U.S. patent application number 11/191790 was filed with the patent office on 2007-02-01 for weight assembly and method of manufacture.
This patent application is currently assigned to Iron Grip Barbell Company, Inc.. Invention is credited to Scott J. Frasco.
Application Number | 20070027007 11/191790 |
Document ID | / |
Family ID | 37695117 |
Filed Date | 2007-02-01 |
United States Patent
Application |
20070027007 |
Kind Code |
A1 |
Frasco; Scott J. |
February 1, 2007 |
Weight assembly and method of manufacture
Abstract
A weight assembly is provided having a handle securely attached
to first and second weight heads. More particularly, each weight
head includes a side wall and an end wall that together define the
bore for receiving an end of the handle via press-fit. The side
wall includes an outer portion disposed at an angle relative to a
longitudinal axis of the bore and an intermediate portion disposed
between the outer portion and the end wall. The end portions of the
handle have a diameter that is greater than that of the gripping
portion of the handle. The bore and the handle ends are
cooperatively sized to enable a secure press-fit. First and second
weld seams are disposed about the handle in contact with the
corresponding outer portion of the side wall of each weight head.
More particularly, the weld seams are substantially confined to a
recess defined between the corresponding outer portion of the side
wall of each weight head and the corresponding end portion of the
handle. Moreover, the upper portion of each weight head is
configured to facilitate a secure weld between the weight head and
the handle, while minimizing damage to the components to include
heat-affected zones on the handle.
Inventors: |
Frasco; Scott J.;
(Huntington Beach, CA) |
Correspondence
Address: |
SHEPPARD, MULLIN, RICHTER & HAMPTON LLP
333 SOUTH HOPE STREET
48TH FLOOR
LOS ANGELES
CA
90071-1448
US
|
Assignee: |
Iron Grip Barbell Company,
Inc.
Santa Ana
CA
|
Family ID: |
37695117 |
Appl. No.: |
11/191790 |
Filed: |
July 27, 2005 |
Current U.S.
Class: |
482/106 ;
482/108 |
Current CPC
Class: |
A63B 21/0726 20130101;
B23K 31/02 20130101 |
Class at
Publication: |
482/106 ;
482/108 |
International
Class: |
A63B 21/072 20060101
A63B021/072; A63B 21/075 20060101 A63B021/075 |
Claims
1. A weight assembly, comprising: first and second weight heads
spaced apart from each other, each weight head having a side wall
and an end wall that together define a bore having a longitudinal
axis, the side wall including portion disposed about an opening to
the bore and at an angle relative to the longitudinal axis of the
bore, and an intermediate portion disposed between the outer
portion and the end wall; an elongated handle having two end
portions and a gripping portion between the end portions, each end
portion having a diameter greater than a diameter of the gripping
portion, each end portion press-fit into a corresponding bore of
the first and second weight heads such that the handle extends
between the first and second weight heads; and first and second
weld seams each substantially confined to a recess defined between
the corresponding outer portion of the side wall of each weight
head and the corresponding end portion of the handle such that the
weld seams are spaced apart from the gripping portion of the
handle.
2. A weight assembly as defined in claim 1, wherein the outer
portion of each side wall has a prescribed curvature, as viewed in
cross-section.
3. A weight assembly as defined in claim 1, wherein each bore has a
depth greater than or equal to the diameter of the corresponding
end portion of the handle.
4. A weight assembly as defined in claim 1, wherein the outer
portion has a frusto-conical configuration.
5. A weight assembly as defined in claim 1, wherein the outer
portion has a notch configuration, the outer portion including a
first surface, adjacent to the intermediate portion, angled
outwardly relative to the longitudinal axis of the bore, and a
second surface extending from the first surface, generally parallel
to the longitudinal axis of the bore.
6. A weight assembly as defined in claim 1, wherein a coating of
compliant material is provided over the first and second weight
heads, substantially covering the first and second weld seams.
7. A method of manufacturing a weight assembly, comprising:
providing first and second weight heads, each weight head having a
side wall and an end wall that together define a bore having a
prescribed diameter, the side wall including an outer portion
disposed about an opening to the bore and at an angle relative to a
longitudinal axis of the bore, and an intermediate portion disposed
between the outer portion and the end wall; providing an elongated
handle having first and second end portions and a gripping portion
between the end portions each end portion having a diameter greater
than a diameter of the gripping portion; pressing the first end
portion of the handle into the bore of the first weight head;
pressing the second end portion of the handle into the bore of the
second weight head; welding the handle to the first weight head
such that the resulting weld seam is substantially confined to a
recess defined between the outer portion of the side wall of the
first weight head and the corresponding end portion of the handle
and such that the weld seam is spaced apart from the gripping
portion of the handle; and welding the handle to the second weight
head such that the resulting weld seam is substantially confined to
a recess defined between the outer portion of the side wall of the
second weight head and the corresponding end portion of the handle
and such that the weld seam is spaced apart from the gripping
portion of the handle.
8. A method as defined in claim 7, wherein the outer portion of
each side wall has a prescribed curvature, as viewed in
cross-section.
9. A method as defined in claim 7, wherein the outer portion of
each side wall has a notch configuration, the outer portion
including a first surface, adjacent to the intermediate portion,
angled outwardly relative to the longitudinal axis of the bore, and
a second surface extending from the first surface, generally
parallel to the longitudinal axis of the bore.
10. A method as defined in claim 7, wherein the weight heads are
covered with a compliant material.
11. A method as defined in claim 7, wherein each bore has a depth
greater than or equal to the diameter of the corresponding end
portion of the handle.
12. A method as defined in claim 7, wherein the step of providing a
handle includes, providing a metal bar of a first diameter,
machining an intermediate region of the bar to a second diameter,
less than the first diameter, thereby defining the gripping
portion, and machining a transition region between the gripping
portion and each end portion.
13. A method as defined in claim 7, wherein the step of providing
first and second weight heads includes, providing a first head
blank and a second head blank, creating a cylindrical hole of a
prescribed depth in each head blank, less than a thickness of the
head blank, thereby forming the intermediate portion of the side
wall and the end wall, and removing material about the outer edge
of the cylindrical hole, thereby forming the outer portion of the
side wall.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to weight assemblies
such as dumbbells and barbells and, more particularly, to such
weight assemblies having a handle welded to two heads of fixed
weight.
[0002] In weightlifting, weight assemblies of various
configurations are commonly used. For example, dumbbells and
barbells both include an elongated handle extending between two
weights. In dumbbells, the handle is sized to accommodate one hand,
whereas, in barbells, the handle is sized to accommodate both
hands, spaced apart from each other.
[0003] Of the various configurations of weight assemblies,
dumbbells and barbells are two of the most common and versatile. As
such, they are typically in high demand at weightlifting
facilities. Thus, it is common for such facilities to provide a
number of dumbbells and barbells configured at different weights,
e.g., ranging from five pounds to 200 pounds. To that end, sets of
barbells and sets of dumbbells are available in which each weight
assembly is fixed at a prescribed weight. Such weight assemblies
typically include an elongated handle permanently attached to
weight heads, providing a preset weight.
[0004] Various approaches have been used to attach the handle to
weight heads in such weight assemblies. In one approach, as
depicted in FIG. 1, the handle 10 is disposed in cylindrical
cavities defined by inwardly facing surfaces 12 of each weight head
14. A fillet-type weld 16 is provided around the handle, securing
the handle to each weight head. Although generally effective,
shortfalls exist. For example, during welding, heat is directed
towards the handle about the junction of the head and the handle.
This heating can discolor the metal and create a heat-affected zone
18 on the handle. Such heat-affected zones can substantially
diminish the strength of the handle. Over time, cracks can occur in
the handle. These cracks can exacerbate after extended use, which
can result in total failure of the connection between the handle
and the weight.
[0005] It should, therefore, be appreciated that there remains a
need for a weight assembly having a handle attached to weight heads
in a secure and durable manner. The present invention fulfills this
need and others.
SUMMARY OF THE INVENTION
[0006] The invention resides in a weight assembly having a handle
securely attached to first and second weight heads. More
particularly, each weight head includes a side wall and an end wall
that together define a bore for receiving an end of the handle via
press-fit. The side wall includes an outer portion disposed at an
angle relative to a longitudinal axis of the bore and an
intermediate portion disposed between the outer portion and the end
wall. First and second weld seams are disposed about the handle in
contact with the corresponding outer portion of the side wall of
each weight head such that the weld is spaced apart from the
gripping portion of the handle. The end portions of the handle have
a diameter that is greater than that of the gripping portion of the
handle. The bore and the handle ends are cooperatively sized to
enable a secure press-fit. Moreover, the upper portion of each
weight head is configured to facilitate a secure weld between the
weight head and the handle, while minimizing damage to the
components to include heat-affected zones on the handle.
[0007] In a detailed aspect of exemplary embodiments, the outer
portion is sufficiently sized to receive the weld seam between the
head and the handle. For example, the outer portion can have a
prescribed curvature, as viewed in cross-section. In another
example, the outer portion has a frusto-conical configuration. More
particularly, each weld seam can be generally confined in a recess
defined between the corresponding outer portion and the
corresponding end portion of the handle. The weight heads can be
covered with a compliant material.
[0008] In another example, the outer portion can have a notch
configuration, in which a first surface, adjacent to the
intermediate portion is angled outwardly relative to the
longitudinal axis of the bore and a second surface extends towards
the opening of the bore generally parallel to the longitudinal axis
of the bore.
[0009] The invention also resides in a method of manufacturing a
weight assembly, comprising: [0010] providing first and second
weight heads, each weight head having a side wall and an end wall
that together define a bore having a prescribed diameter, the side
wall including [0011] an outer portion disposed about an opening to
the bore and at an angle relative to a longitudinal axis of the
bore, and [0012] an intermediate portion disposed between the outer
portion and the end wall; [0013] providing an elongated handle
having first and second end portions and a gripping portion between
the end portions each end portion having a diameter greater than a
diameter of the gripping portion; [0014] pressing the first end
portion of the handle into the bore of the first weight head;
[0015] pressing the second end portion of the handle into the bore
of the second weight head; [0016] welding the handle to the first
weight head such that the resulting weld seam is substantially
confined to a recess defined between the outer portion of the side
wall of the first weight head and the corresponding end portion of
the handle and such that the weld seam is spaced apart from the
gripping portion of the handle; and
[0017] welding the handle to the second weight head such that the
resulting weld seam is substantially confined to a recess defined
between the outer portion of the side wall of the second weight
head and the corresponding end portion of the handle and such that
the weld seam is spaced apart from the gripping portion of the
handle.
[0018] In an exemplary aspect of the method, the step of providing
a handle can include providing a metal bar of a first diameter,
machining an intermediate region of the bar to a second diameter,
less than the first diameter, thereby defining the gripping
portion, and machining a transition region between the gripping
portion and each end portion.
[0019] In another exemplary aspect of the method, the step of
providing first and second weight heads can include providing a
first and second head blank, creating a cylindrical hole of a
prescribed depth in each head blank, less than a thickness of the
head blank, thereby forming the intermediate portion of the side
wall, and removing material about the outer edge of the cylindrical
hole, thereby forming the outer portion of the side wall.
[0020] For purposes of summarizing the invention and distinguishing
it over the prior art, certain advantages of the invention have
been described herein. Of course, it is to be understood that not
necessarily all such advantages may be achieved in accordance with
any particular embodiment of the invention. Thus, for example,
those skilled in the art will recognize that the invention may be
embodied or carried out in a manner that achieves or optimizes one
advantage on group of advantages as taught herein without
necessarily achieving other advantages as may be taught or
suggested herein.
[0021] All of these embodiments are intended to be within the scope
of the invention herein disclosed. These and other embodiments of
the present invention will become readily apparent to those skilled
in the art from the following detailed description of the preferred
embodiments having reference to the attached figures, the invention
not being limited to any particular preferred embodiment
disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Embodiments of the present invention will now be described,
by way of example only, with reference to the following drawings in
which:
[0023] FIG. 1 is a cross-sectional view of a first end of a prior
art weight assembly.
[0024] FIG. 2 is an elevational view of a first embodiment of a
weight assembly in accordance with the invention, depicting a two
weight heads and a handle, the weight heads coated with a compliant
material.
[0025] FIG. 3 is a longitudinal cross-sectional view of the weight
head of the weight assembly of FIG. 2.
[0026] FIG. 4 is a cross-sectional view, taken along line 4-4 of
FIG. 2, of the first end of the weight assembly, excluding the
coating of compliant material and depicted a weld seam spaced from
a gripping portion of the handle.
[0027] FIG. 5 is a longitudinal cross-sectional view of the weight
assembly depicted in FIG. 2
[0028] FIG. 6 is a longitudinal cross-sectional view, similar to
FIG. 5, of a first end of a second embodiment of a weight assembly
in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] With reference now to the drawings, and particularly to
FIGS. 2 to 5, there is shown a dumbbell 20 having two fixed-weight
heads 22 and a handle 24 axially extending between the heads. Each
weight head defines a bore 26 (FIG. 3) for receiving a
corresponding end 28 (FIG. 5) of the handle. More particularly,
each bore is defined by a side wall 30 and an end wall 32,
providing an open end and a closed end. The side wall includes an
outer portion 34 disposed about the bore opening and the
intermediate portion 36 disposed between the outer portion and the
end wall. The bore and the handle end are cooperatively sized to
enable a secure press-fit. Moreover, the upper portion of each
weight head is configured to facilitate a secure weld between the
weight head and the handle, while minimizing damage to the
components to include heat-affected zones on the handle.
[0030] As shown in FIG. 2, the handle 24 includes a gripping
portion 38 sized to receive a single hand, in normal use. Also,
other embodiments of weight assemblies are contemplated having a
comparatively longer gripping portion (e.g., barbells).
[0031] With reference to FIGS. 3 to 5, the outer portion 34 of each
side wall 30 is beveled with a prescribed curvature, as viewed in
cross-section. With the handle end 28 disposed in the bore, the
outer portion and the handle together define a recess, facilitating
welding of the components. More particularly, the outer portion is
configured such that a weld seam 40 can be disposed in the recess.
Moreover, the configuration of the outer portion minimizes exposure
of the handle during welding, thereby inhibiting heat-affected
zones on the handle.
[0032] In the exemplary embodiments, the handle ends are
substantially received within the bore, leaving the narrower
gripping portion extending from the weight heads. In other
embodiments, a portion of the handle end can extend beyond the
opening of the bore, so long as adequate room is provided for
receiving the weld seam, between the upper portion of the bore and
the handle end. Also, in other embodiments, the outer portion can
be provided with various other shapes, so long as sufficient space
is provided for receiving a weld. For example, the outer portion
can have a notch configuration, in which a first surface, adjacent
to the intermediate portion is angled outwardly relative to the
longitudinal axis of the bore and a second surface extends towards
the opening of the bore generally parallel to the longitudinal axis
of the bore.
[0033] The dumbbell 20 includes a compliant material 44, e.g.,
rubber or urethane, coating the weight heads. In the exemplary
embodiment, the compliant material covers the weld seam, hiding it
from view. Other embodiments, the weight heads can exclude a
complaint material entirely.
[0034] The handle 24 is formed of a metal bar having a constant
diameter. In the exemplary embodiment, a steel bar is used. The
gripping portion 38 is formed by machining an intermediate region
of the bar to a second diameter. A transition region 42 between the
gripping portion and each end portion 28 is also machined, forming
the handle. In the exemplary embodiments, the gripping portion has
a textured surface and a constant diameter. In other embodiments,
various configurations for the gripping portion can be used as
desired. In addition, in other embodiments, the handle can be sized
for use with various other weight assemblies, e.g., barbells, as
desired.
[0035] The weight heads 22 and the handle 24 are cooperatively
sized to achieve a secure attachment, considering the anticipated
forces endured. Preferably, the depth of the bore is greater than
or equal to the diameter of the corresponding end portion of the
handle. Each handle end is positioned in secure contact with the
end wall and the side wall.
[0036] In an exemplary method of manufacturing, a machine press,
e.g., a hydraulic press, is used. For each weight head, the machine
press drives the end portion of the handle into the bore under
considerable force. Having a secure press-fit facilitates an
effective distribution of force about the dumbbell. Prior to
installation, the diameter of the end portions is oversized
relative to the diameter of the bore.
[0037] For each weight head 22, the machine press drives the end
portion 32 into the bore 26 into contact with the end wall 32.
Sufficient force is used to drive the end portion into contact with
the end wall of the bore. The operation is performed sequentially,
one handle end at a time. Alternatively, the handle ends could both
be driven into position simultaneously without departing from the
invention.
[0038] Once the handle end is position in the bore of the
corresponding weight head, the weld seam 40 is provided about the
handle. The weld seam is formed of a filler material selected to
provide secure attachment between the materials of the handle and
weight head and is heated to a prescribed temperature. In forming
the weld, heat can be directed towards the outer portion, away from
the handle, minimizing any heat-affected zone on the handle. In
other embodiments, a weld seam can be formed using various other
welding approaches, as needs dictate. Thereafter, the compliant
material 44 is applied. Alternatively, portions of the compliant
material can be applied earlier in the process.
[0039] FIG. 6 depicts a second embodiment, weight assembly 60, in
which an outer portion 62 of a bore has a frusto-conical
configuration on each weight head 64. The outer portion is sized to
receive a weld seam 66 with in a recess defined between the outer
portion and the handle 68.
[0040] It should be appreciated from the foregoing that the present
invention provides a weight assembly having a handle securely
attached to first and second weight heads. More particularly, each
weight head includes a side wall and an end wall that together
define the bore for receiving an end of the handle. The end
portions of the handle have a diameter that is greater than that of
the gripping portion of the handle. The bore of each weight head
and the handle ends are cooperatively sized to enable a secure
press-fit. The side wall includes an outer portion disposed at an
angle relative to a longitudinal axis of the bore and an
intermediate portion disposed between the outer portion and the end
wall. First and second weld seams are disposed about the handle in
contact with the corresponding outer portion of the side wall of
each weight head. More particularly, the weld seams are
substantially confined to a recess defined between the
corresponding outer portion of the side wall of each weight head
and the corresponding end portion of the handle. Moreover, the
upper portion of each weight head is configured to facilitate a
secure weld between the weight head and the handle, while
minimizing damage to the components to include heat-affected zones
on the handle.
[0041] Although the invention has been disclosed in detail with
reference only to the exemplary embodiments, those skilled in the
art will appreciate that various other embodiments can be provided
without departing from the scope of the invention. Accordingly, the
invention is defined only by the claims set forth below.
* * * * *