade member which is stored in a flat shape wound upon the reel, is deployed in an arc shape. Furthermore, the drive assembly operates in a second operating state to retract the blade member into the hilt body through the opening in the hilt body. The blade member comprises a blade cap at the distal end of the blade member, and the blade cap comprises a circular cross-section in a plane orthogonal to a longitudinal axis of the blade member. Furthermore, the hilt assembly comprises at least one light source within the hilt body, wherein light from the light source is directed through at least one lens axially outward towards the blade cap located at the distal end of the blade member. The light from the light source is directed across the blade member internally.


In one possible variation, the blade member of the saber apparatus is tapered at its proximal end, and the blade member includes a hole at the proximal end to attach the blade member to a shaft of the spool gear using a blade retention bolt passing through the hole at the proximal end of the blade member to the shaft of the spool gear.


Additionally, or optionally, wherein the blade member of the saber apparatus is a single blade member, and wherein the arc of the blade member is of 270 degrees and wherein longitudinally opposing edges of the blade member has a gap of 90 degrees.


Additionally, or optionally, wherein the blade cap of the saber apparatus comprises a circular cross-section in a plane orthogonal to a longitudinal axis of the blade member, and wherein the blade cap at the distal end of the blade member comprises a reflective mirror having a hole in center to allow the light from the light source to pass through and illuminate the blade cap.


Additionally, or optionally, the hilt assembly of the saber apparatus comprises a limit switch within the hilt body, and wherein the limit switch stops the drive assembly when the blade cap hits the limit switch during the retention of the blade member to complete the retention.


Additionally, or optionally, the hilt assembly of the saber apparatus comprises a limit sensor within the hilt body, and wherein the limit sensor stops the drive assembly to complete deployment of the blade member.


Additionally, or optionally, the hilt assembly of the saber apparatus comprises a cooling fan within the hilt body for cooling down the light source.


Additionally, or optionally, the hilt assembly of the saber apparatus comprises a removable twist-lock hilt cap at top end of the hilt body.


Additionally, or optionally, the hilt assembly of the saber apparatus comprises a removeable sleeve that covers the removeable twist-lock hilt cap at the top end of the hilt body, and wherein the removable sleeve allows for customization of the hilt assembly.


Additionally, or optionally, the hilt assembly of the saber apparatus comprises the spool gear within the hilt body, wherein the spool gear comprises the shaft extending from one side of the spool gear, wherein the shaft of the spool gear comprises a retention slot that receives the proximal end of the blade member and retain the blade member using the blade retention bolt and a captive nut inside the shaft of the spool gear.


Additionally, or optionally, the drive assembly of the saber apparatus comprises a motor gear attached to a motor, a transfer gear and the spool gear, wherein the motor gear is connected to the transfer gear at one end of the transfer gear and the transfer gear is connected to the spool gear from other end, and wherein the connection between the motor gear and the transfer gear changes orientation of force produced by the motor gear by 90 degrees.


In another embodiment of the present description, a system is provided. The system comprises a hilt assembly comprising a hilt body, wherein the hilt assembly comprises a drive assembly. The system further comprises a blade member operatively connected to the drive assembly. The drive assembly comprises a motor gear attached to a motor, a transfer gear and a spool gear. The drive assembly operates in a first operating state to selectively deploy the blade member outward from an opening in the hilt body. The drive assembly further operates in a second operating state to selectively retract the blade member into the hilt body through the opening in the hilt body. The blade member is flexible. The blade member is deployed in an arc shape, and the blade member is stored in a flat shape wound up in a reel form on the spool gear, within the hilt body. The blade member comprises a blade cap at distal end of the blade member. The blade cap comprises a reflective mirror having a hole in center. Furthermore, the hilt assembly comprises at least one light source within the hilt body, wherein light from the light source is directed through at least one lens axially outward towards the blade cap at the distal end of the blade member to light up the blade cap and the blade member, and wherein the reflective mirror of the blade cap having the hole in the center allows the light from the light source to pass through. The light from the light source is directed across the blade member internally.


Additionally, or optionally, the blade member of the saber apparatus is a single blade member, and wherein the blade member is tapered at proximal end and wherein the blade member comprises a hole at the proximal end to attach the blade member to a shaft of the spool gear using a blade retention bolt passing through the hole at the proximal end of the blade member to the shaft of the spool gear.


Additionally, or optionally, the hilt assembly of the saber apparatus comprises a limit switch within the hilt body, and wherein the limit switch stops the drive assembly when the blade cap hits the limit switch during the retention of the blade member to complete the retention.


Additionally, or optionally, the hilt assembly of the saber apparatus comprises a limit sensor within the hilt body, and wherein the limit sensor stops the drive assembly to complete deployment of the blade member.


Additionally, or optionally, the hilt assembly of the saber apparatus comprises a removable twist-lock hilt cap at top end of the hilt body.


Additionally, or optionally, the hilt assembly of the saber apparatus comprises a removeable sleeve that covers the removeable twist-lock hilt cap at the top end of the hilt body, and wherein the removable sleeve allows for customization of the hilt assembly.


Additionally, or optionally, the hilt assembly of the saber apparatus comprises the spool gear within the hilt body, wherein the spool gear comprises the shaft extending from one side of the spool gear, wherein the shaft of the spool gear comprises a retention slot that receives the proximal end of the blade member and retain the blade member using the blade retention bolt and a captive nut inside the shaft of the spool gear.


In another embodiment of the present description, a method is provided. The method comprises operatively connecting a blade member with a drive assembly, selectively deploying and retracting the blade member by operating the drive assembly in a first operating state to deploy the blade member outward from an opening in a hilt body and in a second operating state to retract the blade member into the hilt body through the opening in the hilt body. The blade member is deployed in an arc shape. The method further comprises storing the blade member in a flat shape wound up in a reel form on a spool gear, within the hilt body, and directing a light from a light source through at least one lens axially outward towards a blade cap at a distal end of the blade member.


Various embodiments of the present description provides the saber apparatus having a brightly lit singe blade member which is selectively deployable and retractable from the hilt assembly. The saber apparatus has the single blade member which does not require any internal support structure to support the blade member. Furthermore, the blade member is flexible. The blade member is deployed in the arc shape and is retracted and stored in a flat shape wound up on a reel.





BRIEF DESCRIPTION OF THE DRAWINGS


FIG. 1 is a diagram that illustrates a saber apparatus, in accordance with an embodiment of the description;



FIG. 2 is a diagram that illustrates a hilt assembly of the saber apparatus, in accordance with an embodiment of the description;



FIGS. 3A-3D are diagrams that illustrates the hilt assembly of the saber apparatus having removeable twist locks;



FIG. 4 is a diagram that illustrate a drive assembly with the hilt assembly of the saber apparatus, in accordance with an embodiment of the description;



FIGS. 5A-5B are diagrams that illustrates removeable sleeve over the hilt assembly of the saber apparatus for customization of the saber apparatus;



FIG. 6 is a diagram that illustrates a spool gear integrated with spool gear shaft;



FIG. 7 is a diagram that illustrates the drive assembly of the saber apparatus;



FIG. 8A is a diagram that illustrates a single blade member attached to the spool gear shaft and spool gear;



FIG. 8B is a diagram that illustrates a blade cap of the blade member of the saber apparatus, and



FIG. 9 is a diagram that illustrates the hilt assembly comprising the single blade member stored in a flat shape wound up on the spool gear shaft in a reel form.



FIG. 10 is a diagram that illustrates a laser sword system, in accordance with an embodiment of the description;



FIG. 11 is a process flow diagram of a method of operating the saber apparatus.





DETAILED DESCRIPTION

Exemplary apparatus, systems and related methods are described herein. Other exemplary embodiments or features may further be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. In the following detailed description, reference is made to the accompanying drawings, which form a part thereof. Accordingly, the exemplary embodiments described herein are not meant to be limiting. It will be readily understood that the aspects of the present description, as generally described herein, and illustrated in the drawings, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are explicitly contemplated herein. Similar features and components of the disclosed implementations include the hundred-place numeral of the corresponding Figure, as appropriate, in which:



FIG. 1 is a diagram that illustrates a saber apparatus 100, in accordance with an exemplary embodiment of the present description. The saber apparatus 100 comprises a hilt assembly 104 comprising a hilt body. The hilt body comprises a drive assembly. The saber apparatus 100 further comprises a blade member 102 that is operatively connected to the drive assembly to selectively deploy and retract the blade member 102. The blade member 102 is flexible and is deployed in an arc shape, and the blade member 102 is then stored in a flat shape wound up in a reel form on a spool gear, within the hilt body. The drive assembly operates in a first operating state to deploy the blade member 102 outward from an opening in the hilt body and operates in a second operating state to retract the blade member 102 into the hilt body through the opening in the hilt body. The blade member 102 comprises a blade cap at the distal end of the blade member 102. The hilt assembly 104 comprises at least one light source within the hilt body. The light from the light source is directed through at least one lens axially outward towards the blade cap at the distal end of the blade member 102.


The hilt body of the hilt assembly 104 (of the saber apparatus 100) can be of an ergonomic shape and can have aesthetic appeal. The hilt assembly 104 can be made waterproof. The hilt body of the saber apparatus 100, which is designed with both ergonomic and aesthetic considerations, enhances the user experience and elevating its status among collectors. The hilt body's having a comfortable grip for the user facilitates a fluid movement and control during performance. This combination of ergonomics and beauty not only enhances the performance of saber apparatus 100, but also transforms it into a cherished collectible. Ultimately, the design of the hilt body plays a significant role in both the user experience and the collector's appreciation of the saber apparatus 100.


Furthermore, the saber apparatus 100 comprises the blade member 102. The blade member 102 is a single blade member 102. The technical effect of the single blade member 102 is that it reduces the overall weight of the saber apparatus 100, improves its handling, and makes it stronger. The single blade member 102 also provides resistance against breaking. The blade member 102 can be made up of an extruded tube of polycarbonate. The polycarbonate is mixed with a dye before being extruded to achieve diffusion of the light from the light source. After extrusion, the polycarbonate is cooled down. The cooled polycarbonate is then machined to score two lines across the length of the polycarbonate. The machined polycarbonate is then flexed to cause a clean break along both score lines. After breaking the machined polycarbonate, a segment of the machined polycarbonate is removed and the remaining polycarbonate material is then moulded into the desired shape and size to achieve the blade member 102. The blade member 102 does not require any support structure.


The blade member 102 is flexible and can be deployed in a straight tubelike structure depicting the blade part of a typical laser sword. Furthermore, by the virtue of the flexibility of the blade member 102, it can be retracted and stored in a flat shape wound up on a spool gear, in a reel form. The blade member 102 can be selectively deployed and retracted by a user. Throughout the present description the term “reel form” refers to winding of a material, such as wire, tape, or cable, around a cylindrical spool or shaft. In accordance with an exemplary embodiment of the present description, the blade member 102 is retracted and stored in a flat shape, wound up on a spool gear in a reel form.


The blade member 102 is deployed in an arc shape. The flat shape of the blade member 102 is converted relatively immediately at the proximal or hilt end of the apparatus into the arc shape upon initial deployment of the blade member 102 from its retracted position. This is by virtue of the flexibility of the blade member 102. The technical effect of the flexible single blade member 102 is that the blade member 102 can be stored in a compact form. Furthermore, the arc of the blade member 102 is of 270 degrees, and longitudinally opposing edges of the blade member 102 have a gap of 90 degrees.


In the illustrated implementations, the arc shaped blade member 102 can be converted into a flat shape and wound up on the spool gear in reel form when the blade member 102 is retracted. This allows for compact storage of the otherwise larger blade member 102 inside the hilt assembly 104, which hilt assembly is significantly smaller than blade member 102.



FIG. 2 is a diagram that illustrates the hilt assembly 204 of the saber apparatus 100, in accordance with an exemplary embodiment of the present description. The hilt assembly 204 is located at the bottom or proximal end of the saber apparatus 100. Hilt assembly 204 comprises a hilt body 206. The hilt body 206 of the hilt assembly 204 can be made using 3D printing techniques. 3D printing helps to archive complex structure of the hilt body 206 with minimal joints. The hilt body 206 of the hilt assembly 204 can be made using other suitable additive manufacturing techniques.


The hilt body 206 houses the drive assembly, at least one light source 212, at least one lens 210 placed in front of the light source 212, at least one cooling fan 216, at least one limit switch 214, a spool gear 218, a joystick 220, a limit sensor 222, an electric motor 226, a battery 230, a speaker 232, a control unit 228, a wire channel 224, and a removeable twist lock hilt cap 208.


The drive assembly comprises a motor gear attached to electric motor 226, a transfer gear and spool gear 218. The motor gear is connected to the transfer gear at one end of the transfer gear and the transfer gear is connected to the spool gear 218 from the other end of the transfer gear. The blade member 102 is operatively connected to the drive assembly to selectively deploy and retract the blade member 102. The drive assembly operates in the first operating state to deploy the blade member 102 outward from an opening in the hilt body 206 and operates in the second operating state to retract the blade member 102 into the hilt body 206 through the opening in the hilt body 206.


Furthermore, limit switch 214 of the hilt assembly 204 is configured to stop the blade member from retracting when the blade cap hits the limit switch 214. Particularly, the limit switch 214 stops the drive assembly when the blade cap hits the limit switch 214 during the retraction of the blade member. The limit switch 214 is placed at a top or distal section of the hilt assembly. The blade cap of the blade member makes contact with the limit switch 214 the moment the blade member is fully retracted inside the hilt body 206. In other words, the blade retraction is complete as soon as contact between the blade cap and the limit switch 214 is made. In one particular implementation, the limit switch 214 is electrically or otherwise operatively connected to the electric motor 226 and the control unit 228. The control unit 228 stops the rotation of the electric motor 226 (in turn stopping the retraction of the blade member) as soon as the blade cap makes the contact with the limit switch 214 during the retraction of the blade member inside the hilt body 206.


The technical effect of the limit switch 214 is that it provides a seamless retraction of the blade member inside the hilt body 206. The limit switch 214 allows for automatic stopping of the retraction of the blade member when the user desires so. Furthermore, limit switch 214 provides a realistic operation of the saber apparatus 100 which mimics the laser swords used in the films. The limit switch 214 can be an electro-mechanical switch which can open or close an electrical circuit when the blade cap makes contact with the limit switch 214. The limit switch 214 can be a roller switch or a plunger switch. Throughout the present description, the term “roller switch” refers to a rolling actuator to detect the presence or position of an object. The actuator, typically a wheel or roller, rolls along the surface of the moving part. When the object (blade cap) makes contact with the roller, it activates the switch, which can open or close an electrical circuit. Throughout the present description, the term “plunger switch” refers to a limit switch 214 that activates when a plunger, typically a button or rod, is pressed or depressed. The plunger extends or retracts, making contact with a moving object (blade cap) or mechanism. When the plunger is engaged, it opens or closes an electrical circuit.


Light source 212 of the hilt assembly 204 can be a single Light Emitting Diode LED that can produce multiple light colors. The light source 212 of the hilt assembly 204 can be a plurality of LEDs, cither operated as a single assembly or as separate units, in either case operable to produce multiple light colors. The light source 212 can be a Red, Blue, Green RGB colored LED. The light source 212 is connected to the battery 230 and the control unit 228 to control the functioning of the light source 212 based on a user input. The light source 212 can produce multiple light colors based on the user input received through the joystick 220 into the control unit 228. The light source 212 can produce multiple light effects and light patterns based on the user inputs received through the joystick 220 into the control unit 228. The light source 212 can produce multiple combinations of the light effects, light patterns and light colors based on the user inputs received through the joystick 220 into the control unit 228. The technical effect of the controllable light source 212 is that it provides a large variety of light colors, light effects and light patterns based on the user input to achieve the desirable effect using the saber apparatus 100. The controllable light source 212 also improves the aesthetic value of the saber apparatus 100.


The light from the light source 212 is directed axially outward through the lens 210 that is placed in front of the light source 212. The lens 210 focuses the light from the light source 212 into a narrow beam in the direction of the blade member. The lens 210 can be a convex lens, or aspheric lens, or collimating lens, or Fresnel lens, or Total Internal Reflection (TIR) lens or a combination thereof. Throughout the present description, the term “collimating lens” relates to the lens which diverges the light from the light source 212 and produce a parallel beam. The technical effect of using the lens 210 in front of the light source 212 is that it distributes the light from the light source 212 into the blade member and to the blade cap. This allows for lighting up the blade member completely.


The light source 212 is cooled by using the at least one cooling fan 216, or, alternately, a heat sink (not shown). The heat generated from the light source 212 while in operation is dissipated using the cooling fan 216. The cooling fan 216 is connected to the control unit 228, and the battery 230.


The cooling fan 216 can be controlled programmably through the control unit 228. The cooling fan 216 can be activated to cool down the light source 212 when the temperature of the light source 212 exceeds a pre-defined threshold value. The cooling fan 216 can be stopped when the temperature of the light source 212 is under the pre-defined threshold value. The controlling of the cooling fan 216 can be entirely autonomous. Cooling fan 216 can be an axial fan, or blower fan, or Direct Current DC brushless fan. The cooling fan 216 of the saber apparatus 100 is designed to be fit inside the hilt body 206. The term “cooling fan”, as used herein, applies broadly to still other means beyond those listed above for dissipating heat, including not only powered structures, but also radiative or similar passive structures, such as a heat sink, louvers, cooling veins, and the like.


The spool gear 218 is suitably interconnected to electric motor 226, and to that end may be connected to or integrated with a suitable spool gear shaft to the electric motor 226 using the transfer gear. The spool gear 218 is the part of the drive assembly. The spool gear 218 is rotated in clockwise or anti-clockwise direction based on the deployment or retraction of the blade member, respectively. The rotation of the spool gear 218 also turns the shaft of the spool gear 218. The blade member is attached to the shaft of the spool gear. When the shaft of the spool gear 218 is rotated in clockwise direction, the blade member is wound up and stored on the shaft of the spool gear 218 in the form of reel. Furthermore, when the shaft of the spool gear 218 is rotated in anti-clockwise direction, the blade member is deployed in the arc shape.


The joystick 220 of the hilt assembly 204 is connected to the control unit 228 and the battery 230. The joystick 220 is configured to take the user input and turn the user input into an electric signal. The joystick 220 is used to take the user input and control the light source 212, speaker 232 and the drive assembly to selectively deploy and retract the blade member form the hilt assembly.


The limit sensor 222 of the hilt assembly 204 is integrated into one or more gears of the drive assembly, such as a transfer gear. The limit sensor 222 can be a hall effect sensor. The limit sensor 222 is connected to the control unit 228 and the battery 230. The limit sensor 222 senses the change in the magnetic field as the transfer gear rotates during the deployment of the blade member. The limits sensor can be used to programmably control the rotation of the drive assembly to control the deployment of the blade member. The technical effect of the limit sensor 222 is that it provides a seamless deployment of the blade member at a predefined length, and it also avoids the over deployment of the blade member which can potentially damage the drive assembly or blade member of the saber apparatus 100.


The electric motor 226 of the drive assembly of the hilt assembly 204 provides the driving force to rotate the drive assembly in the clockwise or anticlockwise direction to retract or deploy the blade member, respectively. The electric motor 226 is connected to the control unit 228 and the battery 230. The electric motor 226 is connected to the transfer gear using motor gear (not shown in FIG. 2), and the transfer gear then connected to the spool gear 218. The electric motor 226 is configured to rotate based on the user input. The electric motor 226 can be brushed electric motor 226, or brushless electric motor, or stepper motor. The electric motor 226 can be placed in the center of the hilt assembly. The technical effect of the electric motor 226 placed in the center of the hilt assembly 204 is that it provides a balanced hilt assembly 204 with even weight distribution. This also improves the handling of the saber apparatus 100 and reduces the fatigue in the hands of the user.


The battery 230 of the hilt assembly 204 of the saber apparatus 100 is connected to the control unit 228. The battery 230 provides power to the electric motor 226, light source 212, speaker 232, limit sensor 222, and control unit 228. The battery 230 can be Lithium Polymer Li—Po battery, or Lithium Ion battery.


The speaker 232 of the hilt assembly 204 of the saber apparatus 100 is connected to the control unit 228 and the battery 230. The speaker 232 provides audio output based on the user input. The speaker 232 can be programmably controlled to produce the audio output which can be in sync with light source 212 and can provide the audio output in synchronization with the light effect, light color, light pattern to deliver the desired effect.


The control unit 228 of the hilt assembly 204 of the saber apparatus 100 is connected to the light source 212, speaker 232, battery 230, electric motor 226 of the drive assembly and joystick 220. The control unit 228 comprises a memory unit which can store the computer executable instructions to control the light source 212, speaker 232, and drive assembly. The control unit 228 is configured to receive at least one input from the user to control the light source 212, speaker 232, and drive assembly in order to deploy or retract the blade member and provide at least one desired light and audio output. The control unit 228 can be Arduino™, or Mixed Signal Processor (MSP) 430, or Alf and Vegard's RISC (AVR) Microcontroller, or Peripheral Interface Controller (PIC) Microcontroller, or ESP8266, or Raspberry Pi™, or STM32.


The wire channel 224 in the hilt body 206 of the hilt assembly 204 is designed to route wiring for electrically connecting the speaker 232, drive assembly, light source 212, joystick 220 to the control unit 228 and the battery 230.


The removeable twist lock hilt cap 208 of the hilt body 206 of the hilt assembly 204 is placed on top of the hilt assembly 204. The removeable twist lock hilt cap 208 comprises a set of grooves on the inside to guide the removeable twist lock hilt cap 208 onto the hilt assembly 204, and helps in securely fitting the removeable twist lock hilt cap 208 onto the hilt assembly 204 to close the hilt assembly 204.



FIGS. 3A-3D are diagrams that illustrate a hilt assembly 304 of the saber apparatus 100, in accordance with an exemplary embodiment of the present description. The hilt assembly 304 comprises an opening 306 in the center at the top of the hilt assembly 304. The hilt assembly 304 comprises a twist lock retention mechanism 308. The twist lock retention mechanism 308 is configured to attach the removable twist lock hilt cap 312 on the top of the hilt assembly 304. In FIG. 3B the removable twist lock hilt cap 312 is attached (fastened) to the twist lock retention mechanism 308 by twisting the removable twist lock hilt cap 312 over the twist lock retention mechanism 308. The twist lock retention mechanism 308 comprises at least one cap retention slot 310 in which a press-fit spring plunger is compressed while turning and snaps into the cap retention slot 310, when the removeable twist lock hilt cap 312 is in fastened position. In FIG. 3C the removable twist lock hilt cap 312 is fastened on the twist lock retention mechanism 308. In FIG. 3D is the top view of the hilt assembly 304 comprising the at least one cap retention slot 310 and the opening 306 and at least one assembly holes 314. The assembly holes 314 receives at least one bolts and wherein the bolt engages with at least one captive nut to secure the removeable twist lock hilt cap 312 on to the twist lock retention mechanism 308.



FIG. 4 is a diagram that illustrates a drive assembly 400 of the saber apparatus 100, in accordance with an exemplary embodiment of the present description. The drive assembly 400 comprises a motor gear 402, a transfer gear 404, a limit sensor 406, a spool gear 408, and a shaft 410 of the spool gear 408. The motor gear 402 is connected to the electric motor 226. The motor gear 402 is also connected to the transfer gear 404 and the transfer gear 404 is then connected to the spool gear 408. The motor gear 402 is a 45 degree bevel gear. The transfer gear 404 is connected to the motor gear 402 in a way that it re-orients the direction of force produced by the motor gear 402 by 90 degrees. The technical effect of this connection between the transfer gear 404 and the motor gear 402 is that it creates a space between the motor gear 402 and the shaft of the spool gear 410 to allow the blade member to be easily stored in the flat shape, wound up on the shaft of the spool gear 410 in the reel form. The transfer gear 404 has the limit sensor (hall effect sensor) 406 embedded inside the structure of the transfer gear 404. The limit sensor is configured to sense a change in the magnetic fields as the transfer gear 404 rotates. The technical effect of embedding the limit sensor 406 into the transfer gear 404 is that it allows for programmatically limit the blade member deployment and preventing the excessive deployment of the blade member.



FIGS. 5A and 5B are diagrams that illustrates a hilt assembly 504 of the saber apparatus 100, in accordance with an exemplary embodiment of the present description. The hilt assembly 504 comprises a joystick 520, removeable twist lock hilt cap 512, and a removeable customization sleeve 502 for customization of the hilt assembly 504 of the saber apparatus 100. The removeable customization sleeve 502 is configured to cover the top portion of the hilt assembly 504 including removeable twist lock hilt cap 512 and twist lock retention mechanism 308. The removeable customization sleeve 502 is flexible and elastic in nature which allows the removeable customization sleeve 502 to cover the hilt assembly 504 with an elastic fit. The removeable customization sleeve 502 can be used as an accessory that allows users to personalize the grip and appearance of the saber apparatus 100. The removeable customization sleeve 502 can be made from materials such as but not limited to silicone, rubber, flexible polymers, or polymeric materials. The removeable customization sleeve 502 can enhance comfort and provide better grip during use. The removeable customization sleeve 502 can be of various colors, textures, and designs, enabling users to express their individuality or match their saber apparatus 100 to a specific theme or character.



FIG. 6 is a diagram that illustrates the combination 600 of a spool gear 608 and a shaft 610 of the spool gear 608 of the saber apparatus 100, in accordance with an exemplary embodiment of the present description. In the present description the term spool gear 608 is also referred to as a combination of the spool gear 608 and shaft 610 of the spool gear 608. Shaft 610 of spool gear 608 extends from one side of the spool gear 608 and includes a retention slot 612 that receives the proximal end of the blade member 102 and retains the blade member 102 using the blade retention bolt 614 and a captive nut 616 inside the shaft of the spool gear 610. The proximal end of the blade member 102 is tapered and has a hole punched in the center of the proximal end of the blade member 102. The technical effect of the tapered proximal end of the blade member 102 is that allows for an easy attachment of the blade member 102 to the shaft of the spool gear 610. Furthermore, the hole in the center of the proximal end of the blade member 102 allows the blade retention bolt 614 to pass through and screw onto the captive nut 616 which is inside the shaft of the spool gear 610, and securely attach the blade member 102 to the shaft of the spool gear 610. The retention slot 612 allows the blade member 102 to wound up in the reel form on the shaft of the spool gear 610, when the shaft of the spool gear 610 is rotated. Furthermore, the blade retention bolt 614 The retention bolt is screwed in or out of the captive nut 616. Screwing the blade retention bolt 614 fully into the captive nut 616 while the blade member 102 is correctly positioned in the blade retention slot 612 secures the blade member 102. Furthermore, unscrewing the blade retention bolt 614 from the captive nut 616 releases the blade member 102 from the shaft of the spool gear 610.



FIG. 7 is a diagram that illustrates a drive assembly 700 of the saber apparatus 100, in accordance with an exemplary embodiment of the present description. The drive assembly 700 comprises a motor gear 702, a transfer gear 704, an electric motor 706, a spool gear 708, a shaft 710 of spool gear 708, and a blade retention bolt 714. The motor gear 702 is connected to the electric motor 706. The motor gear 702 is also connected to the transfer gear 704 and the transfer gear 704 is then connected to the spool gear 708. The motor gear 702 is a 45 degree bevel gear. The transfer gear 704 is connected to the motor gear 102 in a way that it re-orients the direction of force of the motor gear 702 by 90 degrees. The technical effect of this connection between the transfer gear 704 and the motor gear 702 is that it creates a space between the motor gear 702 and the shaft of the spool gear 710 to allow the blade member to be easily stored in the flat shape, wound up on the shaft of the spool gear 710 in the reel form.



FIG. 8A is a diagram that illustrates an arrangement 800 of a blade member 802 attached to the spool gear 808, and a shaft 810 of the spool gear 808, in accordance with an exemplary embodiment of the present description. The shaft 810 of the spool gear comprises a blade retention slot 812, in which the tapered proximal end of the blade member 802 is inserted. The proximal end of the blade member 802 is tapered and has a hole punched in the center of the proximal end of the blade member 802. This hole lines up with the blade retention bolt 714 in the shaft of the spool gear 810, and the blade retention bolt 714 passes through the hole of blade member 802 to captive nut 616 in the shaft of the spool gear 810 and hold the blade member securely to the shaft of the spool gear 810. The proximal end of the blade member 802 is in the flat shape when the blade member 802 attached to the shaft of the spool gear 810, and when the blade member is deployed or retracted.



FIG. 8B is a diagram that illustrates the blade cap 804 in accordance with an exemplary embodiment of the present description. The blade cap 804 is attached at the distal end of the blade member 802. The blade cap 804 of the saber apparatus 100 comprises a circular cross-section in a plane orthogonal to a longitudinal axis of the blade member 802. The blade cap 804 at the distal end of the blade member 802 comprises at least one reflective mirror having a hole 806 in center to allow the light from the light source 212 to pass through and illuminate the blade cap 804. Furthermore, the light from the light source 212 reaches the end of the blade member 802 and in the blade cap 804 after it passes through the hole present at its center. This light is then reflected by the reflective mirror to provide the illumination of the blade cap 804 and blade member 802. The blade member 802 wraps around in the inside of the blade cap 804 and is attached using suitable adhesive compounds. The blade member 802 is adhered to the blade cap 804.



FIG. 9 is a diagram that illustrates a hilt assembly 904 having a blade member 902 retracted and stored in the flat shape and wound up on the spool gear in the reel form. The retracted blade member 902 is stored within the hilt assembly 904.


In accordance with another exemplary embodiment of the present description, saber apparatus 100 may be configured to be in the form of a laser sword system 101 (FIG. 10). Laser sword system 101 may make use of a blade which consists of only a single blade member 102. Saber apparatus 100 or laser sword system 101 may include multiple, interchangeable or replaceable blade members 102. Similar to saber apparatus 100, laser sword system 101 comprises a hilt assembly 204 comprising a hilt body 206, wherein the hilt assembly 204 comprises a drive assembly, and a blade member 102 operatively connected to the drive assembly. The drive assembly comprises a motor gear attached to a motor, a transfer gear and a spool gear, wherein the drive assembly operates in a first operating state to selectively deploy the blade member 102 outward from an opening in the hilt body 206 and in a second operating state to selectively retract the blade member 102 into the hilt body 206 through the opening in the hilt body 206. The blade member 102 is flexible and is deployed in an arc shape, and wherein the blade member 102 is stored in a flat shape wound up in a reel form on the spool gear 218, within the hilt body 206. The blade member 102 comprises a blade cap 804 at a distal end of the blade member 102, and wherein the blade cap 804 comprises a reflective mirror having a hole in center. The hilt assembly 204 comprises at least one light source 212 within the hilt body 206, wherein light from the light source 212 is directed through at least one lens axially outward towards the blade cap 804 at the distal end of the blade member 102 to light up the blade cap 804 and the blade member 102, and wherein the reflective mirror of the blade cap 804 having the hole in the center allows the light from the light source 212 to pass through and light up the blade cap 804 and the blade member 102.


Furthermore, the blade member 102 is tapered at its proximal end and wherein the blade member 102 comprises a hole at the proximal end to attach the blade member 102 to a shaft 410 of the spool gear 408 using a blade retention bolt 614 passing through the hole at the proximal end of the blade member 102 to the shaft 410 of the spool gear 408.


Certain ones of the above-described components of laser sword system 101, such as blade retention bolt 614 may be selectively disconnected or disassembled by a user sufficiently to replace blade member 102 when it wears out, gets broken, or when preference or fancy dictates. For example, blade retention bolt 614 has a head or similar drive portion accessible to and operable by the user to loosen blade retention bolt 614 and detach blade member 102 from the shaft 410 spool gear 408 of the corresponding implementation of the saber apparatus 100.


As such, laser sword system 101 is readily adaptable to still further modes of play or use, simulating different characters or moments, as may be preferred at different times by the user. Furthermore, repair of damaged or broken blade member, or other user-accessible components, is facilitated. To that end laser sword system 101 may include a plurality or a set of interchangeable blade members 102. Still further, the multiple blade members 102 may be of the same or differing physical characteristics, such as length, color, and the like.


As described in reference to earlier implementations herein, the hilt assembly 204 comprises a limit switch within the hilt body 206, and wherein the limit switch 214 stops the drive assembly when the blade cap 804 hits the limit switch 214 during the retention of the blade member 102 to complete the retention,


Furthermore, the hilt assembly 204 comprises a limit sensor 222 within the hilt body 206, and wherein the limit sensor 222 stops the drive assembly to complete deployment of the blade member 102.


Furthermore, the hilt assembly 204 comprises a removable twist-lock hilt cap 312 at top end of the hilt body 206.


Furthermore, the hilt assembly 204 comprises a removeable sleeve 502 that covers the removeable twist-lock hilt cap 312 at the top end of the hilt body, and wherein the removable sleeve 502 allows for customization of the hilt assembly 204.


Furthermore, the hilt assembly 204 comprises the spool gear 218 within the hilt body 206, wherein the spool gear 218 comprises the shaft extending from one side of the spool gear, wherein the shaft of the spool gear 810 comprises a retention slot 812 that receives the proximal end of the blade member 102 and retain the blade member 102 using the blade retention bolt 614 and a captive nut 612 inside the shaft of the spool gear 810.


In accordance with another exemplary embodiment of the present description, a method 1100 is provided. The method 1100 comprises, at step 1102 operatively connecting a blade member with a drive assembly. At step 1104, selectively deploying and retracting the blade member by operating the drive assembly in a first operating state to deploy the blade member outward from an opening in a hilt body and in a second operating state to retract the blade member into the hilt body through the opening in the hilt body, wherein the blade member is deployed in an arc shape. At step 1106, storing the blade member in a flat shape wound up in a reel form on a spool gear, within the hilt body. At step 1108, directing a light from a light source through at least one lens axially outward towards a blade cap at a distal end of the blade member.


Furthermore, the method 1100 comprises stopping the drive assembly when a blade cap hits a limit switch during the retention of the blade member to complete the retention.


Conditional language such as, among others, “can,” “could,” “might” or “may,” unless specifically stated otherwise, are otherwise understood within the context as used in general to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular embodiment.


The term “blade member,” as used herein is synonymous with “blade,” and, unless otherwise specified, may take on any number of elongate forms extending from the hilt, and may be a single, integral component or multiple components.


Disjunctive language such as the phrase “at least one of X, Y, or Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to present that an item, term, etc., may be either X, Y, or Z, or any combination thereof (e.g., X, Y, and/or Z). Thus, such disjunctive language is not generally intended to, and should not, imply that certain embodiments require at least one of X, at least one of Y, or at least one of Z to each be present.


It will be understood by those within the art that, in general, terms used herein, are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.).

Claims
  • 1. A saber apparatus, comprising: a hilt assembly comprising a hilt body, wherein the hilt body comprises a drive assembly; anda blade member operatively connected to the drive assembly to selectively deploy and retract the blade member, wherein the blade member is flexible and is deployed in an arc shape, and wherein the blade member is stored in a flat shape wound up in a reel form on a spool gear, within the hilt body,wherein the drive assembly operates in a first operating state to deploy the blade member outward from an opening in the hilt body and in a second operating state to retract the blade member into the hilt body through the opening in the hilt body,wherein the blade member comprises a blade cap at a distal end of the blade member, andwherein the hilt assembly comprises at least one light source within the hilt body, wherein light from the light source is directed through at least one lens axially outward towards the blade cap at the distal end of the blade member.
  • 2. The saber apparatus of claim 1, wherein the blade member is tapered at proximal end, and wherein the blade member comprises a hole at the proximal end to attach the blade member to a shaft of the spool gear using a blade retention bolt passing through the hole at the proximal end of the blade member to the shaft of the spool gear.
  • 3. The saber apparatus of claim 1, wherein the blade member is a single blade member, and wherein the arc of the blade member is of 270 degrees and wherein longitudinally opposing edges of the blade member has a gap of 90 degrees.
  • 4. The saber apparatus of claim 1, wherein the blade cap comprises a circular cross-section in a plane orthogonal to a longitudinal axis of the blade member, and wherein the blade cap at the distal end of the blade member comprises a reflective mirror having a hole in center to allow the light from the light source to pass through and illuminate the blade cap.
  • 5. The saber apparatus of claim 1, wherein the hilt assembly comprises a limit switch within the hilt body, and wherein the limit switch stops the drive assembly when the blade cap hits the limit switch during the retention of the blade member to complete the retention.
  • 6. The saber apparatus of claim 1, wherein the hilt assembly comprises a limit sensor within the hilt body, and wherein the limit sensor stops the drive assembly to complete deployment of the blade member.
  • 7. The saber apparatus of claim 1, wherein the hilt assembly comprises a cooling fan within the hilt body for cooling down the light source.
  • 8. The saber apparatus of claim 1, wherein the hilt assembly comprises a removable twist-lock hilt cap at top end of the hilt body.
  • 9. The saber apparatus of claim 1, wherein the hilt assembly comprises a removeable sleeve that covers the removeable twist-lock hilt cap at the top end of the hilt body, and wherein the removable sleeve allows for customization of the hilt assembly.
  • 10. The saber apparatus of claim 1, wherein the hilt assembly comprises the spool gear within the hilt body, wherein the spool gear comprises the shaft extending from one side of the spool gear, wherein the shaft of the spool gear comprises a retention slot that receives the proximal end of the blade member and retain the blade member using the blade retention bolt and a captive nut inside the shaft of the spool gear.
  • 11. The saber apparatus of claim 1, wherein the drive assembly comprises a motor gear attached to a motor, a transfer gear and the spool gear, wherein the motor gear is connected to the transfer gear at one end of the transfer gear and the transfer gear is connected to the spool gear from other end, and wherein the connection between the motor gear and the transfer gear changes orientation of force produced by the motor gear by 90 degrees.
  • 12. A laser sword system, comprising: a hilt assembly comprising a hilt body, wherein the hilt assembly comprises a drive assembly; anda single blade member operatively connected to the drive assembly,wherein the drive assembly comprises a motor gear attached to a motor, a transfer gear and a spool gear, wherein the drive assembly operates in a first operating state to selectively deploy the blade member outward from an opening in the hilt body and in a second operating state to selectively retract the blade member into the hilt body through the opening in the hilt body,wherein the blade member is flexible and is deployed in an arc shape, and wherein the blade member is stored in a flat shape wound up in a reel form on the spool gear, within the hilt body,wherein the blade member comprises a blade cap at a distal end of the blade member, and wherein the blade cap comprises a reflective mirror having a hole in center,wherein the hilt assembly comprises a single LED light source within the hilt body, wherein light from the light source is directed through a single lens axially outward towards the blade cap at the distal end of the blade member to light up the blade cap and the blade member, and wherein the reflective mirror of the blade cap having the hole in the center allows the light from the light source to pass through;wherein the blade member has a proximal end attached to a shaft of the spool gear; andwherein the blade member and the spool gear are configured to permit user detachment of the blade member from the shaft of the spool gear.
  • 13. The system of claim 12, comprising a set of the blade members, each of the blade members being user attachable and detachable from the spool gear.
  • 14. The system of claim 13, wherein the hilt assembly comprises a limit switch within the hilt body, and wherein the limit switch stops the drive assembly when the blade cap hits the limit switch during the retention of the blade member to complete the retention.
  • 15. The system of claim 14, wherein the hilt assembly comprises a limit sensor within the hilt body, and wherein the limit sensor stops the drive assembly to complete deployment of the blade member.
  • 16. The system of claim 15, wherein the hilt assembly comprises a removable twist-lock hilt cap at a top end of the hilt body.
  • 17. The system of claim 16, wherein the hilt assembly comprises a removeable sleeve that covers the removeable twist-lock hilt cap at the top end of the hilt body, and wherein the removable sleeve allows for customization of the hilt assembly.
  • 18. The system of claim 17, wherein the hilt assembly comprises a spool gear within the hilt body, wherein the spool gear comprises the shaft extending from one side of the spool gear, wherein the shaft of the spool gear comprises a retention slot that receives the proximal end of the blade member and retain the blade member using the blade retention bolt and a captive nut inside the shaft of the spool gear.
  • 19. A method of operating a saber apparatus with an illuminated blade member, the method comprising: operatively connecting a blade member with a drive assembly;selectively deploying and retracting the blade member by operating the drive assembly in a first operating state to deploy the blade member outward from an opening in a hilt body and in a second operating state to retract the blade member into the hilt body through the opening in the hilt body, wherein the blade member is deployed in an arc shape;storing the blade member in a flat shape wound up in a reel form on a spool gear, within the hilt body, anddirecting a light from a light source through at least one lens axially outward towards a blade cap at a distal end of the blade member.
  • 20. The method of claim 19, further comprising the step of stopping the drive assembly when a blade cap hits a limit switch during the deployment of the blade member to complete the deployment thereof.
Provisional Applications (1)
Number Date Country
63598738 Nov 2023 US