The present disclosure provides an inflatable toy sword device with a blade configured to extend from and retract into the handle. A flexible blade material may be stored in a spooled configuration within the handle and inflated during extension. During retraction, the process is reversed and air is controllably released while the material is spooled. A method of extending and retracting the flexible blade material of an inflatable toy sword is also provided.

BACKGROUND OF INVENTION

1. Field of the Invention

The present invention relates generally to sabers and more specifically it relates to an inflatable, extending, and retracting sword for novelty use as a toy sword, prop or for simulated combat. A method of using such a device is also provided.

2. Discussion of the Related Art

Simulated weapons, such as swords are frequently used as children's toys, theatrical props and combat training aids. Some such simulated weapons are designed to include specific functional components and ornamental appearances in order to replicate weapons from fictional or non-fictional stories and genres. For example, a toy sword that is intended for use in a theatrical production of an Aurtherian legend may include functional and ornamental aspects that are indicative of the sword Excalibur. Alternatively, if the toy sword was an accessory to a samurai costume, the sword may include functional and ornamental aspects that are indicative of a Japanese katana. In the genre of science fiction, many characters utilize swords that include a retractable blade formed of energy and/or light that selectively extends from the handle. The fictional nature of such devices renders accurate simulation of the functional components and ornamental appearances difficult.

Prior attempts to replicate such devices have included an apparatus of two-piece construction, where the rigid elongated blade is selectively attached to the handle or hilt by the user. Alternatively, some devices have utilized a telescopic blade that reduces, but does not eliminate the visible appearance of a portion of the blade when in the retracted configuration. However, all such devices fail to provide an accurate simulation of the blade extension and retraction.

In an effort to remedy these deficiencies, more recent attempts to replicate such energy swords have included the use of LED strips disposed on a flexible substrate that are mechanically driven between extended and retracted configurations. However, such devices are exceedingly delicate and not well suited for use in simulated combat. As such there remains a need for a device that both accurately simulates the extension and retraction of a science fiction energy sword while also being well suited for use in simulated combat and play.

Accordingly, the present invention addresses this long felt need by providing a toy sword which includes in at least one embodiment a blade chamber, handle or hilt, blade, switch, pump, battery, electric motor or motors, and controller.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the invention, this need is satisfied by providing an adjustable sword apparatus configured for use in simulated combat that includes a housing having a sidewall extending between opposing first and second ends, an inflatable blade having a flexible wall extending between a first connected end affixed within a void defined by the sidewall of the housing and an opposing second end that is movable relative to the connected end. The apparatus includes an extension system disposed within the void that is configured to inflate an interior of the blade such that the second end of the flexible wall extends outwardly from the void in the housing, and a retraction system disposed within the void configured to retract at least a portion of the blade within the void.

A nonlimiting feature of this embodiment is to provide an inflatable expanding sword for novelty use as a toy or prop in simulated combat.

Another aspect of the invention is to provide an apparatus comprising a power source and a controller in electrical communication with the extension system and the retraction system, the power source and controller disposed within the housing void.

A nonlimiting feature of this embodiment is to provide a power source located in the apparatus for activating the blade extension and retraction systems.

Another aspect of the invention is to provide an air pump activated by the controller, the air pump in fluid communication with the interior of the blade and configured to provide positive air pressure to the interior of the blade upon activation.

Another nonlimiting feature of this embodiment is to provide an inflatable, expanding sword that contains significant pressure to hold shape while being swung.

Another aspect of the invention is to provide a motor activated by the controller and a lead extending between the motor and the second end of the flexible wall of the blade, the motor configured to retract the lead and the second end of the flexible wall upon activation.

Another nonlimiting feature of this embodiment is to provide an inflatable, expanding sword that has a blade that returns back into the housing when retracted.

In accordance with a another aspect of the invention, an adjustable saber apparatus configured for use in simulated combat is provided that includes a housing having a sidewall extending between opposing first and second ends, a pressurizable blade having a flexible wall extending between a first connected end affixed within a void defined by the sidewall of the housing and an opposing second end that is movable relative to the connected end. The apparatus includes a control circuit disposed within the housing, including, a power supply, an extension system that is configured to inflate an interior of the blade such that the second end of the flexible wall extends outwardly from the void in the housing, a retraction system configured to retract at least a portion of the blade within the void, and a controller.

In accordance with a another aspect of the invention, an inflatable device is provided that includes a rigid housing affixed to a generally cylindrical inflatable portion formed of a flexible high-tensile strength material configured to move between an expanded configuration and retracted configuration. The inflatable portion is generally contained within a void disposed in the rigid housing when in the retracted configuration and extends outwardly from the void when in the extended configuration.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, in which similar reference characters denote similar elements throughout the several views, the figures illustrate various components and embodiments of the present invention. In describing the embodiments of the invention which are illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific terms so selected and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For example, the words “connected,” “attached,” or tennis similar thereto are often used. They are not limited to direct connection or attachment, but include connection or attachment to other elements where such connection or attachment is recognized as being equivalent by those skilled in the art.

Referring now toFIG.1to13, and initiallyFIG.1, a sword or device1for simulated combat that has an expanding and retracting blade30is shown. During use, the blade30automatically expands or extends from the handle or hilt10and is then configured to retract back within. Once extended, the blade30is monolithic, which is to say fortited of a continuous outer surface that is preferable to a segmented blade. Moreover, the device1can be used for simulated combat when the blade30is in the extended configuration. Inflating the blade30above atmospheric pressure provides rigidity to an otherwise soft and flexible material making it less destructive in simulated combat, than blades formed of rigid plastic.

Generally, the housing10, i.e., the handle or hilt, as may be used interchangeably herein, may contain all or most of the electromechanical components of the device1. The rigidity of the housing10retains the internally housed components protected and firmly situated for use during simulated combat. As shown inFIGS.7and8, a portion of the interior void27of the housing1defines a blade chamber13that connects to the blade30and is designed to hold pressure during operation of the device1. In one embodiment of the present invention, the remaining portion of the housing10, i.e. the interior void27that does not define the blade chamber13may not be pressurized above atmospheric pressure. When retracted, the blade10is stored or retained in the void27defined by the inner surfaces of the one or more walls of the housing10disposed within the blade chamber13. The blade chamber13may be separated from the non-pressurized portion of the housing10by an airtight barrier14. However, the blade chamber13may not define the entirety of the pressurized section of the housing10. That is to say that the blade chamber13is configured with at least one opening26to receive air flow from the non-pressurized portion of the housing10through the airtight barrier14. In this manner, the blade chamber13plays a role in the extension and retraction of the blade30as will be described in further detail below. When retracted, the blade30is situated in a void27within the blade chamber13, such that at least the majority of the blade is recesses within the void27.

As shown inFIG.5, the blade chamber13may be permanently affixed within the pressurized portion of the housing10, or it may be releasably affixed. If releasably affixed, the blade chamber13may be inserted into a void in the pressurized portion of the housing10and affixed such that it will create an airtight seal from the atmosphere as depicted inFIG.4. Alternatively, the blade chamber13may make up an external portion48of the pressurized portion of the housing and may detach from the remaining housing.FIG.5shows the two portions of the housing with blade chamber13detached from the pressurized portion. When attached, this portion of the housing10will form an airtight seal to the blade chamber13, and an airtight seal from the atmosphere.

The blade30, which will receive the majority of striking force during simulated combat and use of the device1, is made to be a resilient inflatable structure. Accordingly, the blade30and its connection to the blade chamber13are configured to maintain positive air pressure, even when the blade30is struck against more rigid structures with generally harder or sharper surfaces such as: walls, furniture, wrist watches and plants. The blade30has an outer wall32that extends outwardly from the blade chamber13. The outer wall32is generally cylindrical, but more preferably conical and/or tapered such that its circumference decreases along its length as the blade30extends further from the first end that is affixed to the blade chamber13until the blade30reaches a desired length. At the second end of the extended blade30, which is located at a point between the opposed ends of the fully extended blade, as shown inFIG.10, the wall32of the blade30folds inwardly on itself. As a result of this inward fold, as shown inFIG.13, at the second end of the blade30, the outer diameter of the blade30becomes an inner diameter. From the end of the inwardly projecting portion of the blade30is a lead33or tether, extends from the opposing second end, into the blade chamber13. This configuration allows for an axial extension and retraction of the blade30. The blade30is preferably made of a high tensile strength, highly flexible fabric or material that has a weight of preferably 4 to 310 denier.

While the first end of the lead33extends from the blade30, the opposing second end of the lead33is affixed, and more preferably movably affixed, within the blade chamber13. During extension, air pressure created by the pump20increases within the interior cavity of blade30. This increased pressure forced the blade30to expand from within itself, unraveling away from the blade chamber13. The outward extension from the housing10of the device1will stop as the lead33reaches its full length and is placed under tension. During use, in one embodiment the pump20may be activated at a lower flow rate to maintain desired positive pressure in the blade30. Conversely, for retraction from the pressurized and extended shape shown inFIG.2, the blade30is controllably depressurized as it is simultaneously retracted, e.g., rolled by the motor16into the blade chamber13by rolling or spooling of the lead33from its spool end37. In one embodiment, the motor16is an electric DC motor that creates preferably between 100 and 500 kg-cm of torque and spools the lead33at a rate of 100-500 rpm, such that the retraction of the blade30occurs in preferably under 10 seconds. The top of the internal cone35, referred to as the folding point34will begin to move down the length of the outer wall32, towards the housing10, as the spooling begins. Eventually, the entirety or majority of the blade30will be inverted and rolled into the blade chamber13.

Extension and retraction of the blade30are controlled by a system of components that may work in tandem. By way of nonlimiting example, during extension of the blade30, increased air pressure is created by a pump20, as shown inFIGS.6through9, to inflate and extend the blade30. Extension of the blade30may also incorporate activation of the motor16to unspool or otherwise physically move the blade30out of the blade chamber13. In another embodiment, the motor16may be placed in a neutral position during blade extension as to minimize drag on the blade30while it is extended, in the event that the motor is not reversed to apply active assistance in extension. Conversely, the retraction system may utilize the motor16to spool or roll the lead33and blade30into the blade chamber13. Simultaneously, the blade30and blade chamber13may be controllably depressurized by a pressure relief mechanism15. Alternatively, the retraction system may also incorporate use of the pump20if the pressure falls below the desired value for retraction, which is to say a set threshold of air pressure maybe maintained in the blade30during retraction such that the blade30does not undesirably wilt during retraction, but rather maintains its general cylindrical shape while retracting. Both systems may also incorporate a switch25, power source21, controller22, sensors, fluid pathways23, and check valve19, as shown inFIGS.6through9.

In addition to extension and retraction functions, the device1may also incorporate components that enhance the audio-visual experience during use of the device1. By way of non limiting examples, these components may include lights, such as one or more LEDs, speakers, and sensors to detect motion and impact, some or all of which may be incorporated as part of the controller22.

Still referring toFIGS.6through9, the housing10or as it's more commonly known, the hilt or handle, will now be described in greater detail. The housing10houses the blade chamber13, retracted blade30, and electromechanical components of the device1. The housing10preferably defines a plastic shell, likely of PC or ABS material that keeps the internal components firmly situated within. Alternatively, the housing10may also be constructed entirely or partially of metal, likely steel or aluminum if desired for higher durability or a specific aesthetic appearance. In most cases, the housing10will be generally cylindrical for ergonomics but may be many shapes and sizes that fit within a user's hand or hands. The housing10will preferably be 6 inches to 14 inches long and 1 inch to 3 inches wide, however it may be longer or wider in some embodiments such as a double bladed or staff saber. Furthermore, it should be understood that the shape of the housing10does not need to be cylindrical, can be curved or a multitude of other shapes. Multiple hilts can connect to one another at the bottom or sides of the housing10to form a staff or multiple blade saber. Other accessories may be designed to connect to the housing10. It is also possible that the functional components of the devices are separated into two housings that are linked by a flexible connection, likely containing fluid pathways and/or electrical wiring. Such an embodiment may be preferable to reduce the size of the housing10that is held in the user's hands.

Within the housing10, the power source21, charging port24and controller22are preferably disposed at a second end opposite the blade30. In such an embodiment, their location is within the non-pressurized portion of the housing10. In one preferred embodiment, pump20is preferably situated between the power source21with its outlet directed towards the airtight barrier14. The outlet of pump20is connected to a fluid pathway23which may be connected to check valve19. In one embodiment, the pump20has a flow rate of approximately 5-50 liters of air per minute. Check valve19passively maintains the pressure built by the pump20from flowing back into the pump20. The pressurized portion of housing10is configured to hold significant pressure until that pressure is released by the actuation of relief mechanism15. Air intake18is preferably located near the inlet of pump20and the outlet and/or relief mechanism15. Air intake18may be a perforated opening in the housing10that allows free flow of air inside and out of the housing10. It is preferably large enough that pump20will not be starved for air while at peak function and as to not restrict the desired flow of relief mechanism15. In one embodiment, as shown inFIG.5, the housing10may define a set of two injection molded halves that screw or clip together. Disposed upon the outer surface of the housing10is a switch25. Switch25can be placed anywhere along the housing10, and is configured to activate extension and retraction of the blade30via the extension and retraction systems as described above.

Alternatively, the housing10connection to the blade chamber13may include an embodiment wherein the electric motor16is not separated by an airtight barrier from the non-pressurized portion of the housing10, but rather has a connection through an airtight barrier with an airtight shaft configuration which attaches the motor driveshaft. Another embodiment may include the pressure sensor17connected directly to a fluid pathway between the check valve19and the airtight barrier14. The blade chamber13may include other mechanical or electrical components, such as gears45or additional sensors.

Referring now to the blade chamber13, which defines a portion of the housing10that connects to the blade30and is designed to hold pressure during extended blade operation of the device1. In contrast, the remaining portion of the housing10is preferably not pressurized above atmospheric pressure. When retracted, the blade30is stored within a void27in the blade chamber13. The airtight barrier14divides the housing10into a pressurized portion11on one side of the barrier and non-pressurized portion12on the opposing side of the barrier. The blade chamber13is positioned on the pressurized portion12of the housing10. Various components will be disposed within the pressurized side of the airtight barrier14. Most or all of the retraction mechanism will preferably be positioned within the pressurized portion12of the housing10since the blade30is both attached to the blade chamber13and stored in a void27within. The motor16is preferably positioned on the pressurized side of the airtight barrier14, as it is easier to pass electrical current through the airtight barrier14than mechanical motion. However, it should be understood that the present invention is not so limited, and that location of the motor16within the nonpressurized portion of the housing10is well within the scope of the present invention. The motor16may also connect to other mechanical elements of the retraction system within the blade chamber13, such as gears45, belts, chains, a driveshaft, spool46, or roller47to the extent present

The pressure relief mechanism15can be placed on either side of the airtight barrier14with appropriate connections to a fluid pathway23passing through the airtight barrier14. Likewise, the check valve19can also be placed on either side of the airtight barrier14with appropriate connections to a fluid pathway23passing through the airtight barrier14. The pump20is preferably positioned within the housing on the non-pressurized side of the airtight barrier14so that it can intake air from the atmosphere. The pump9is connected to a fluid pathway23to the blade chamber13to create air pressure in the blade chamber13and blade30. However, it is possible to place the pump20within the pressurized side of the airtight barrier14if there is a fluid pathway23connection through the airtight barrier14that opens to atmosphere.

The blade chamber13may be permanently affixed within the pressurized portion12of the housing10, or more preferably it may be releasably affixed. Having a releasably affixed blade chamber13allows for replacement of a damaged blade30while retaining the comparably more mechanically complex, and theoretically undamaged, components within the housing10.

If releasably affixed, the blade chamber13may be inserted into a void in the housing10and affixed in a manner that the connection will create an airtight seal from the atmosphere as depicted inFIG.4. For example, the blade chamber13can be seated internally within the pressurized portion12of the housing and affixed therein by a threaded or locking collar41disposed at the first end of the housing10, as shown inFIG.4. Such an embodiment provides the additional benefit of maintaining the entirety or majority of the external surface of the housing10independent from the replaceable blade chamber13. Therefore, a common replaceable blade chamber13may be used in multiple different housing10designs. The airtight barrier14that separates the pressurized portion12of the housing10from the non-pressurized portion11of the housing10may be affixed to the pressurized portion12or the blade chamber13. When the blade chamber13is inserted, it will form a mechanical linkage with the housing10. This linkage may be formed with an external threaded lock collar, screws, or other similar retaining structure. The blade chamber13itself may have integral threads or a quick connect design to easily attach to the main housing. Air seals, such as O-rings or an alternative resilient structure, may be present so that when affixed, the blade chamber13is pressurized with the pressurized portion12of the housing10. The blade chamber13may be keyed to ensure proper orientation when inserted into the housing10. The retraction system, such as gears45, will need to mate properly when the blade chamber13is installed.

In an alternative embodiment, rather than the blade chamber13inserting into the housing10as shown inFIG.4and described above, a detachable blade chamber13may incorporate and define an external portion48of the housing10as depicted inFIG.5. This embodiment provides the additional benefit of providing a blade chamber13that may be more durable as it is formed integrally with the outer surface of a portion of the housing10, and/or provides an opportunity for the ornamental design of the housing10to be altered with a replacement blade chamber13. When attached, the blade chamber13will form an airtight seal, closing the pressurized portion12of the housing and allowing for appropriate mating of the fluid pathways23, electrical connections, and mechanical components of the retraction system to be made. The blade chamber13may be keyed or indexed to ensure proper orientation when attached to the housing10. When the blade chamber13is attached, it will form a mechanical connection with the non-pressurized portion12of the housing10. This connection may be formed with an external threaded lock collar, screws, or other similar retaining features. The blade chamber13itself may have integral threads or a quick connect design to easily attach to the housing10. Air seals, such as O-rings, will be used so that when affixed, pressure can be raised and held to the desired value.

Turning now toFIGS.10thorough13, the blade30will be described in further detail. The blade30, which will receive the greatest about of wear and tear from receiving striking blows, is made to be a resilient inflatable structure. The blade30is preferably made of a high tensile strength, highly flexible fabric or material that is air impermeable, for example a nylon or polyester material. Air impermeability is preferably achieved with a thermoplastic polyurethane (TPU) coating disposed on or more sides of the flexible fabric or material. The TPU coating also allows for bonding or sealing to itself during the construction of the blade30. The blade30is designed to maintain air pressure, even when hit against other inflatable blades or comparably harder and sharper objects. The blade30is preferably sealed at its connecting end36to the blade chamber13and in fluid communication with the pressurized portion12of the housing10. The blade30is generally cylindrical, but more preferably conical. The blade30preferably has a length of approximately between 10 and 40 inches in length between the connected end36and the folding point34when fully extended, and a cross-sectional width of approximately 1 to 5 inches, and more preferably approximately 2 inches. As used herein the term approximately is understood to mean plus or minus 10%. The sidewall of the blade may be inclined at an angle of between 0.1° and 20° relative to a central longitudinal axis of the blade. Furthermore, the degree of taper may vary along the length of the blade30. The blade30may have a conical outer wall32that extends from the outer diameter of the blade chamber13. The outer wall32is preferably conical and has an outer circumference that decreases along the length of the blade as it travels further from the connecting end36. The opposing end of the blade34when fully or partially extended defines a fold point34, where the blade30folds inwardly, toward the center of the blade30, causing the outer wall32to become an internal surface. At this opposing exposed end defined by the folding point34of the blade30, the outer diameter is tensioned inward for a small section that forms a short conical inlet in the center. This portion is called the inner cone35. The point at which the material bends at the second end and is redirected is defines the folding point34. From the center of the inner cone35there is a lead33that extends down into the internal center of the blade chamber13. The lead33may be a thin band of the same material the blade30is constructed of, or a different material such as a string or wire which engages the handle10as described above.

FIG.10illustrates an embodiment of the blade30fully extended and before it is inverted to attached to the blade chamber13. Once the blade30is inverted over itself, sealed edge31will be internal to the outer wall32. The specified length of the lead33, from the spool end37to the inner cone35, determines the length to which the blade30can expand. Air pressure will build within the blade30, forcing it to extend from within itself, unraveling away from the blade chamber13. The expansion outward from the device1will stop as the lead33reaches its full length and is placed under tension. From there, the inverted cone35extends to the folding point34where the material folds and becomes the outer wall32, as is shown inFIG.11.FIG.11also illustrates the connecting end36and spool end37. The connecting end36is the location at which the outer wall32connects with the blade chamber13to create an airtight seal.FIG.11shows an isometric view of the second end of blade30in its expanded form, which depicts the lead33centered within the outer wall32. It's preferable that the length of the outer wall32is drafted. The smaller end being at the folding point34and the larger at the connecting end36. Such a tapered configuration provides ease of retraction into itself, ease of expansion from within itself, as well as increased line of sight for light emitted from internal LEDs to the internal surface of the blade30's outer wall32.

In an alternative embodiment, the inner cone35may extend fully or most of the way to the spool end37and define the lead33.FIG.13shows this alternative embodiment. Such an embodiment may give the blade30increased rigidity and reduce the volume that is pressurized within the blade30. Such a reduced in interior volume of the blade30would correspondingly reduce the time to full expansion and pressurization of the blade30.

Turning now toFIG.8, one system and method of retraction of the blade30within the blade chamber13is illustrated. That is to say, from its pressurized/extended shape inFIG.2, the blade30is controllably depressurized as it is rolled into the blade chamber13by rolling of the lead33from its spool end37. The top of the inner cone35, referred to as the folding point34, will begin to move down the length of the outer wall32, towards the connected end36, as the spooling begins. Eventually, the entire blade30will be inverted and the majority of its length rolled into the blade chamber13.

In another system and method of retraction, the lead33is rolled as previously described but the outer portion of the blade30collapses down as it retracts in the manner consistent with a compression spring. The compressed outer blade fits down into a void27within the blade chamber13or housing10. in this embodiment, a spring or lattice like structure could be coupled to the blade to aid in guiding the retraction so the blade30collapses desirably, or to add rigidity when extended. A lattice structure (not shown) could be configured similar to an isokinetic expanding hinged sphere, i.e., Hoberman sphere, arranged instead in a cylindrical shape. In another embodiment, the lead33may be comprised of a spring metal or spring plastic that rolls flat but when extended has shape memory to form a rigid member, much like a tape measure. In another embodiment, the lead33may be comprised of a coil spring, flat spring, or shape memory alloy that extends upon extension of the blade30. One end of the spring would be affixed in the blade chamber13, while the other end is affixed or positioned at the second end of the blade30. The spring may be configured to maintain an opposing return force applied to the folding point34of the blade30to aid in retraction of the blade30. The spring may alternatively be configured to maintain opposing expanding force while the blade30is retracted to aid in extension of the blade. In another embodiment, the lead33may be spooled and coupled to a torsion spring that maintains a return force while the lead is fully extended to aid in retraction when air pressure is removed. The lead33can be a string or different thicknesses for weight or size reduction or even increased tensile strength. The lead33could potentially be elastic for increased recovery to its desired shape when the blade30shape is deformed from impact.

Other embodiments include of the blade30as described above may include or incorporate different colors, lengths and blade shapes. Such variable colors may include translucency. The blade30could be colored instead of white to help with color visualization. This may be necessary for use in brightly lit areas or to make a lower cost device that is not able to use LEDs of sufficient brightness as to fully illuminate the blade30when fully extended. It is also considered within the scope of the present invention to have printed patterns, textures, layers or multiple types of materials on the blade30to further improve the visual effect of device1

As indicated above, while blade30with a conical shape aids in expansion and retraction, other shapes are considered well within the scope of the present invention in order to achieve a specific visual look, including cylindrical, curved, square, or flat blades30which can be made using internal structures that connect to opposing inner blade walls to hold a flatter shape while staying out of the way of the retraction system. Alternatively, a flat blade could be formed using two pressurized tubes with additional material spanned between them. The device may incorporate a multitude of blades. One embodiment incorporating multiple blades would be a dual bladed device with blades extending from opposite ends of the housing10. This embodiment may require additional internal components, such as a second pump and additional sensors, retraction motors, etc. Another multiple blade embodiment would include small blades extending out perpendicular to the main blade30forming a hilt guard. These smaller blades may have retraction components similar to the main blade30, a retraction shaft coupled to a motor, a retraction shaft that is spring loaded, or may function more simply using elastic center leads or tensile springs to retract when air pressure is released. The housing of a multi-blade device may be separable, joinable, foldable, or otherwise assembled in a way to match a desired style and configuration.

As indicated above, blade retraction is performed by an interworking system of components. One embodiment of the system includes a spool46which is attached to the lead33of the blade30.FIG.8illustrates such an embodiment, in which the blade30is rolled around the spool46. The opposite end of the blade30, i.e., end36is connected to the top of the blade chamber13and creates an airtight seal. Retraction of the blade in such a system may utilize both the release of pressure and the mechanical movement of the spool46by means of the motor16.

In another system and method of retraction, one or more rollers47are positioned such that they pinch and then pull the lead33and then blade30into an internal void27when they are bunched. The rollers47, which may include one or more actively driven rollers and/or one or more passive following rollers may exert sufficient force onto the blade30to grip the blade30and are sufficiently compliant as to adapt to the changing thickness as retraction progresses from the lead33to the outer wall32. The rollers47may be round in shape as shown inFIG.9or have a gear or other shape to aid in gripping the blade30.

The motor16of the device1is in a mechanical connection to the retraction components, which may take the form of either the spool46or the rollers47. One embodiment of transmitting mechanical power is a set of gears45, with the first gear on the output shaft of the motor16, the final gear on the spool46or rollers47, and any necessary gears45between to achieve the desired orientation, distance, and rotation speed.FIGS.7through9illustrate the span of these gears45. Other methods of connection, such as a driveshaft, pulley and belt, chain and sprocket, or a combination of a multitude of the aforementioned structures are also considered within the scope of the present invention.

Within the blade chamber13, there may also be a structure or structures referred to herein as the shaper or blade guide44. The purpose of the blade guide44is to orient the blade during retraction. There may also be a multitude of blade guides44. The blade guide44could be for merely centering the blade30relative to the interior of the housing10during retraction. Alternatively, the blade guide44may fold the edges of the blade30before rolled or fold the entire blade30in half. Such shaping of the blade prior to retraction may reduce the width and allow the blade30to be rolled within a smaller diameter blade chamber13.

During retraction of the blade30, it is desirable to maintain some air pressure in the blade30during retraction to keep the blade30straight, and prevent wilting. Therefore the pump20may also be engaged at a controlled rate during retraction. The controller22may determine when the blade30is fully retracted in a multitude of ways as to trigger deactivation of the retraction system. The controller may monitor current to the retraction electric motor16to detect a stall. Alternatively, a sensor on the blade30or a trigger that pairs with a sensor in the blade chamber13, such as a hall effect or optical sensor, that will signal full retraction, or a sensor in the housing10, such as optical or IR proximity, can determine when the blade30is fully retracted, and single the controller22accordingly.

During use, extension of the blade30is primarily driven by the pump20increasing air pressure in the blade chamber13and blade30. As air pressure fills blade chamber13, the rolled blade30being a highly flexible material will innately conform to exert internal pressure outward toward lower atmospheric pressure. Since there is only one direction that the blade30it can expand, i.e. through the open first end of the housing10, the blade30will begin to unravel from within, extending the folding point34from the pressure chamber13to its full length opposite the connecting end36. The motor16may also be engaged in the reverse direction to help unspool or otherwise actively move the blade30out of the blade chamber13. If the motor16has sufficiently low resistance, it may spin freely to allow the blade30to extend without electrically engaging the motor16. Alternatively, the motor16may be mechanically decoupled from the retraction mechanisms to remove any resistance during extension. Extension will continue until the device1determines that the blade30is fully extended and the desired air pressure is achieved within the interior of the blade. Desired pressure is preferably in the range 3-30 and more preferably 3-20 psi, and can be determined with a pressure sensor17or switch. It may also be possible to measure the current of the pump20to determine when the pump20has reached the maximum pressure it can achieve, or by using a timer knowing that the pump will max out at the correct pressure. Complete blade30extension can be determined by a sensor on the blade30or a trigger that pairs with a sensor in the housing10, such as a hall effect or optical, that will signal when fully extended, or a sensor in the housing10, such as optical or IR proximity.

Turning now toFIGS.6through9, the power source21, is configured to fit within the housing10. The power source21is directly connected to the controller22which is in electrical communication with the remaining electrical components of the device1. The power source21is preferably a rechargeable (secondary) lithium ion battery, composed of either a cylindrical cell or cells or a polymer pack. The battery size and chemistry selected is configured to provide sufficient current to satisfy the electrical current draw of the pump and the electric motor. The battery may be comprised of one or more cells to achieve the required voltage and capacity for operation. The battery may be removable from the hilt for charging or replacement. Alternatively, other battery types may be used including nickel-metal hydride (Ni-MH) or nickel cadmium (NiCad), however these are no longer as popular due to lower performance compared to lithium ion. Charging of the power source may be achieved by connecting a power supply via a cable to an external charging port24on the hilt, a charging base or connector that connects via contacts externally mounted on the hilt, or a charging base or connector that wirelessly charges via induction. Alternatively, non-rechargeable primary cells can also be used to power the device to allow replacement instead of recharging. Alternatively, the power source may be comprised of a non-traditional battery type, such as a supercapacitor, or any emerging battery technologies.

As previously indicated, device1include an activation switch25. The function of the device1relies on the user to turn it on and off. A main element of this activation/deactivation, i.e., extension and retraction of the blade20is the switch25. The switch25is preferably embedded within the clamshell of the housing10and is preferably located just above the grip portion of the housing10, where someone comfortably holding the device1could easily access it but will avoid incidental contact during simulated combat. The switch25location may change based on ornamental design of the housing10. The switch is configured to power the device on and off, which coincides with the expansion and retraction of the blade30. The switch25will be directly connected to the controller22to interface with its operation. The switch25, attached to the outside of the hilt or within, is preferably activated from the outside of the housing10by the user.

The switch25may be an electronic switch that signals all functions to be performed by the circuitry. The electronic switch may be but is not limited to a push button, toggle switch, slider, rotary switch, capacitive switch, or pressure switch. The electronic switch may be momentary or hold an on-off position. The movement of the switch25may also be mechanically linked to perform a function within the housing10. For example, movement of a slider switch may mechanically open or close an air release valve or move the motor into position to couple or decouple with the retraction components.

At least a second switch, dial, or similar user interface may also be added to make other adjustments to the function of the device, such as adjusting the LEDs activation, LED color, air pressure, or blade length, speaker volume, etc.

The motor16, firmly affixed within the housing10, is used in the extension and retraction of the blade30. The motor16, likely of cylindrical shape, is preferably located within the pressurized portion12of the housing10as previously indicated. The motor16will be controlled by the controller22and powered by the power source21. The motor16will preferably be coupled to gears45to reduce the speed and increase the torque. The motor could be of brushed or brushless design. Alternatively, if the motor can be mechanically decoupled, or has sufficiently low free-spinning resistance, it may not be used during extension of the blade20.

The controller22connects all the electrical components and runs basic firmware so the device1can operate as indicated herein. Located within the housing10, the controller22will be firmly affixed as to avoid damage during simulated combat.

The controller22will feature numerous electrical parts common to operation of motors, LEDs, power source, speakers, and all other components included in the device1. These parts may include, but are not limited to, some or all of the following: a voltage regulator, voltage step up (boost) circuit, battery monitoring and charging circuit, motor driver or drivers, LED driver or circuitry to control current and voltage supplied to LEDs, speaker controller, vibrator, motion sensing including accelerometer or gyroscope, circuit to read or communicate with the air pressure sensor, Bluetooth receiver/transmitter, NFC or RFID reader, and various electrical connectors. The speaker may be mounted on the controller22or mounted off board and connected with wires. The controller22will respond to user input via the switch25and motion and impact of the blade30. The controller22may be interfaced by the user to change the color of the blade30. Programming may be done by adjusting an internally or externally mounted switch or dial or buttons, wirelessly with Bluetooth and a connected app, memory card, or changed by the physical or wireless connection of different parts that the user will be able to swap within the housing1. The blade30could be made of a conductive fabric that is connected electrically to the controller22so that it functions as a sensor to detect when it makes contact with another blade, which could be distinguished from contact with another object.

Programming of the controller22will account for all envisioned scenarios during use so that the device remains functional. For example, if the power source21is depleted during use the device I will be able to extend or retract a partially extended blade30when recharged. For another example, if a blade30is obstructed during expansion or retraction, it will stop inflating once it reaches set pressure even if partially extended, or will stop retraction if the controller22senses a motor stall. Constant monitoring of the state of the blade30could allow the controller22to resume extension or retraction once able, or the user could trigger extension or retraction to resume as desired. Error codes could be given to the user through LED indication, audio indication, or wireless communication with another device such as a cellphone.

There are several possible embodiments of the pressure relief mechanism15. One possible embodiment is that the motor16used for retraction is also configured to move a pressure valve open and closed. This can be done with a cammed or toothed element operation when spinning in one direction. After the valve is open, the element could de-clutch as it spins to prevent damage. The valve could be spring loaded so that when the motor16stops spinning it closes. This operation of the air valve could also be controlled by a second electric motor that is not also being used for retraction.

One embodiment of the present invention includes an electric solenoid that directly opens and closes an air valve in fluid communication with atmospheric pressure. Other electric possibilities include an electric motor or electric stepper motor that opens a valve through turning motion (i.e. a ball valve, stop-cock or screw valve), or a linear stepper or actuator that slides a valve open and closed.

Another possible embodiment may include user actuation of the switch25, which physically opens and closes an air valve. In such an embodiment, the switch25would further include adequate air seals to prevent leaking.

One system and method of lighting the blade30is an LED ring or array43that is situated at the base of the blade30within the blade chamber13. The LEDs may be positioned circumferentially around the base of the blade30for even illumination, for example around locking collar41. However, a smaller number of LEDs may be used so it may not resemble a ring. If the blade30is shaped differently from a cylinder or cone, the LEDs may not necessarily be arranged in a ring as to provide even illumination. A light diffuser may also be disposed adjacent the LEDs to achieve desired light distribution. Alternatively, it is possible to light the blade30with at least one centrally located LED behind the spool. The central location of the LEDs may be desirable to interact with optical or luminescent elements down the center lead33of the blade. The LEDs may be directed to emit light in line with the blade or directed at optical elements located therein. Optical elements, such as fiber optics may be included to further direct the light for full and even illumination of the blade. Optics could include lenses, collimators, filters, mirrors, diffraction elements, or fiber optics. Fiber optics may be incorporated into the construction of the blade30or lead33to improve light transmission. An additional light emitter may be affixed to the second end of the blade and oriented to emit light back down the blade to aid in full blade illumination.

Alternatively, the LEDs may be incorporated into the construction of the blade30. LEDs may be mounted on the lead33and distributed down the length of the blade30. The associated circuitry and wiring connecting the LEDs will be made flexible so that the blade30can still be rolled up or otherwise stored when retracted.

If the blade30is constructed of a translucent white or gray colored material, the LED color can dictate the illuminated color of the blade. LEDs may be of a single color or multiple colors that allow for adjustment of the output hue, i.e. RGB LEDs. Alternatively, the blade may be constructed of a translucent colored material which can be lit by colored or white LEDs. Blades may be constructed of a multitude of colored materials to achieve the desired visual effect.

The blade30material may also be constructed containing a photoluminescent material that reacts with the emitted light to enhance the lighting effect of the blade, or an electroluminescent material that emits light when an electrical current is applied. The blade may be constructed of varying densities, layers, or woven patterns that vary the light output for the desired visual effect.

A laser diode or diodes could also be used with the proper optical components. The beam would need to be split a multitude of times and projected in an even spread throughout the length of the blade for an even lighting effect. There may also be the addition of an o-ring lens or lenses above the LED's that have movements for optical effects.