Abstract:
A kit for installing discrete light sources in a flying disc includes a self-contained lighting circuit and supporting structure and a die for punching holes in the disc in which the discrete light sources are situated. The lighting assembly unit includes a transparent membrane, some double-faced adhesive tape and a set of conductive strips sandwiched between the tape and the membrane. The discrete light sources are mounted on the underside of the distal portions of the membrane arms and are kept apart from the distal portions of the tape by non-stick removable liner segments which are also used on the underside of the double-faced tape. A method of installing the lighting unit is disclosed in which the liner is removed from the underside of the tape to attach the lighting assembly to the disc, holes are punched through the distal portions of the tape and the distal portions of the membrane arms are secured to the disc as the lighting sources are being inserted into the holes where they are seen from the top and the bottom and at points radially outward from the disc.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to illuminated flying discs of the type that are thrown and caught by people as a recreational activity. 
     2. Description of the Prior Art 
     There are various ways known in the art of flying discs for adding the feature of illumination. Perhaps the most common type of illuminated flying disc is formed of a phosphorescent material so that the disc will &#34;glow&#34; in dimly lighted environments. Another type of illumination is based on chemical materials carried in pods or housings added to the basic disc. A third type carries electronic light sources such as light-emitting diodes (LED&#39;s). The invention is directed to overcoming the technical problems associated with this third type of illuminated flying disc. 
     A typical flying disc, of the type being commercially offered, resembles an overturned dish. An upper deck of the disc includes a flat, central portion which extends radially outward to a downwardly turned leading edge. This leading edge gives the disc the profile of a wing and also forms a transition surface between the flat portion of the upper deck and a depending rim that is provided for gripping during throwing and catching actions. 
     Several different approaches have been taken to locating discrete light sources on such discs. Often these have been located in housings or pods attached either to the topside or the underside of the deck and usually located centrally to maintain the balance of the disc for flight. When LED&#39;s are used these are typically mounted in the depending rim so as to be visible at points radially outward of the disc. In other discs, the LED&#39;s are easily visible from the top or bottom, but special windows or other means must be provided to transmit light in the radial direction. The known prior art does not provide a construction in which the discrete light sources are located in an exposed position to be seen from all vantage points, i.e. from above, below or radially outward of the disc. Since the disc can fly through the air at various elevations relative to the thrower and catcher, it would be advantageous to provide a disc with light sources that are visible from as many directions as possible. It would also be advantageous to eliminate extra pods or housings for the light sources. 
     With a prior construction in which the light sources are located in the rim, there is a further problem that any exposure or projection of the light sources will interfere with gripping the disc. When the disc is caught, the electrical connections to the LED&#39;s may be damaged or still worse, there may be a minor injury to the hand of the catcher. Another problem in this prior construction is the employment of wires which are encased in a melted plastic material leading up to the connections to the discrete light sources. Although the wires were not exposed, they become brittle and subject to breakage. 
     There are already well-established manufacturers of the basic flying disc and the number of discs that have already been sold is probably in the millions. Since many disc owners would not want to invest in a complete new disc merely to obtain a lighting feature, there is a need for a less expensive alternative. Although lighting kits are suggested in the art, none are known which overcome the disadvantages of the prior lighted discs that are discussed above. 
     SUMMARY OF THE INVENTION 
     The invention relates to a lighting adapter kit and a method for installing lights in a flying disc. The kit provides a structure for insulating and attaching a set of conductive strips on the underside of a flying disc and for supporting a plurality of discrete light sources that are situated in holes in the disc. 
     The support structure includes a central base and a plurality of arms extending radially outward from the base. Power source retaining means are attached to the membrane base to house a power source and provide electrical connections between the power source and a circuit formed by the conductive strips. The kit provides a segmented liner releasably attached to the underside of double-faced tape which is used to secure the supporting structure to the underside of the flying disc. There are additional liner strips releasably attached to the topside of radially distal portions of the tape and opposite the discrete light sources, which are mounted on the distal portions of the respective membrane arms. These liner strips carry means for indicating locations for punching holes in the disc that will receive the light sources. The liner strips allow this punching operation to be carried out prior to securing the distal portions of the membrane arms that hold the light sources in their installed positions. 
     A further aspect of the invention relates to centering the main kit component on the underside of the disc by trimming the arms at preselected index marks corresponding to various sizes of flying discs and locating the component on the disc with the trimmed ends just reaching a crease that is commonly found on the underside of the discs. 
     Another aspect of the invention relates to providing a series circuit in the main kit component so that non-blinking LED&#39;s can be made to blink by controlling current to them through a blinking LED. 
     The invention also relates to a second kit component which is a die that can be inexpensively made from a hollow cylindrical casing and shaped to provide a cutting edge for cutting non-circular holes in the disc that correspond in shape to the LED&#39;s. 
     The invention further provides a kit that is especially suitable for installation in phosphorescent discs because the preferred, transparent membrane and preferred, transparent tape are very thin and will not interfere with observing the glow of the disc body. 
     The invention also relates to a method of installing discrete light sources on board a flying disc in which the supporting structure for the light sources is progressively secured to the underside of the disc beginning with the central base portion and moving radially outward, and in which the radially distal portions of membrane arms are free from the corresponding portions of the tape until holes can be punched through the tape as indexed locations. Then, by exposing adhesive on the topside of the tape, the distal portions of the arms can be secured to the disc to hold the LED&#39;s in apertures located in a particularly desirable position on the disc. 
     The invention provides for a flying disc with lighting circuit that is insulated and protectively covered by a transparent membrane, which allows observation of the LED&#39;s and, to a user, seems substantially flush with the underside of the disc. The LED&#39;s are rounded at one end and tapered at an opposite end, so that when exposed on the topside of the upper deck, they do not present any rough edges to be grabbed by a user. 
     Various objects and advantages of the invention will appear in the following description, wherein reference is made to the accompanying drawings that form a part hereof, and in which there is shown by way of illustration a preferred embodiment of the invention. This embodiment, however, does not necessarily represent the full scope of the invention, but is merely illustrative, and therefore reference is made to the claims at the end of the description for determining the scope of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a lighted flying disc in which a plurality of discrete light sources have been installed with the kit of the present invention; 
     FIG. 2 is a view of the underside of the disc of FIG. 1 with a portion of a cover broken away for a better view; 
     FIG. 3 is a fragmentary sectional view taken in the plane indicated by line 3--3 in FIG. 1; 
     FIG. 4 is a partially exploded, perspective view of the primary kit component of the invention; 
     FIG. 5 is a bottom view of the kit component of FIG. 4; 
     FIG. 6 is a view of a method step in trimming the ends of the arms of the kit component of FIG. 4; 
     FIG. 7 is a detail view of one arm of the kit component of FIG. 4 as it is being installed in a flying disc; 
     FIG. 8 is a detail view showing a method step wherein a hole is punched with a die through the masked tape of the kit component in FIG. 4; and 
     FIG. 9 is an end view of the die seen in FIG. 8. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIGS. 1-3 show a flying disc 10 in which discrete light sources are provided by light emitting diodes 11-13 (LED&#39;s) that have been installed wih the kit and method of the present invention. The disc 10 is typically made of ABS (acrylonitrile-butadiene-styrene) plastic and has an upper deck with a flat central area 14 extending over its largest part. At the outer reaches of this area 14 there may be a series of ridges and grooves (not shown) which contribute to the aerodynamic characteristics of the disc as an airfoil. As seen best in FIG. 3, the upper deck also has a leading edge 15 around the outside of the flat area 14, and this edge 15 curves downwardly from the flat area 14 to a rim 16 that depends from the upper deck. The rim 16 is reinforced to a greater thickness than the upper deck and has a substantially flat, vertical interior wall 17, which encircles a portion of the cavity formed in the disc 10 and allows the rim 16 to be more easily grasped by a human thrower or catcher. 
     The three LED&#39;s 11-13 are angularly spaced 120 degrees apart as seen in FIGS. 1 and 2, and are located in holes 18 in the leading edge of the upper deck as seen best in FIG. 3. There, it can be seen that each LED 11-13 has been trimmed to provide a twenty degree taper 11a from the middle to the rear of its topside and a fifteen degree taper 11b  from just behind its rounded nose to the rear of its bottom side. These tapers provide a low profile for the LED 11, without rough edges, when positioned in the locating holes 18 as seen in FIG. 3. The LED&#39;s 11-13 are spaced inwardly from the rim 16 by at least the thickness of an average human fingertip, so as to be out of the way when the disc 10 is being gripped on its rim 16 by a human thrower or catcher. 
     Still referring to FIG. 3, the LED&#39;s 11-13 are held in place by a flat, transparent, flexible membrane 19 of insulating material that is secured to the underside of the upper deck by double-faced adhesive tape 20 of a type suitable for use with the material of the disc 10. The membrane 19 is preferably cut from a sheet of transparent polyester film with a thickness of 0.007 inches. The tape is preferably made of polyester film that has an acrylic adhesive on both sides and a thickness of about 0.002 inches. Opaque tapes can also be used but these may affect the appearance of phosphorescent discs. The thicknesses of these membrane 19 and tape 20 has been exaggerated somewhat in FIG. 3, so as to be more clearly visible. 
     The LED&#39;s 11-13, the membrane 19 and the tape 20 are installed as a single component 21 as seen in FIG. 4. The membrane 19 has a circular base 19a at its hub and three, elongated rectangular arms 19b-19d extending radially outward from the base 19a. The tape 20 is of the same shape as the membrane 19 and is secured to the underside of the membrane 19 so that only an edge is seen in FIG. 4. 
     The membrane base 19a carries a two-piece power source enclosure formed by a cylindrical tubular body 22 and a screw-on cap 23. The tubular body 22 is made of a polyethylene or other strong plastic material and has a central cavity in its interior that opens to the front and to the rear. The back edge of the enclosure body 22 is adhesively attached to the membrane base 19 to close the rear opening into the body cavity. The cap 23 is also made of a polyethylene material and has threads (not shown) which engage threads 24 formed on the outer wall of the enclosure body 22 to become attached thereto and close the front opening. The body cavity is large enough to receive a conventional nine-volt dry cell battery 25, which can be provided separately from the kit component 21. 
     A pair of wedge-shaped abutments 26 are mounted on the inside wall of the enclosure body 22 and project into the body cavity in spaced apart relationship to assist in retaining the battery 25 in place during flight of the disc 10. A conventional battery terminal connector 27 is provided for attachment to the battery terminals, and when this connector 27 is wedged between the top of the battery 25 and the inside wall of the enclosure body 22, as seen in FIG. 2, it also assists in retaining the battery 25 in place. 
     Referring now to FIGS. 2, 3 and 4, the battery 25 is connected in series with a slide switch 28 and the LED&#39;s 11-13 by flat conductive strips 29 and 30 of copper foil and several lead wires 31-33. The conductive strips 29 and 30 are captured between the membrane 19 and the tape 20 as seen best in FIG. 3. The thickness of the conductive strips 29 and 30 has been exaggerated somewhat in FIG. 3 for a better view. As seen best in FIG. 2, there are two long conductive strips 29 and two shorter conductive strips 30. The first long strip 29 has a first radial portion extending from the membrane base 19a to the first LED 11 and a second radial portion extending from a junction on the base 19a with the first portion out to a connection to the second LED 12. The second long strip 29 also has two radially extending portions 120 degrees apart, with the distal end of one portion being connected to the second LED 12 and the distal end of the second portion being connected to the third LED 13. The shorter conductive strips 30 extend radially from a pair of solder connections 34 seen in FIG. 2 outward along respective membrane arms 19b and 19d to the first and third LED&#39;s 11 and 13, respectively. The solder connections 34 are made to termination portions of the conductive strips 30 that are underneath the membrane base 19a. Leads 32 and 33 extend through small openings in the base 19a to connect the battery 25 and switch 28 in series with the LED&#39;s 11-13 through these connections 34. 
     Referring to FIG. 2, the series circuit can be traced as follows. A first lead 31 that is part of the battery terminal connector 27 connects one side of the battery 25 to one side of the switch 28. A second lead 32 connects the other side of the switch 28 through the conductive strip 29 to the first LED 11. The first LED 11 is connected to the second LED 12 through the first long strip 29, and the second LED 12 is connected to the third LED 13 through the second long strip 29. The second short strip 30 connects the third LED 13 to the last lead 33 which is connected to the other side of the battery 25. For greater security, leads 31 and 33 can be anchored to the inside wall of the enclosure body 22 to protect the solder joints 34. 
     Although a series circuit is not mandatory for practicing the invention, it is preferred in order that a first blinking LED 11 be used with two non-blinking LED&#39;s 12 and 13. Using a series circuit, the interruption of current in the circuit by the first LED 11 also interrupts current to the second and third LED&#39;s 12 and 13, so that the three LED&#39;s 11-13 will blink in unison. The LED&#39;s 11-13 are soldered to the distal ends of the conductive strips 29 and 30 to provide both an electrical and mechanical connection. The LED&#39;s 11-13 are also supported by the spot application of adhesive between each LED 11-13 and its respective membrane arm 19b-19d. 
     To allow the kit component 21 of FIG. 4 to be handled during installation, the underside of the double-faced tape 20 is covered with a segmented liner 35 seen in FIG. 5. The segments of this liner 35 are made of paper having a silicone-based release coating on the side in contact with the adhesive, which allows each segment to be peeled off to expose the adhesive on the underside of the tape. A pair of semicircular segments 36a and 36b are used to cover the underside of the membrane base 19a. Three other segments 37a-37c are used to cover the underside of the tape portions corresponding to the radially adjacent portions of the membrane arm 19b-19d that are next to the base 19a. Three other segments 38a-38c are used to cover the underside of the portions of the tape corresponding to the radially distal portions of the membrane arms 19b-19d. For reasons that will become apparent later, the distal portions of the tape 20 are to be kept separate from the distal portions of the membrane arms during installation, and therefore additional liner segments 39a-39c are provided for the topsides of these distal portions as illustrated in FIGS. 4 and 7. The liner segments 38a-38c and 39a-39c as well as the tape 20, have apertures 40 therein corresponding to the shape of the LED&#39;s 11-13 and located to receive the LED&#39;s 11-13 therethrough. 
     In preparation for installing the main kit component 21, reference is made to the indicia 110, 119, 133 across the distal end of the membrane arms 19b19d, as seen in FIGS. 2, 4 and 6. These indicia are positioned at different radial distances from the center of the kit component 21, the nearest of these marks corresponding to the length of the arms for a 110-gram flying disc. Succeeding index marks are provided for arm lengths for flying discs of the 119, 133, and 141-gram sizes. For 150-gram and 165-gram sizes, the full length of the membrane arms 19b-19d is utilized. The example illustrated here is a flying disc 10 of the 133-gram size. Therefore, in a preliminary step the tips of the arms and underlying portions of the masked tape 20 are trimmed, preferably with a scissors as illustrated in FIG. 6. After the arms 19b19d have been shortened to the appropriate length, the disc 10 is placed upside down as seen in FIG. 2 and the kit component 21 is centered thereon, with the tips of the radial arms 19b19d extending to a crease 41 seen in FIG. 3 separating the underside of the leading edge 15 from the rim 16. With the kit component 21 in this position an outline can be traced on the underside of the disc 10 along the edges of the base 19a and the arms 19b-19d. 
     The next step is to peel off the semicircular liner segments 36a and 36b and adhesively attach the base 19a to the area of corresponding shape marked lightly on the underside of the disc 10. The arms 19b and 19d may be radially oriented with the outline, but as long as the base 19a is centered, radial alignment of the arms 19b-19d is optional. The primary purpose of the outline is to center the kit component 21 rather than to orient its radial arms 19b-19d. 
     Taking one arm at a time the liner segments 37a-37c and 38a-38c on the radially adjacent and radial distal portions of the liner are removed to fully secure the tape 20 and partially secure the membrane 19 on the underside of the disc 10. This will locate the apertures 40 in the tape 20 as seen in FIG. 7. 
     To punch a hole in the location marked by the tape in FIG. 7, a die 42 is also provided with the kit. This die 42 is preferably in the form of a hollow casing that is about two inches along with an upper cylindrical portion and a portion shaped at its lower end as seen in FIG. 9 to provide a cutting edge 43. This edge has a rounded portion at its front and a pair of corners at its back to cut a hole out corresponding to the shape of typical LED&#39;s. The die 42 is positioned in the aperture 40 in the tape 20 as seen in FIG. 8 and a hammer or other striking implement is used to provide a sharp blow and cleanly cut a hole 18 of the correct shape in the flying disc 10. 
     Next, the upper liner segments 39a-39c are removed one at a time from the distal portions of the tape 20 underlying each arm 19b-19d. When the distal portion of each 19b-19d arm is pressed down upon the topside of the adhesive tape 20 it will become secured by the tape 20 as the LED&#39;s 11-13 are popped through the hole 18 cut in the flying disc 10. 
     The position of the LED&#39;s 11-13 in the upper deck has been preselected so that in the above-mentioned sizes of flying discs, the LED&#39;s 11-13 will project through the upper deck and be visible from the top of the flying disc 10, from points radially outward of the flying disc, and--by virtue of the clear, transparent membrane and transparent tape--from the bottom of the flying disc 10. The tapering of the LED&#39;s and the roundness of their noses provides a relatively smooth surface in the event that a user inadvertently slides a fingertip over them. 
     The battery need not be installed until the kit has been attached to the flying disc as seen in FIG. 2. The die in FIG. 8 is shorter than the battery so that it can be conveniently packaged in the enclosure for commercial distribution. 
     The invention provides a lighting adapter kit for installation of low profile light sources in the upper deck of a flying disc. The kit also positions the LED&#39;s away from the hands of users that might grasp and interfere with the electrical components. The main kit component 21 is lightweight and radially balanced and the disc 10 retains all sailing characteristics in flight.