Patent Publication Number: US-2007111636-A1

Title: Foam Battle Swords, Spear and Shield

Description:
This invention relates to foam covered swords, spear and shield intended for recreational battle. In addition to having light weight durable construction, each is designed to provide a user and their opponent protection during full contact simulated battle.  
     BACKGROUND OF THE INVENTION  
      For centuries swords, spears and shields have been used in battle. A time tested physical activity for young and old has been to simulate such battle with improvised weaponry. With each new film portraying such skills in action (Star Wars, Gladiator, Pirates of the Carribean to name a few recent offerings), a whole new generation of would be play time warriors emerges looking for weaponry. Often the weaponry settled upon is of unsafe homemade construction (wooden swords), or too flimsy to really let the users exercise their imagined skills fully. Play weaponry sold in toy departments is to date ornamental in design. For example various designs have been patented to simulate the appearance, but not interactive contact function of swords. Some have have been enhanced to produce light (toy replicas of the famous ‘Star Wars’ light sabres), and others even simulate the clashing sound of weapons. Others have integrated trigger mechanisms to indicated when the sword has made contact (U.S. Pat. No. 6,945,842 B1 to Gulmesoff). However, none of these are structurally suitable to provide for user/opponent safety when actually engaging in a physically aggressive battle. On the other end of the spectrum, commercially available weaponry (replica swords, fencing swords, spears) carries a similar risk in usage as the ancient weapons they simulate. Users without proper protective equipment and training can inflick serious injury using even practice versions of these weapons.  
      Currently the middle ground is weaponry specifically designed for training of students by skilled martial arts or fencing instructors. Typically the swords in this category are for amateur play or professional competition. The play models are often cut from foam sheets or molded from high density foam and although suitable for fencing are otherwise lacking the internal rigidty and durability necessary to effectively block and withstand repeated sword blows (U.S. Pat. No. 20040162003 to Vanaver, and U.S. Pat. No. 4,892,303 to Lohre) and depending upon design illustrating a tendency to develop less predictable whipping action (U.S. Pat. No. 5,127,871 to Miller); The competitive model sword systems developed for self defense arts such as ‘Chanbara’ (a registered trademark) can be of wooden construction with a rubber coating (commonly called Bokken swords); be more manufacturing intensive utilizing gas presurized air bags/cyclinders instead of urethane foam padding (U.S. Pat. No. 6,010,435 to Tetsundo Tanabe for sword and spear design), or using urethane foam padding covered with a bag and held on with grip tape to prevent the padding from sliding off the shaft during competitive battle (U.S. Pat. No. 5,295,926 to Tetsundo Tanabe).  
      In contrast the weaponry proposed in this patent application is designed principly with safety in mind but also with the aim of providing full contact functionality whilst remaining affordable to manufacture. These items would occupy the marketing space between weaponry for trained competive users and play toys not durable or structurally suitable for aggressive physical battle. Essentially these items provide an arsenal for aggressive amateur warriors.  
     SUMMARY OF THE INVENTION  
      This application is for  4  complimentary foam covered items embodying a full arsenal: a lightweight sword (Sabre) for single handed or younger child usage, a larger (Broadsword) for two handed older users, a throwing Spear and a protective shield, that together provide a set of armament for users to interactively practice medieval battle skills in a low risk, fun manner. To ensure users are not injured during battle the lightweight PVC pipe used for the light sword, broad sword and spear shafts are covered with a thick 1.25″ to 2″ layer of lightweight, closed cell polyethylene hollow foam tubing which has excellent tear resistance, tensile strength, and general resiliency to abuse. This foam is commonly marketed in the form of affordable ‘pool noodles’ or ‘water logs’ sold as a swimming pool play accessory.  
      This thick and durable foam provides a soft impact surface sufficient to protect those hit even with significant force. Although constructed to take rigorous abuse each weapon is also built as lightly as possible to reduce the mass and thus force of impact further. All materials used in construction are lightweight, waterproof and as per their manufacturing specifications resistant to common causes of material aging (sunlight, and common household/pool chemicals). In effect this inherent property of the materials used in the inventions construction ensures the safety of the weaponry does not degrade with time as would be the case of weaponry using urethane, or polystyrene foam. However in the event that the protective foam has somehow been compromised, each weapon has also been designed to allow the protective foam be replaced with minimal cost and difficulty using commonly available ‘Pool Noodles/water logs’ while economically retaining the original handle and shaft. 
    
    
      For clarity all item descriptions to follow reference by figure number the attached drawing sheets and the components detailed in the tables which follow each drawing sheet. 
    
    
      Although sample dimensions are provided these are not restrictive and in manufacture each item can be sized as deemed best to meet its intended user/demographic market. Similarly the simple black &amp; white drawings allowed in this patent application should not be deemed restrictive. The foam used in construction of the weapons is readily available in a plentitude of colors, and in reference to the shield surface an unlimited variety of patterns, imprints and branding is possible. Finally although the sample drawings illustrate the sword, sabre and spear core/shaft as having been constructed from multiple components this should not preclude that in manufacture each weapon&#39;s core/shaft could be formed with fewer (multiple purpose) components or even perhaps as a single molded entities provided the protective foam component remains securely attached, yet replaceable by the user with minimal effort.  
      Description of Broadsword  
       FIG. 1  shows the components typical in the Broadsword invention. The principle components are the  4 ″ hollow foam tube ( FIG. 1 . 1 ) and the PVC pipe used as the sword shaft ( FIG. 1 . 2 ). To strengthen the sword handle and improve handling a second larger diameter PVC pipe ( FIG. 1 . 3 ) is heat fitted (or bonded with PVC cement) overtop. To prevent the foam tubing from sliding back on the sword handle after repeated intense usage, a rubber washer ( FIG. 1 . 6 ) is slid over the shaft until it abuts the top of the handle essentially forming a simple hilt. This could also be replaced with a similarly durable, yet pliable material in the design of a formal hilt. The butt of the enlarged handle has a rounded PVC or rubber cap ( FIG. 1 . 5 ) permanently affixed to provide a blunt surface should user impact mistakenly occur there. Slid in and bonded into the tip of the shaft is a PVC threaded male insert adapter ( FIG. 1 . 4 ). The foam ( FIG. 1 . 1 ) is then slid onto the shaft and while compressed against the ‘hilt’/lower rubber washer the upper rubber washer(  FIG. 1 . 7 ) and threaded cap ( FIG. 1 . 8 ) are affixed. Ideally these washers are beveled on one edge to allow it to recess into the foam easier. The rubber washers commonly sold as sink basin washers work well in this regard when the beveled edge is positioned to face the foam. After the foam is uncompressed the cap and rubber washer affixed to the shaft tip becomes recessed a safe 2-4 inches from the outer edge of the protective foam. The cap/washer serve both to prevent the foam from sliding off as well as blunts the tip of the shaft to reduce the shaft edge from wearing through the foam. It also presents a less hazardous blunt tip should the foam be unknowingly damaged and the shaft exposed.  FIG. 2  shows the broad sword assembled.  
      Description of Sabre  
       FIG. 3  shows the components typical in the Sabre (light sword) invention. The principle components are the 2.5″ hollow foam tube ( FIG. 3 . 1 ) and the PVC pipe used as the sword shaft ( FIG. 3 . 2 ). To strengthen the sword handle and improve handling a second larger diameter PVC pipe ( FIG. 3 . 3 ) is heat fitted (or bonded with PVC cement) overtop. To prevent the foam tubing from sliding back on the sword handle after repeated intense usage, a rubber washer ( FIG. 3 . 6 ) is slid over the shaft until it abuts the top of the handle essentially forming a simple hilt. This could also be replaced with a similarly durable, yet pliable material in the design of a formal hilt. The butt of the enlarged handle has a rounded PVC or rubber cap ( FIG. 3 . 5 ) permanently affixed to provide a blunt surface should user impact mistakenly occur there. Slid in and bonded into the tip of the shaft is a PVC threaded male insert adapter ( FIG. 3 . 4 ). The foam ( FIG. 3 . 1 ) is then slid onto the shaft and while compressed against the ‘hilt’/lower rubber washer the upper rubber washer(  FIG. 3 . 7 ) and threaded cap ( FIG. 3 . 8 ) are affixed. Ideally these washers are beveled on one edge to allow it to recess into the foam easier. The rubber washers commonly sold as sink basin washers work well in this regard when the beveled edge is positioned to face the foam. After the foam is uncompressed the cap and rubber washer affixed to the shaft tip is recessed safely 1-3 inches from the outer edge of the protective foam. The cap/washer serve both to prevent the foam from sliding off as well as blunts the tip of the shaft to reduce the shaft edge from wearing through the foam. It also presents a less hazardous blunt tip should the foam be unknowingly damaged and the shaft exposed.  FIG. 4  shows the Sabre assembled.  
      Description of Foam Spear  
       FIG. 5  shows the components typical in the Foam Spear invention. The principle components are the 2.5″ hollow foam tube ( FIG. 5 . 1 ), the 4″ foam spear head ( FIG. 5 . 2 ) and the PVC pipe used as the spear shaft ( FIG. 5 . 3 ). To strengthen the spear head end of the PVC shaft and to provide for a larger blunt spear head tip a second larger diameter PVC pipe ( FIG. 5 . 4 ) is heat fitted (or bonded with PVC cement) overtop. A rubber cap ( FIG. 5 . 10 ) is then permanently affixed to the exposed end of this pipe to provide a blunt surface should the foam spear head be unknowingly compromised and the shaft exposed. The solid foam spear head ( FIG. 5 . 2 ) will have a 1¼″ * 8″ hole drilled into the blunt end to allow it to tightly slide onto the enlarged shaft. Although the rubber cap will prevent the spear head from sliding off, the foam spear head may also be bonded on using a  3 M or similar foam spray adhesive. If 4″ hollow foam tubing is used for the spear head the resulting hole extending back from the tip can be plugged with a replaceable foam insert.  
      To prevent the foam spear head from sliding back on the spear handle after repeated impact, a large rubber washer ( FIG. 5 . 7 ) is slid over the shaft until it abuts the top of the larger PVC pipe. To prevent this washer from sliding back, a second shorter piece of the larger diameter PVC pipe ( FIG. 5 . 6 ) is slid over the shaft and bonded in place to tightly sandwich the rubber washer in place. Slid in and bonded into the handle end of the spear shaft is a PVC threaded male insert adapter ( FIG. 5 . 5 ). The foam handle ( FIG. 5 . 1 ) is then slid onto the shaft and while compressed against the upper rubber washer ( FIG. 5 . 7 ) the lower rubber washer (ideally beveled on one edge) ( FIG. 5 . 8 ) and threaded cap ( FIG. 5 . 9 ) are affixed. After the foam is uncompressed the threaded cap and rubber washer recess a safe 1-3 inches from the outer edge of the protective foam.  FIG. 6  shows the foam spear assembled.  
      Foam Shield  
      The shield is composed of a single 2″ thick piece of heavier density polyethylene closed cell foam ( FIG. 7 . 1 ). Ideally the foam used has a softer continuous gas blown polyethylene skin to prevent skin abrasion with extend usage. This is the same layered foam combination presently used in many of the commonly marketed ‘boogie’ or ‘body surf’ boards which use polyethylene foam as a core. The shield is fitted with a rubber hand grip assembly ( FIG. 7 . 2  hose and  FIG. 7 . 3  strap) and forearm pad assembly ( FIG. 7 . 4  pad and  FIG. 7 . 5  strap). Four holes are drilled through the shield in positions which allow both retaining straps to be attached such that they allow a user to don the shield on either arm while still maintaining full movement of their arms.  FIG. 8  shows the shield assembled as well as some possible design samples of the plentitude of shapes and pattern options this simple yet versatile shield system allows.