United States Patent: (10) Patent No .: US 10, 065, 127 B1 (45) Date of Patent: Sep - 4, 2018
United States Patent: (10) Patent No .: US 10, 065, 127 B1 (45) Date of Patent: Sep - 4, 2018
A120
HILT ASSEMBLY 122
BODY
DIFFUSE
PENUMBRA PROXIMAL BASE BLADE EXTENSION AND
OF LIGHT, 119 END , 113 RETRACTION ASSEMBLY
BLADE
117 BLADE MEMBER
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SHAPING STORAGE
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STORAGE
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750
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116 111 RETRACT
RETRACT OFFBOARD )
DISTAL 1139
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LBLADE - SOUND
EFFECTS
CONTROLLER
ASSEMBLY
10 140
BLADE, 110
US 10 ,Page
065,2127 B1
(56 ) References Cited 8 ,790 , 180 B2 * 7 /2014 Barney .............. A63F 13/08
463/ 39
U . S . PATENT DOCUMENTS 8,961,312 B2 * 2/2015 Barney ....... ........... A63F 13 / 10
345 / 158
5 ,321,591 A * 6 /1994 Cimock ................. H05B 39 /09 9,579, 587 B1 * 2 /2017 Chen ... A63H 33 /009
315 /200 A 9 ,630 , 120 B2 * 4 /2017 Stubenfoll ........... A63H 33 /009
5 ,324 ,227 A * 6 / 1994 Yuh - Ching .......... A63H 33 / 009 9 ,675, 878 B2 * 6 /2017 Barney ................. Ab3F
A63F 13 /245
446 /473 9 ,707 ,478 B2 * 7 / 2017 Barney ............. A63F 13/235
5 ,919 ,079 A * 7/1999 Coleman .................. A23G 3 / 50 9 ,737 ,797 B2 * 8 /2017 Barney ...... A63F 13 / 235
426 / 134 2001/0024973 A1* 9 /2001 Meredith ............... A63F 13/ 06
5 ,947,789 A * 9 / 1999 Chan ............... A63H 33 /009 463/ 36
362/277 2007 /0218803 A1* 9/2007 Tong .................... A63H 33 /009
6 ,030 ,272 A * 2/ 2000 Hu .................. A63H 33/009 446 / 473
446 /233 2007/0254553 Al * 11/2007 Wan .................. A63H 33 /22
6 ,036 ,576 A * A63H 33/009 446 / 175
446 / 170 2007/ 0270077 A1 * 11/ 2007 Woodhouse ......... A63H 33/009
6 ,082,876 A * 7 /2000 Hanson .................. A63H 33/22 446 /473
362 /293 2008 /0051003 A1* 2/2008 Hom ................... A63H 33 / 009
6 ,150 , 947 A * 11/2000 Shima ...................... A63H 5 /00 446 /473
340 /692 2010/0048097 A1 * 2/2010 Ma. ................ A63H 33 /009
6 ,244 ,723 B1 * 6 / 2001 Talamo ............ GO9F 13 /00 446 / 473
362/ 157 2014 /0106644 Al * 4 /2014 Urbaniak ................ A63J 21/00
D603, 464 S * 11/ 2009 Roos ......... D21/567 446 /473
7 ,611,398 B2 * 11/ 2009 Woodhouse ......... A63H 33 / 009 2015/0314213 A1* 11/2015 Zhou ... ............. A63J 21/00
446 / 473 446 /485
7 ,766 ,721 B2 * 8/2010 Ma . ..................... A63H 33 /009 2016 /0008730 A1* 1/2016 Stubenfoll ......... A63H 33 /009
446 /473 446 / 170
8 ,089 ,458 B2 * 1/2012 Barney .... ............. A63H 30 /04 2017/0306180 A1* 10 /2017 Albright .............. C09D 179 /02
345 / 158 * cited by examiner
U . S . Patent Sep . 4 , 2018 Sheet 1 of 8 US 10 , 065, 127 B1
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US 10 ,065 ,127 B1
SWORD DEVICE WITH RETRACTABLE , blade that appears to emanate from a handheld hilt due to a
INTERNALLY ILLUMINATED BLADE lighting effect that appears to provide bright hilt-based
lighting.
BACKGROUND In some useful embodiments , the special effects device
5 includes two long plastic cylinders that are cut lengthwise .
1 . Field of the Description These two pieces ( or blade body members ) are then each
rolled perpendicular to their length ( or their central axis ),
The present description relates, in general, to theatrical which creates compact cylinders of material of relatively
props and toys simulating fictional energy swords or light small volume that can be provided on a pair of spools or
sabers and, more particularly, to a special effects device for 10 reels . The spools holding the blade body members, along
use as a toy, theatrical prop , or collector 's item that accu with other blade -producing elements, are housed within the
rately simulates fictional operations of an energy sword or body of the hilt assembly of the special effects device or
“ lightsaber” found in many popular films. lightsaber prop.
To extend the blade , a motor provided in the hilt body is
2 . Relevant Background 15 operated to unroll the rolled / spooled plastic blade body
members from their reels / spools with each member (or blade
There are many fictional characters whose weapon of half ) acting much like a metal carpenter's tape measure .
choice is an energy sword , and many films have been Each blade body member passes through a blade forming
produced depicting these characters doing battle with their guideway or passageway that acts to " zip " the two semi
fantastical energy swords. In some stories , these energy 20 cylindrical blade body members together (or with portions
swords are called lightsabers, and a typical lightsaber in a along their length overlapping each other or one nesting
film is depicted as including a metal hilt that allows the inside the other ) as they leave the hilt body, thereby forming
lightsaber to be a handheld weapon . The hilt is activated by the energy blade . To retract the blade, the process is reversed
the character in the film to project a brightly lit energy blade with the motor acting to wind the pair of spools to reel or
that is two to four or more feet long (e . g ., an average of 3 25 wind the extended blade body members back into the hilt
feet in length but that is generally proportionate to the body and onto the pair of spools /reels .
operator ) and that in the films can cut, burn , and melt The special effects device or lightsaber prop is designed
through most substances with little resistance . In the films, to illuminate the two blade body members internally or from
an active lightsaber makes a distinctive humming , which within the interior space of the blade to provide the illusion
rises in pitch and volume as the blade of the lightsaber is 30 of a hilt -illuminated energy blade. In some embodiments,
moved rapidly through the air , and contact between another lighting of the blade is achieved by including a flexible strip
lightsaber's blade produces a loud crackling noise . of light sources (such as a flexible strip of light emitting
To provide energy swords in films, many post -production diodes (LEDs)) . The flexible strip of light sources is attached
techniques such as computer - generated imagery (CGI) exist in the center of the two semi-cylindrical blade body mem
that can be used to realistically extend and retract a long 35 bers ( such as to an end cap attached to exposed or outer ends
energy blade from a hilt, which can be a physical prop in a of the two blade body members ) such that it is pulled up (or
character's hand . Producing a toy, a collector's item , or a unspooled ) along with the blade body members during their
theatrical prop for live theater or shows that effectively extension or deployment. During retraction of the blade
simulates an energy sword such as a lightsaber has proven body members , the flexible strip of light sources is also
much more challenging . 40 pulled back into the hilt body such as through the use of a
There are many commercially -available lightsaber prod - one -way bearing.
ucts, but most have only been effective at simulating a In some particular embodiments, the blade includes an
portion of the unique features of the fictional energy swords anisotropic (or 1D ) diffuser whose diffusion direction is
seen in films. For example , many lightsaber products focus along the length of the extended or deployed blade (i.e .,
on combat durability but fall far short on providing realistic 45 parallel to the central axes of the two blade body members ).
appearance . Others provide very realistic appearing and The anisotropic diffuser blends the points of light from the
brightly lit blades along with effective sound effects . How - individual light sources (e .g.,LEDs) into a single continuous
ever, very few lightsaber products have even attempted to and evenly illuminated line . The anisotropic diffuser may be
recreate the extending and retracting capabilities of the spaced a distance away from the LEDs to provide the
lightsaber blade shown in films, and these products have 50 appearance of a penumbra or glow around the central axis of
typically failed in other aspects such as failing to produce a the extended blade or central axis of the flexible strip of light
brightly lit blade or producing a less realistic blade than sources (e . g ., central blade of blended LEDs). In some cases ,
other products without a retractable blade. None of these the anisotropic diffuser or diffusion function is provided by
lightsaber products have been able to achieve extending and forming the two blade body members out of flexible diffu
retracting of the energy blade with bright hilt lighting 55 sion material that is formed into half cylinders .
combined with a lack of a visible support structure for the More particularly , an apparatus ( e.g ., a lightsaber prop or
blade. the like ) is provided for producing an energy sword special
effect. The apparatus includes a hilt assembly including a
SUMMARY drive assembly within a hilt body. The apparatus also
60 includes a blade including a flexible strip with a plurality of
Briefly , the inventors recognized that there was a need for light sources arranged in a linear pattern and an anisotropic
a new special effects device that can be used as a theatrical diffuser diffusing light output from the plurality of light
prop , toy, or collector's item that effectively simulates sources . During operations , the drive assembly operates in a
fictional energy swords including the lightsabers found in first operating state to extend the blade outward from an
many popular films. Particularly, the special effects device 65 opening in the hilt body and in a second operating state to
( or energy sword , lightsaber prop , or the like ) is specially retract the blade into the hilt body through the opening in the
configured to provide an extendable and retractable energy hilt body .
US 10 , 065 , 127 B1
In some embodiments , the blade includes an end cap and FIG . 3 is a bottom view of the special effects device of
a pair of blade body members each attached at a first end to FIG . 2 ;
the end cap . The blade body members each has a semicir- FIG . 4 is a first side view of the special effects device of
cular cross section (in a plane orthogonal to a longitudinal FIGS. 2 and 3 ;
axis of the blade body member ) when in the extended 5 FIG . 5 is a second side view of the special effects device
position / state . In the same or other embodiments , the pair of of FIGS . 2 - 4 that is opposite the view of FIG . 4 ;
blade body members are at least partially nested together FIG . 6 illustrates a light source spool for storing/ holding
( e . g., with an edge of one member overlapping the adjacent and feeding out a flexible strip of light sources from a hilt
edge of the other member ) to define a hollow cylindrical assembly ;
body of the blade . To provide internal illumination of the 10 FIG . 7 is a side view of a special effects device of the
blade, the flexible strip with the plurality of light sources is present description , such as an implementation of the
attached at an end to the end cap and is positioned within the devices of FIGS. 1 - 5 , that has been activated or operated to
hollow cylindrical body of the blade . In one useful imple have an extended blade ; and
mentation of the apparatus, the light sources each is a light FIGS. 8A and 8B illustrate side and bottom perspective
emitting diode (LED ) such as a white or colored LED with 15 views, respectively , of a blade end cap .
the flexible strip including a flexible circuit board in some
cases and /or such as by tinting of the diffusion material to DETAILED DESCRIPTION OF THE
produce the blade color ( as used in one prototype with white PREFERRED EMBODIMENTS
LEDs).
In some cases, the anisotropic diffuser is a separate 20 Briefly, a special effects device is provided that is useful
component while in other cases it is provided by the pair of for simulating an extending and retracting , internally lit, and
blade body members with each of the blade body members handheld energy sword (e .g ., a lightsaber popular in many
formed from a strip of diffusion material ( e . g ., a rectangular science fiction movies ). The special effects device solves
strip with a width of 0 .5 to 2 inches and a length of 2 to 6 several issues with prior devices as it provides a retractable
feet or the like). To facilitate retraction , each of the blade 25 blade with a single (or continuous) width along its length .
body members has a planar cross section in a plane orthogo - When extended , the blade appears to be energized from the
nal to a longitudinal axis of the blade body member when the hilt or illuminated from a hilt assembly through the use of a
blade body member is retracted into the hilt body. To form flexible strip of point light sources positioned between two
the blade and support retraction , the hilt assembly also blade body members . The blade body members along with
includes a blade form shaping the blade body members into 30 the strip of light sources can be reeled back into the body of
the planar cross section during retraction of the blade into the hilt assembly to imitate activation and deactivation of an
the hilt body and into the semicircular cross section during energy sword such as a lightsaber found in many movies .
extension of the blade from the hilt body. Further, the lighting effect is furthered by forming the blade
In some embodiments , the hilt assembly includes a first body members of flexible diffusion material to provide an
spool, pivotally supported in the hilt body , for receiving a 35 anisotropic (or 1D ) diffuser whose diffusion is along the
first one of the blade body members during retraction of the length of the blade (or along the central axes of the extended
blade into the hilt body and a second spool, pivotally blade body members and strip of light sources ) to blend the
supported in the hilt body , for receiving a second one of the light into a contiguous and evenly illuminated beam of light.
blade body members during retraction of the blade into the In operation , the special effects device provides a more
hilt body, and the drive assembly may include a drive motor 40 aesthetically correct (relative to movie depictions) energy
operating to concurrently rotate the first and second spools sword than prior lightsaber products and designs .
in a first direction during retraction of the blade into the hilt FIG . 1 illustrates a functional block diagram of a device
body and in a second direction , opposite the first direction , 100 that is useful for implementing an energy sword such as
during extension of the blade out of the hilt body. The hilt a lightsaber for use as a theatrical prop or a toy. The device
assembly further may include a third spool, pivotally sup - 45 100 includes an elongated blade 110 , with an extended
ported in the hilt body, for receiving the flexible strip with length , L Blade, which can be in the range of 2 . 5 to 6 feet (with
the light sources during retraction of the blade into the hilt 3 feet being common in some prototypes ) asmeasured from
body . The blade has a uniform outer diameter along its a proximal or base end 113 to an outer surface of an end cap
length when extended out from the hilt body , and the blade 116 near the distal outer end 115 of the blade 110 . Generally ,
width may be in the range of 0 . 5 to 2 inches . Also , the drive 50 the blade 110 is cylindrical in shape when deployed or
assembly is configured such that the blade is moved between extended as shown in FIG . 1. The blade 110 is configured for
a fully retracted state and a fully extended state in less than retraction (i.e ., is retractable as shown in FIGS. 2 -5 ) and also
1 second , with a blade having a length of at least 24 inches for extension or deployment as is shown in FIG . 1 with
( such as 30 to 36 inches or more ). double arrows 111 ( from the shown extended or deployed
55 length , LBlade to being fully retracted or no length ). The
BRIEF DESCRIPTION OF THE DRAWINGS blade 110 has a single or uniform width , W Blode, along its
length (or at least along the length of the blade body
FIG . 1 is a functional block diagram of a special effects members 112 , 114 ), which can be in the range of 0 .5 to 3
device (or an energy sword device or a lightsaber prop /toy inches ( or a cylinder having an outer diameter (OD ) of 0 .5
or the like ); 60 to 3 inches), which is in contrast to prior telescoping devices
FIG . 2 is a top perspective view of one embodiment of a with a tapering OD from their bases to their tips .
special effects device , such as may be used to implement the The blade 110 is formed of a pair of elongated blade body
device of FIG . 1 , with outer sidewalls of the hilt body members 112 , 114 that are formed of a flexible yet relatively
removed to show internal components and prior to feeding stiff material. Each blade body member 112 , 114 , when
of the blade body members to an end cap via a blade form 65 extended , is shaped to have a semi-circular cross section or
and prior to attaching an end of a strip of LEDs to the end to provide half or more of a cylinder, and portions of the two
cap also through the blade form ; body members 112 , 114 meet or overlap along the length ,
US 10 ,065 , 127 B1
L Blade, of the blade 110 . In this way , the two blade body diameter greater than the blade width , W Blade
late . The body 122
members 112 , 114 , when extended 111 as shown in FIG . 1 , may be formed of a metal, a plastic, or a ceramic and have
form a blade 110 that is hollow and cylindrical. This rigid sidewalls to support the blade extension and retraction
cylindrical shape is maintained or held , in part, by attaching assembly 130 and other components of the hilt assembly 120
each of the blade body members 112, 114 at the distal or 5 housed within its interior space .
outer end 115 to an interior surface or edge of a semispheri- The blade extension and retraction assembly 130 includes
cal-shaped cap 116 ( e .g ., a clear or translucent plastic cap a blade forming/shaping assembly 132 proximate to the
with an OD matching the width , WBlade, of the blade 110 ). outlet/ aperture of the body 122 . This assembly 132 is
As explained below , the blade body members 112 , 114 are configured to , during extension , receive planar sections of
reshaped to be planar ( except for distal ends 115 ) when 10 the blade body members 112, 114 ( e . g ., from reels /spools )
retracted /reeled -in for storage in the hilt assembly 120 and and to impart a semi-circular cross -sectional shape to the
are separated from their overlapping configuration shown in blade body members 112 , 114 at or prior to the aperture /
FIG . 1 by being wrapped onto two different spools or reels outlet of the body 122 and to encourage the nesting of one
in the body 122. member 112 (or 114 ) within the other member 114 (or 112 )
The blade 110 is illuminated from within or internally lit 15 to provide overlapping portions along each edge/side of the
when extended 111 to provide a diffuse penumbra of light blade body members 112 , 114 .
119 . In some embodiments , light sources are powered on as The blade extension and retraction assembly 130 also
the blade is extended and powered off as the blade is includes a blade member storage 134 and a light source
retracted . Diffusion is aided or achieved in some implemen - storage 136 . These may take the form of a spool or reel for
tation by forming the blade members 112 , 114 of a translu - 20 each of the blade body members 112 , 114 and the flexible
cent plastic material, and , in some embodiments, the blade strip of light sources 118 , with the members 112 , 114 and
body members 112 , 114 are formed of a diffusion material strip body/substrate (e.g ., a flexible circuit board ) of flexible
( e . g ., a Light Shaping Diffuser available in sheets/ rolls on strip of light sources 118 being wrapped with a planar or
polycarbonate or polyester substrates from Luminit, LLC or linear cross -sectional shape onto the spools/ reels . Each
another diffusion material available from this or another 25 spool or reel may be mounted within the body 122 to be
commercial source ) chosen to allow them to behave as an freely rotatable about its center axis (e . g ., on a supporting
anisotropic (1D ) diffuser. shaft/axle ).
The blade 110 includes a flexible strip of light sources 118 The blade extraction and retraction assembly 130 also
that extends from the proximal or base end 113 of the blade includes a drive assembly 138 that is selectively operable
to (or past ) the distal or outer end 115 of the blade 110 . In 30 ( via control signals from a controller 140 or to a power
one embodiment, the flexible strip of light sources 118 is source 139 operating the drive assembly 138 ) to drive the
provided as a strip of colored light emitting diodes (LEDs) blade body members 112 , 114 outward from the body 122
( e . g ., green , red , or blue LEDs ) or as a strip ofwhite LEDs via the blade forming/shaping assembly 132 during exten
(with the blade being dyed /colored a desired color to get sion and to pull or wind the blade body members 112 , 114
accurate color control) that are concurrently operable along 35 into the body 122 during retraction . In the example of
the length of the strip 118 ( e .g ., all are powered on upon spools /reels being used for storage devices 134 , the drive
initiation of extension and powered off upon initiation of assembly 138 may include an electric motor that operates to
retraction or after retraction is completed ). The LEDs may rotate the spools / reels in a first direction to provide exten
be ganged into segments , and the segments can be illumi sion and in a second direction to provide retraction . Full
nated in sequence right before they exit the hilt so as to not 40 extension may be provided by a number of rotations of the
overheat the spool. One end of the strip of light sources 118 spool/ reel, by a timed amount of operation of the motor,
is attached to an interior surface of the cap 116 as shown at and /or by rotating the spools/ reels until the full length ,
117 ( e . g ., to the center of the cap 116 ), and the strip 118 has L Blade, is achieved (sensed via resistance to further rotation
a width less than the blade width , W Blades to allow its free or the like), and the extension and retraction rates may be
or non -binding movement relative to the blade body mem - 45 chosen to be relatively quick in some embodiments to
bers 112 , 114 . This attachment to the cap 116 causes the achieve a desired visual effect ( e. g ., a rate in the range of 6
flexible strip of light sources 118 to be pulled out of the body to 10 feet per second or the like in either direction ). An
122 of the hilt assembly 120 concurrently with extension or onboard (e. g., a battery in the hilt body 122 ) or offboard
deployment 111 of the two blade body members 112 , 114 power source 139 may be provided as part of the assembly
( which also push the cap 116 outward into space ahead of 50 130 to power the drive assembly 138 and , in some cases, the
their ends 115 ). light sources on the flexible strip 118 .
The device 100 includes a hilt assembly 120 from which The hilt assembly 120 further includes a controller 140
the blade 110 is extended 111 and into which the blade 110 operable to respond to a user ' s operation of input/output
is retracted 111 when not activated . Specifically , the hilt (I/O ) devices 144 to trigger the extension 111 of the blade
assembly 120 includes a body 122 that may have one or 55 110 or to trigger its retraction 111 . Particularly , the I/ O
more sidewalls defining an interior space for receiving the devices 144 may include any kind of input, including for
blade 110 when it is retracted 111 and for including a blade example a button , a switch , a trigger device, or the like for
extension and extraction assembly 130 with components for manual input or may take the form of a touchscreen or the
providing the extending/retracting 111 of the blade 110 . The like , or voice activation or the like, or trigger based on
body 122 may be generally cylindrical in shape and sized for 60 output by an IMU or the like, and the controller 140 may
being held in a person ' s hand such as with a length of 6 to respond to operation of the I/ O devices 144 to power the
12 inches or the like with an outer diameter in the range of drive assembly 138 ( or its electric motor( s )) to rotate the
2 to 4 inches ( or with a smaller portion to provide a gripping storage spools/reels of blade member storage 134 in a first
surface for a user ). The body 122 may include an outlet or direction ( e . g . , clockwise (CW ) or counterclockwise
aperture on one end through which the blade 110 may extend 65 (CCW )) and to concurrently power the light sources on the
during extension and may be withdrawn during retraction , flexible strip 118 during extension and then halt power to the
and this outlet/aperture may be circular in shape with a drive assembly 138 upon full extension 111 . Upon a second
US 10 ,065 , 127 B1
input indicating retraction is desired by an operator, the body 210 such that the blade body members 232, 236 can
controller 140 may act to power the drive assembly 138 and unspooled and reeled - in directly from the opening 212 of the
operate the motor of the drive assembly 138 to rotate the body 210 without twisting.
spools /reels of the blade member storage 134 in a second The material of the body members 232 , 236 is flattened to
direction (e . g ., CCW or CW ) and to cut off power to the light 5 facilitate wrapping onto the spools 230 , 234 and then is later
sources on the flexible strip 118 . during deployment or blade extension shaped to have a
The hilt assembly 120 furthermay include a sound effects semi-circular cross section by the blade form 220 . Particu
assembly 150 in the body 122 . The sound effect assembly larly , the blade form (or blade forming/shaping assembly )
150 may include a speaker (s ) and sound equipment includ - 220 is arranged in the interior space of the hilt body 210 with
ing soundtracks to selectively output a sound ( e . g ., a hum - 10 a first end 222 adjacent the pair of spools 230 , 234 , and this
ming noise , a cracking noise, and the like) during use of the end 222 has a pair of relatively wide and planar openings or
device 100 such as humming when the blade 110 is extended slots for receiving the material of the blade body members
and changing the hum pitch upon detection of particular 232 , 236 as it is fed off the spools/reels 230 , 234 into the
movements of the blade 110 . Detection of movements could blade form 220 during blade extension (or for dispensing the
be done by, for example , an inertial measurements unit 15 material of the blade body members 232, 236 as it is returned
( IMU ) in the assembly 150, which may be placed in or on back onto the spools/ reels 230 , 234 during retraction ).
the body 122 . In other embodiments , the sound effects The blade form 220 further includes a second end 224
assembly 150 is at least partially provided offboard to adjacent the hilt body opening /outlet 212. This end 224
provide higher quality sound ( e . g ., more volume) and to save includes a circular outlet/ aperture 225 that has an ID of
space in the body 122 . 20 about the OD of the blade end cap , and , when the blade is
FIG . 2 is a top perspective view of one embodiment of a retracted , the end cap would be positioned proximate to (or
special effects device 200 , such as may be used to implement some distance within the outlet/aperture 225 . The outer
the device 100 of FIG . 1 . The device 200 is shown with outer ends of the blade body members 232, 236 are attached to the
sidewalls of the hilt body 210 removed to show internal end cap ( such as to its inner surfaces or about its sidewall)
components . Also , the device 200 is shown prior to feeding 25 so as to each be semi- circular shaped at their ends. Further,
the blade body members 232 and 236 to an end cap (not the blade form 220 includes guide surfaces that urge , during
shown but understood from FIG . 1 and cap 116 ) via a blade extension , the planar blade body members 232 , 236 to take
form 220 and prior to attaching an end of a strip of LEDs 262 on a semi-circular cross sectional shape as they travel
to the end cap also through the blade form 220 . FIG . 3 is a between the first and second ends 222 , 224 of the blade form
bottom view of the special effects device 200 of FIG . 2 , FIG . 30 220 . Further, one of the body members 232 or 236 is caused
4 is a first side view of the special effects device 200 of to partially overlap the edges of the other body member 236
FIGS. 2 and 3 , and FIG . 5 is a second side view of the special or 232 and/ or to cause the two body members 232 , 234 to
effects device 200 of FIGS. 2 -4 that is opposite the view of become at least partially nested as they are pushed out of the
FIG . 4 . outlet/ aperture 225 of the blade form 220 (and follow the
As shown , the special effects device 200 includes a hilt 35 end cap with its circular end to which they are attached ).
assembly ( as discussed with reference to FIG . 1 ) that The special effects device 200 includes an electric motor
includes a hilt body or housing 210 , which generally is 250 in the body 210 that is operated ( e. g.,by a controller not
composed of a frame covered by one or more sidewalls (not shown but understood from controller 140 of FIG . 1 ) to
shown in FIGS. 2 -5 to shown internal components of the hilt rotate a shaft 251 in a first direction during extension of the
assembly and device 200 ). The frame along with the side - 40 blade (or blade body members 232 , 236 ) and in a second
walls of the hilt body 210 are designed to provide supporting direction during retraction of the blade (or blade body
structures and surfaces for the other components of the members 232, 236 ). A drive train 253 is provided between
device 200 and also to take a form factor similar to an energy the motor 250 and the blade spools 230 , 234 that is driven
sword or light saber hilt being simulated or replicated . To by rotation of the motor shaft 251 to rotate as shown with
this end , the hilt body 210 may be 6 to 12 inches ( or more ) 45 arrows 233 and 237 the spool axles /shafts 231 , 235 , respec
long and have a diameter of 2 to 4 inches to allow the device tively, to rotate the spools 230 , 234 in a concurrent manner
200 to be handheld during its use . At an upper or outer end and also in the samedirection (i.e., either CW or CCW ). The
of the body 210 , an opening or outlet 212 is provided with drive train 353 is shown to include a pair of drive gears
an inner diameter that is at least as large as the outer combined with a chain drive , but other configurations may
diameter of the end cap of the blade formed with the device 50 be used to implement the device 200. Further , in the illus
200 ( e . g ., 1 to 2 inch (or more ) ID ) so that the end cap can trated embodiment, a tensioner 354 is included to retain a
be received through the opening or outlet 212 when the desired amount of slack in the two blade body members 232,
blade is retracted through operation of the device 200 and to 236 during operations of the special effects device 200 as the
allow the end cap to freely pass outward when the device circumferences of the spooled material changes over time.
200 is operated to extend or deploy the blade. 55 The motor 250 is selected to provide relatively rapid exten
The special effects device 200 further includes a pair of sion and retraction with the rotations 233 , 237 such as to
blade spools ( or reels ) 230 and 234 pivotally mounted within fully extend or retract the blade in less than 1 second (with
the interior space of the body 210 on a pair of axles/shafts a 3 to 6 foot blade). An offboard power source may be used
231, 235 . One spool 230 is used to store or hold a first blade for the motor 250 or an onboard source ( e .g ., a battery ) may
body member 232 ( e . g ., a length of flexible diffusion mate - 60 be added to the device 200 and positioned within the body
rial of a desired width (e .g ., a width of 1 to 4 inches ) to suit 210 .
the OD of the blade formed with this body member 232). The special effects device 200 further includes an LED
The other spool 234 is used to store or hold a second blade spool 260 that is mounted within the interior space of the hilt
body member 236 (again , a length of flexible diffusion body 210 for rotation about a central axis 261 as shown with
material of a width useful for forming the blade with the 65 arrows 263 . Particularly , a spool drive 264 that is also
other body member 232 ). The axles/shafts 231, 235 are coupled (e. g., via gear sets ) to the drive shaft 251 of the
arranged to be orthogonal to the longitudinal axis of the electric motor 250 , and the spool drive 264 is configured to
US 10 ,065 , 127 B1
10
rotate 263 the spool 260 to wind or unwind a flexible strip 2 inches (with 1 .75 inches used in one prototype ). The blade
of light sources ( e. g., LEDs) 262 at the same rate and in the 710 is formed by extending outward from the hilt body 740
same direction into or out of the body 210 ) as the spools a pair of blade body members 712 , 714 that, as discussed
230, 234 . Although not shown in FIGS. 2 -5 , the exposed or above , are each semi-circular in cross section (when a cross
outer end of the light strip 262 would be attached to the 5 section is taken orthogonal to the longitudinal axis of the
interior of the blade end cap and a length of the strip 262 members 712 , 714 ) and the two members 712 , 714 are
would be fed through the body 210 to and through the blade nested with overlapping portions along each of their edges /
form 210 so as to extend between the blade body members sides along the blade 710 to form a hollow cylinder with a
232, 236 in the blade form 210 and be fed out of and back length ,L ode ( such as in the range of 24 to 60 inches with
into the body 210 via apertures 225 , 212 with the end cap 10 30 inches used in one prototype ).
and body members 232 , 236 in the center of the formed ( and The outer ends of the blade body members 712 , 714 are
retracted ) blade. The width of the flexible light strip 262 attached to an end cap 730 , which is semi-spherical in shape
typically is significantly less than the width of the blade and has a circular opening such that the blade members are
body members 232 , 236 and less than a width (or OD ) of the curved into their semi-circular shape at these attached ends
formed blade (such as 0 .25 to 0 .5 inches in width when the 15 (and the semi-circular shape is further formed /urged by a
blade OD is 1 to 2 inches ). blade form in the housing /body 740 (as discussed above
FIG . 6 illustrates one useful example of a light source with reference to blade form 220 in FIGS. 2 -5 )) . The other
spool610 for use in a hilt assembly of the present descrip ends of the blade body members 712 , 714 are attached to
tion such as for light source storage 136 in FIG . 1 or LED spools/ reels in the housing /body 740 (as discussed with
spool 260 in FIGS . 2 -5 . As shown , the spool 610 includes a 20 reference to FIGS. 2 -5 ). The blade 710 is configured to have
central support shaft/axle 612 that would be pivotally sup - a single width along its length such as one in the range of 0 . 5
ported within a hilt body and rotated , e.g., by rotation of a to 2 inches (with 0 .7 inches used in one prototype ), which
drive motor shaft , as shown with arrows 613 to rotate the matches the OD of the end cap 730 (as measured at is open
spool 610 in CW and CCW directions ( one used for unwind - end thatmates with the ends of the blade body members 712 ,
ing during blade extension and one used for reeling in the 25 714 ). In practice , there is a mathematical relationship
light source strip during retraction ) about the spool' s axis of between blade length and hilt outer diameter.
rotation , Axis Rotation The special effects device 700 further includes a flexible
A flexible light source strip 620 is shown to be loosely light source strip 720 thatmay take the form of the strip 620
wound onto the spool 610 . In this embodiment, the strip 620 of FIG . 6 , and the strip 720 is positioned in the interior space
includes a length (e. g ., 4 to 7 feet or the like ) of substrate or 30 of the cylinder formed by the nesting of blade body members
tape 624 upon which a flexible circuit board 630 is mounted 712 , 714 . The light source strip 720 is affixed at an outer end
or applied . Further, the strip 620 includes numerous LEDs to the blade end cap 730 such as to an interior surface of the
634 ( e . g ., hundreds of LEDs of a particular color) that are cap 730 at a center location . As shown in FIG . 7 , the light
selectively powered on and off via the circuit board 630 and source strip 720 moves outward from the housing/body 740
control/power circuitry 631 mounted onto one face of the 35 with the cap 730 , which is pushed outward from and away
spool 610 in this exemplary embodiment. The LEDs 634 from the housing /body 740 by extension of the two blade
may be powered on as a group upon initiation of extension body members 712 , 714 ( e.g ., with a drive motor rotating a
(and turned off as a group upon retraction ) or sequentially in pair of pulleys used to store the blade body members 712 ,
an individual manner with those near the end 624 being 714 when the blade 710 is retracted into the body /housing
turned on first during extension (and last upon retraction ) or 40 740 ). The light sources on the strip 720 are not shown to be
in groups ( such as groups of 10 to 20 being fired on or off lit/powered on in FIG . 7 , but typical operations would call
together ) to achieve a desired illumination effect for the for the lights on the strip to be powered on during the
interior of a blade . When installed , the exposed /outer end extension (and to remain on ) to provide internal illumination
624 of the light strip 620 is attached , such as via mounting of the blade body members 712 , 714 (which may be formed
hole 625 , to an inner surface ( generally , centrally ) of a blade 45 of diffusion material as discussed above to provide aniso
end cap such that the flexible light strip 620 extends outward tropic diffusion of the light from the light source strip 720 ) .
with the cap and is retracted inward with the cap (or, more The sensors in the device 700 can drive lighting effects such
accurately , the cap is pushed outward and pulled back as flashes when the sensors detect an impact between the
inward with rotation 613 of the spool 610 about axis , blade and another object ( such as another blade ).
Axis Rotation , during driving by a drive motor such as motor 50 FIGS . 8A and 8B illustrate a blade end cap 850 that may
250 of FIGS. 2 -5 ). be used within a special effects device of the present
FIG . 7 is a side view of a special effects device 700 of the description such as those shown in FIGS. 1, 2 -5 , and 7 . As
present description , such as an implementation of the shown , the end cap 850 has an outer tip / end 852 that is
devices of FIGS. 1 -5 , that has been activated or operated to semi-spherical in shape (e .g ., a hemisphere ) with a radius,
have an extended blade 710 . As shown , the device 700 55 Rcap, that typically will suit the OD of the desired blade
includes a blade 710 extending outward from a hilt body / such as 0 .35 inches when the OD of the blade is 0 .7 inches.
housing 740 (e .g ., a body similar to body 210 of FIG . 2 with The end cap 850 may be a solid plastic cap ormay be formed
sidewalls installed ) or, more specifically , from an outlet of a clear -to -translucent material such as a transparent
opening in an end of the body 740 that is proximate to a plastic , glass , or ceramic .
blade shaping / forming assembly or blade form . The device 60 The end cap 850 is configured for mating with and
700 is configured for external power (and /or control) with supporting with a particular shape the ends of a pair of blade
power connector 750 shown in FIG . 7 extending from the body members and a flexible strip of light sources ( e. g ., for
hilt body/housing 740 . use as end cap 730 in the device 700 of FIG . 7 ). To this end ,
The device 700 is a handheld device , and the hilt body 740 the end cap 850 includes a cylindrical shaft/body 854
may have a length , LHilt, and width (or OD ), WHilt, to suit 65 extending outward from the base of the end /tip 852 , and the
such a purpose such as in the ranges, respectively, of 10 to outer surfaces of the cylindrical shaft/body 854 defines a
14 inches (with 12 inches used in one prototype) and 1.5 to mating surface for receiving the ends of two blade body
US 10 ,065,127 B1
11 12
members and retaining these ends in a circular sectional the hilt body and in a second operating state to retract
shape (with overlapping edges to form an enclosed cylin the blade into the hilt body through the opening in the
drical blade ). hilt body,
The OD of the shaft/body 854 is less than the OD ( or wherein the blade comprises an end cap and a pair of
twice the radius, Rcan) of the tip / end 852 so as to form a 5 blade body members each attached at a first end to the
lip / stop 856 at the end abutting an upper edge of the received end cap and having a semicircular cross section in a
blade body members . In some embodiments, the surface of plane orthogonal to a longitudinal axis of the blade
the shaft/body 854 is offset from the base of the tip /end 852 body member ,
by the thickness of the received blade body member ( or wherein the pair of blade body members are at least
twice this to allow for overlapping edges or nesting of the 10 partially nested to define a hollow cylindrical body of
blade body members ). A hole 858 is provided to receive a the blade , and
rivet/pin for attaching an end of the blade body member to wherein the flexible strip with the plurality of light
the shaft/body 854 of the cap 850 . A slot 859 is provided at sources is attached at an end to the end cap and is
the base of the shaft/body 854 of the cap 850 for receiving positioned within the hollow cylindrical body of the
and mating with an end of a flexible light source strip , and 15 blade .
this slot 859 may have a width , W Slot, that matches or is 2 . The apparatus of claim 1 , wherein the light sources
some small amount larger than a width of the flexible light each comprises a light emitting diode (LED ) .
source strip (e. g., of the substrate /tape 624 of flexible light 3. The apparatus of claim 1, wherein the anisotropic
source strip 620 of FIG . 6 ) such as in the range of 0 . 3 to 0 .75 diffuser is provided by the pair ofblade body members and
inches or the like ). The end of the light source strip may 20 each of the blade body members comprises a strip of
include a hole (such as hole 625 shown in FIG . 6 ) for diffusion material.
allowing the light source strip to be pinned /affixed to the cap 4 . The apparatus of claim 1, wherein each of the blade
850 once its end is inserted into the slot 859 . body members has a planar cross section in a plane orthogo
Although the invention has been described and illustrated nal to a longitudinal axis of the blade body member when the
with a certain degree of particularity , it is understood that the 25 blade body member is retracted into the hilt body and
present disclosure has been made only by way of example , wherein the hilt assembly includes a blade form shaping the
and that numerous changes in the combination and arrange - blade body members into the planar cross section during
ment of parts can be resorted to by those skilled in the art retraction of the blade into the hilt body and into the
without departing from the spirit and scope of the invention , semicircular cross section during extension of the blade
as hereinafter claimed . 30 from the hilt body.
The lightsaber props or special effects devices of the 5 . The apparatus of claim 1 , wherein the hilt assembly
present description provide a solution to the design chal- includes a first spool, pivotally supported in the hilt body, for
lenges associated with an extendable and retractable energy receiving a first one of the blade body members during
sword that is more aesthetically correct than prior devices retraction of the blade into the hilt body and a second spool,
( such as those with a single bulb in the hilt or swords that 35 pivotally supported in the hilt body, for receiving a second
extend and retract cutting nested conical shapes ). By using one of the blade body members during retraction of the blade
anisotropic diffuser films to form the two blade body mem - into the hilt body and wherein the drive assembly comprises
bers, the LED strip (or other flexible strip of light sources )
a drive motor operating to concurrently rotate the first and
is operable to form an even continuous illumination along second spools in a first direction during retraction of the
the extended blade, which can be rolled or reeled - in to 40 blade into the hilt body and in a second direction , opposite
retract it into the hilt. the first direction , during extension of the blade out of the
The design taught herein also produces a blade of con - hilt body .
tinuous (or a single ) width along its length (i.e., a width at 6 . The apparatus of claim 5 , wherein the hilt assembly
the base that matches a width at or near the tip of the blade). further includes a third spool, pivotally supported in the hilt
In contrast, other device designs telescope the blade , which 45 body, for receiving the flexible strip with the light sources
creates a stair- stepped , conical appearance for the blade that during retraction of the blade into the hilt body.
is typically undesirable as it does notmatch the lightsabers 7 . The apparatus of claim 1 , wherein the blade has a
shown in films, and it can be problematic in other regards. uniform outer diameter along its length when extended out
Particularly, the concentric stages may be loose fitting and from the hilt body and wherein the blade width is in the
not transversely rigid . Also , when a telescoping blade is only 50 range of 0 .5 to 2 inches .
slightly bent, it may jam and not fully retract. Overall and in 8 . The apparatus of claim 1 , wherein the blade is moved
brief, the special effects device or lightsaber prop described between a fully retracted state and a fully extended state in
provides much more desirable lighting and extension / retrac - less than 1 second and wherein the blade has a length of at
tion effects than prior devices and uses a lighting solution least 24 inches .
that is in line with safety and operating procedures for many 55 9 . A special effects device , comprising :
theatrical and entertainment settings . a hilt body ;
We claim : a drive assembly positioned within the hilt body ;
1 . An apparatus for producing an energy sword special an end cap ;
effect, comprising: a pair of blade body members each attached at a first end
a hilt assembly including a drive assembly within a hilt 60 to the end cap ;
body ; and a flexible strip with a plurality of light sources arranged in
a blade including a flexible strip with a plurality of light a linear pattern , wherein the flexible strip is attached at
sources arranged in a linear pattern and an anisotropic an end to the end cap and is positioned between the pair
diffuser diffusing light output from the plurality of light of blade body members,
sources , 65 wherein the drive assembly operates in a first operating
wherein the drive assembly operates in a first operating state to extend the blade body members outward from
state to extend the blade outward from an opening in an opening in the hilt body and in a second operating
US 10 , 065 , 127 B1
13 14
state to retract the blade body members into the hilt 17 . The apparatus of claim 15 , wherein the blade further
body through the opening in the hilt body . includes a flexible strip with a plurality of light sources ,
10 . The special effects device of claim 9 , wherein each of wherein the flexible strip with the plurality of light sources
theblade body members has a planar cross section in a plane is attached at an end to the end cap and is positioned within
orthogonal to a longitudinal axis of the blade body member 5 the hollow cylindrical body of the blade.
when the blade body member is retracted into the hilt body, 18 . The apparatus of claim 17 , wherein the light sources
wherein the hilt assembly includes a blade shaping assembly each comprises a light emitting diode (LED ) and wherein
shaping the blade body members into the planar cross the blade body members comprise strips of diffusion mate
section during retraction of the blade into the hilt body and rial, whereby the blade body members act as an anisotropic
into a semicircular cross section during extension from the 10 diffuser for light output from the light sources when powered
hilt body, and wherein the pair of blade body members are on when the blade is extended from the hilt body.
at least partially overlapping when extended from the hilt 19 . The apparatus of claim 15 , wherein each of the blade
body to define a hollow cylindrical blade . body members has a planar cross section in a plane orthogo
11. The special effects device of claim 9 , wherein the light nal to a longitudinal axis of the blade body member when the
sources each comprises a light emitting diode (LED ) . 15 blade body member is retracted into the hilt body and
12 . The special effects device of claim 9, wherein each of wherein the hilt assembly includes a blade form shaping the
the blade body members comprises a strip of diffusion blade body members into the planar cross section during
material, whereby the blade body members function as an retraction of the blade into the hilt body and into the
anisotropic diffuser for light output from the lights sources semicircular cross section during extension of the blade
when the blade body members are extended from the hilt 20 from the hilt body.
body and the light sources are operated to output light. 20 . An apparatus for producing an energy sword special
13 . The special effects device of claim 9 , further including effect, comprising:
a first spool, pivotally supported in the hilt body, for receiv a hilt assembly including a drive assembly within a hilt
ing a first one of the blade body members during retraction body; and
of the blade into the hilt body and a second spool, pivotally 25 a blade including a flexible strip with a plurality of light
supported in the hilt body , for receiving a second one of the sources arranged in a linear pattern and an anisotropic
blade body members during retraction of the blade into the diffuser diffusing light output from the plurality of light
hilt body, wherein the drive assembly comprises a drive sources ,
motor operating to concurrently rotate the first and second wherein the drive assembly operates in a first operating
spools in a first direction during retraction of the blade into 30 state to extend the blade outward from an opening in
the hilt body and in a second direction , opposite the first the hilt body and in a second operating state to retract
direction , during extension of the blade out of the hilt body . the blade into the hilt body through the opening in the
14 . The special effects device of claim 13 , further includ hilt body,
ing a third spool, pivotally supported in the hilt body, for wherein the blade has a uniform outer diameter along its
receiving the flexible strip with the light sources during 35 length when extended out from the hilt body, and
retraction of the blade into the hilt body. wherein the blade width is in the range of 0 .5 to 2 inches .
15 . An apparatus for producing an energy sword special 21 . The apparatus of claim 20 , wherein the blade com
effect, comprising: prises an end cap and a pair of blade body members each
a hilt assembly including a drive assembly within a hilt attached at a first end to the end cap and having a semicir
body ; and 40 cular cross section in a plane orthogonal to a longitudinal
a blade comprising an end cap and a pair of blade body axis of the blade body member, wherein the pair of blade
members each attached at a first end to the end cap and , body members are at least partially nested to define a hollow
when the blade is extended out from the hilt body, cylindrical body of the blade, wherein the flexible strip with
having a semicircular cross section in a plane orthogo - the plurality of light sources is attached at an end to the end
nal to a longitudinal axis of the blade body member, 45 cap and is positioned within the hollow cylindrical body of
wherein the pair of blade body members are at least the blade , and wherein the light sources each comprises a
partially nested to define a hollow cylindrical body of light emitting diode (LED ).
the blade, 22 . The apparatus of claim 20 , wherein the blade com
wherein the drive assembly operates in a first operating prises an end cap and a pair of blade body members each
state to extend the blade outward from an opening in 50 attached at a first end to the end cap and having a semicir
the hilt body and in a second operating state to retract cular cross section in a plane orthogonal to a longitudinal
the blade into the hilt body through the opening in the axis of the blade body member, wherein the pair of blade
hilt body, and body members are at least partially nested to define a hollow
wherein the blade has a uniform outer diameter along its cylindricalbody of the blade, wherein the flexible strip with
length when extended out from the hilt body. 55 the plurality of light sources is attached at an end to the end
16 . The apparatus of claim 15 , wherein the hilt assembly cap and is positioned within the hollow cylindrical body of
includes a first spool, pivotally supported in the hilt body , for the blade, and wherein the anisotropic diffuser is provided
receiving a first one of the blade body members during by the pair of blade body members and each of the blade
retraction of the blade into the hilt body and a second spool, body members comprises a strip of diffusion material.
pivotally supported in the hilt body , for receiving a second 60 23 . The apparatus of claim 20 , wherein the blade com
one of the bladebody members during retraction of the blade prises an end cap and a pair of blade body members each
into the hilt body and wherein the drive assembly comprises attached at a first end to the end cap and having a semicir
a drive motor operating to concurrently rotate the first and cular cross section in a plane orthogonal to a longitudinal
second spools in a first direction during retraction of the axis of the blade body member, wherein the pair of blade
blade into the hilt body and in a second direction , opposite 65 body members are at least partially nested to define a hollow
the first direction , during extension of the blade out of the cylindrical body of the blade , wherein the flexible strip with
hilt body. the plurality of light sources is attached at an end to the end
US 10 , 065 , 127 B1
15 16
cap and is positioned within the hollow cylindrical body of pivotally supported in the hilt body , for receiving a first one
the blade, wherein each of the blade body members has a of the blade body members during retraction of the blade
planar cross section in a plane orthogonal to a longitudinal into the hilt body and a second spool, pivotally supported in
axis of the blade body member when the blade body member the hilt body , for receiving a second one of the blade body
is retracted into the hiltbody, and wherein the hilt assembly 5 members during retraction of the blade into the hilt body,
includes a blade form shaping the blade body members into and wherein the drive assembly comprises a drive motor
the planar cross section during retraction of the blade into operating to concurrently rotate the first and second spools
in a first direction during retraction of the blade into the hilt
the hilt body and into the semicircular cross section during body
extension of the blade from the hilt body . and in a second direction , opposite the first direction ,
24 . The apparatus of claim 20. wherein the blade com - 10 during extension of the blade out of the hilt body.
prises an end cap and a pair of blade body members each 25 . The apparatus of claim 24 , wherein the hilt assembly
attached at a first end to the end cap and having a semicir further includes a third spool, pivotally supported in the hilt
cular cross section in a plane orthogonal to a longitudinal body, for receiving the flexible strip with the light sources
axis of the blade body member, wherein the pair of bladew 15 during retraction of the blade into the hilt body.
bodymembers are at least partially nested to define a hollow between a apparatus
26 . The of claim 20 , wherein the blade is moved
fully retracted state and a fully extended state in
cylindrical body of the blade, wherein the flexible strip with
less than 1 second and wherein the blade has a length of at
the plurality of light sources is attached at an end to the end least
cap and is positioned within the hollow cylindrical body of 24 inches .
the blade, wherein the hilt assembly includes a first spool, * * * *