U.S. patent application number 11/679141 was filed with the patent office on 2007-06-21 for method of manufacturing a weight plate for interlocking and weight adjustment.
This patent application is currently assigned to USA SPORTS, INC.. Invention is credited to Louis Lien.
Application Number | 20070142188 11/679141 |
Document ID | / |
Family ID | 37011092 |
Filed Date | 2007-06-21 |
United States Patent
Application |
20070142188 |
Kind Code |
A1 |
Lien; Louis |
June 21, 2007 |
Method of manufacturing a weight plate for interlocking and weight
adjustment
Abstract
A weight plate have integrally formed handles is provided. The
weight plate has a weight plate body having an outer periphery, a
first side, and a second side that is substantially flat. The
weight plate also has a central bore extending through the body, a
raised flange member forming a portion of the outer periphery on
the first side, and at least one handle opening extending through
the body and through ht least a portion of the outer periphery. The
handle formed by each handle opening, the corresponding recess, and
the raised flange member is sufficient for a human hand to grip. In
one embodiment, the weight plate further includes an interlock for
interlocking the weight plate with another weight plate when
positioned together. In another embodiment, the weight plate
further includes a pock defined in the weight plate. The pock
allows the weight of the weight plate to be adjusted to a desired
weight by allowing additional material to be added to the pock.
Inventors: |
Lien; Louis; (Bellaire,
TX) |
Correspondence
Address: |
WONG, CABELLO, LUTSCH, RUTHERFORD & BRUCCULERI,;L.L.P.
20333 SH 249
SUITE 600
HOUSTON
TX
77070
US
|
Assignee: |
USA SPORTS, INC.
2516 Fairway Park Drive
Houston
TX
77092
|
Family ID: |
37011092 |
Appl. No.: |
11/679141 |
Filed: |
February 26, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11083426 |
Mar 18, 2005 |
7198591 |
|
|
11679141 |
Feb 26, 2007 |
|
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Current U.S.
Class: |
482/93 |
Current CPC
Class: |
Y10S 482/908 20130101;
A63B 21/0728 20130101 |
Class at
Publication: |
482/093 |
International
Class: |
A63B 21/06 20060101
A63B021/06 |
Claims
1-19. (canceled)
20. A method of manufacturing a weight plate with a desired weight,
the method comprising not necessarily in sequence: forming a cast
for the weight plate such that a first side of the weight plate is
substantially flat and defines an interlock space; forming the cast
for the weight plate such that a second side of the weight plate
includes an interlock protrusion for interlocking with the
interlock space in the first side of another similar weight plate;
casting the weight plate with material in the cast; comparing the
weight of the cast weight plate with the desired weight; and
adjusting the weight of the cast weight plate substantially to the
desired weight by removing a portion of the material from the
substantially flat side of the weight plate.
21. The method of claim 20, wherein further comprising performing
the acts of comparing and removing in an alternating fashion.
22. The method of claim 20, wherein act of removing the portion of
the material from the substantially flat side of the weight plate
comprises milling the portion of material from the substantially
flat side of the weight plate.
23. The method of claim 20, wherein act of removing the portion of
the material from the substantially flat side of the weight plate
comprises filing the portion of material from the substantially
flat side of the weight plate.
24. A method of manufacturing a weight plate with a desired weight,
the method comprising not necessarily in sequence: forming a cast
for the weight plate such that the weight plate defines a pocket;
casting the weight plate with material in the cast; comparing the
weight of the cast weight plate with the desired weight; and
adjusting the weight of the cast weight plate substantially to the
desired weight by adding additional material to the pocket defined
in the weight plate.
25. The method of claim 24, wherein further comprising performing
the acts of comparing and adding the additional material in an
alternating fashion.
26. The method of claim 24, wherein act of adding the additional
material to the pocket defined in the weight plate comprises
packing the pocket with a material capable of being substantially
held within the pocket.
27. The method of claim 24, wherein act of adding the additional
material to the pocket defined in the weight plate comprises
filling the pocket with an aggregate material and holding the
aggregate material in the pocket with a cover or resin.
28. A weight plate manufacturing method, comprising: forming a cast
for the weight plate such that a first side of the weight plate is
substantially flat and defines at least one interlock space;
forming the cast for the weight plate such that a second side of
the weight plate defines at least one pocket and includes at least
one interlock protrusion for interlocking with the at least one
interlock space in the first side of another similar weight plate;
casting the weight plate with material in the cast; comparing the
weight of the cast weight plate with a desired weight; and
adjusting the weight of the cast weight plate substantially to the
desired weight by performing at least one of: (i) removing a
portion of the material from the substantially flat first side of
the weight plate, and (ii) adding additional material to the pocket
defined in the weight plate.
29. The method of claim 28, wherein further comprising performing
the acts of comparing and adjusting in an alternating fashion.
30. The method of claim 28, wherein the act of removing the portion
of the material from the substantially flat first side of the
weight plate comprises milling the portion of material from the
substantially flat first side of the weight plate.
31. The method of claim 28, wherein the act of removing the portion
of the material from the substantially flat first side of the
weight plate comprises filing the portion of material from the
substantially flat first side of the weight plate.
32. The method of claim 28, wherein the act of adding the
additional material to the pocket defined in the weight plate
comprises packing the pocket with a material capable of being
substantially held within the pocket.
33. The method of claim 28, wherein act of adding the additional
material to the pocket defined in the weight plate comprises
filling the pocket with an aggregate material and holding the
aggregate material in the pocket with a cover or resin.
34. The method of claim 28, wherein the act of forming the cast for
the weight plate comprises substantially aligning the at least one
interlock space on the first side with the at least one interlock
protrusion on the second side of the weight plate.
35. The method of claim 28, wherein the act of forming the cast for
the weight plate comprises forming a plurality of the at least one
interlock spaces and a plurality of the at least one interlock
protrusions around a periphery of the weight plate.
36. The method of claim 28, wherein the act of forming the cast for
the weight plate comprises forming a handle for the weight plate at
the at least one interlock space.
37. The method of claim 28, wherein the act of forming the cast for
the weight plate comprises defining at least one pocket in the
second side of the weight plate for adding additional material to
the weight plate.
Description
FIELD OF THE DISCLOSURE
[0001] The present disclosure relates generally to physical fitness
equipment, and more specifically to an improved weight plate that
may be used during weight lifting.
BACKGROUND OF THE DISCLOSURE
[0002] Free weight exercises generally require weight plates for
use with barbells or dumbbells. The weight plates are typically
disc-shaped and include a central opening for receiving a barbell
or dumbbell bar through the central opening. One major problem with
free weight lifting and a cause of many accidental injuries is that
it is difficult to pick up a weight plate, particularly disc-shaped
plates having substantially flat sides. Most users can typically
handle the lighter weights of 5 or 10 pounds without too much
difficulty. But as the size and weight of the weight plate
increases, one must be very careful to avoid injury. The problem,
simply stated, is that a flat sided weight plate does not have a
convenient hand hold to be grasped by the user for lifting it off
of a flat surface, such as the floor or a stack of adjacent weight
plates. Lifting a typical weight plate off of a flat surface
requires that the user apply sufficient radial and frictional force
on the periphery or outer perimeter of the disc-shaped plate to
lift at least one side of the plate a sufficient distance off the
flat surface to permit the user to place at least a portion of his
fingers around the periphery and onto one side of the plate. Of
course, the heavier the weight plate, the more difficult this
lifting maneuver becomes. Lifting a weight plate according to the
generally accepted method described above can cause injury if the
weight plate slips out of the grasp of the user and falls on his or
her toes or fingers.
[0003] Some weight plates include an upstanding circumferential
flange about the periphery of the plate. This provides a raised
surface that may be gripped by the user for lifting the weight
plate. The same problems are encountered, however, when an
individual attempts to lift the weight plate by its circumferential
flange. A sufficient radial and frictional force must still be
applied to lift the plate on its peripheral edge so that the user
can grip the plate by wrapping his or her fingers and thumb about
the upstanding flange and outer edge of the plate.
[0004] The problems noted above are not encountered solely when
exercising with free weights. Many exercise apparatus require the
weight plates be added or removed to vary the resistance provided
by the exercise apparatus. The typical weight plate is not only
difficult to lift off a flat surface, as noted above, but is also
difficult to hold and raise up, perhaps to chest level, to mount
the weight plate on an exercise apparatus. Likewise, removing a
weight plate from a relatively high position on an exercise
apparatus is also difficult and, if not done with care, may result
in injury to the individual removing the weight plate.
[0005] Yet another constraint on the design of weight plates is
control of manufacturing costs. Intricate plate designs typically
cost more to manufacture than a standard weight plate, thus
creating a unit cost that the market is unwilling to bear. What is
needed is a simple solution to the above noted problems that also
minimizes manufacturing costs. The weight plate of the present
disclosure satisfies this need.
SUMMARY OF THE DISCLOSURE
[0006] A weight plate having integrally formed handles is provided.
The weight plate has a weight plate body having an outer periphery,
a first side, and a second side that is substantially flat. The
weight plate also has a central bore extending axially through the
body, a raised flange member forming a portion of the outer
periphery on the first side, and at least one handle opening
extending axially through the body and radially through at least a
portion of the outer periphery. Each handle opening in cooperation
with the raised flange member define a handle sufficient for a
human hand to grip. Where multiple handle openings are employed,
including two or more handle openings, the handle openings are
equiangularly spaced apart. Additionally, each handle opening
includes edge surfaces which are rounded to improve the comfort of
the user. In one embodiment, the weight plate further includes an
interlock for interlocking the weight plate with another weight
plate when positioned together. In another embodiment, the weight
plate further includes a pock defined in the weight plate. The pock
allows the weight of the weight plate to be adjusted to a desired
weight by allowing additional material to be added to the pock.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] A more complete understanding of the present disclosure may
be obtained with reference to the accompanying drawings:
[0008] FIG. 1 is a perspective view of the first side of an
illustrative embodiment of the present disclosure.
[0009] FIG. 2 is a plan view of the first side of the illustrative
embodiment of the present disclosure.
[0010] FIG. 3 is a perspective view of the second side of the
illustrative embodiment of the present disclosure.
[0011] FIG. 4 is a plan view of the second side of the illustrative
embodiment of the present disclosure.
[0012] FIG. 5 is a side view of the illustrative embodiment of the
present disclosure.
[0013] FIGS. 6A-6C illustrate an embodiment of an interlocking
weight plate according to certain teachings of the present
disclosure.
[0014] FIGS. 7A-7C illustrate another embodiment of an interlocking
weight plate according to certain teachings of the present
disclosure.
[0015] FIGS. 8A-8B illustrate an embodiment of a weight plate
having pocks according to certain teachings of the present
disclosure.
DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0016] The present disclosure will now be described more fully with
reference to the accompanying drawings in which a preferred
embodiment of the disclosure is shown. This disclosure may,
however, be embodied in many different forms and should not be
construed as being limited to the embodiment set forth herein.
[0017] Referring to FIGS. 1-5, a weight plate 10 in accordance with
certain teachings of the present disclosure is shown. Weight plate
10 may be cast, rubber coated, and/or polyurethane coated. Weight
plate 10 includes a substantially flat body 11 defined by a first
planar surface or side 12 and a second planar surface or side 14.
The planar surfaces 12, 14 are generally opposed and define the
axial thickness T of weight plate 10. FIGS. 1 and 2 depict the
first side of weight plate 10, while FIGS. 3 and 4 depict the
second side of weight plate 10. A centrally located bore 16 defines
the rotational axis of plate 10 and is adapted to receive a
mounting member (not shown), such as a barbell or a dumbbell
bar.
[0018] The bore 16 is further defined by an integrally formed
collar 18 which projects outwardly from the first planar surface 12
and adds axial length to bore 16. Support ribs 19 may also be used
to provide further support for collar 18. It is understood that the
diameter of bore 16 may vary to accommodate various diameter sizes
of mounting members to be received through bore 16, and will
generally vary between 1 to 2 inches to accommodate most standard
bars.
[0019] The opposed planar surfaces or sides 12, 14 terminate at an
outer periphery 20 of plate body 11. Although FIGS. 1-5 show a
substantially circular outer periphery, any periphery shape may
also be used, including any polygonal-shaped. The first side of
weight plate 10 also includes a flange member 22 integrally formed
therewith and forming a portion of the outer periphery 20 that
extends outwardly from the first planar surface 12.
[0020] In the weight plate 10 shown in FIGS. 1-5, weight plate 10
includes three handle openings 24 formed in the plate body 11 and
extending at least partially to the outer periphery 20. Although
the FIGS. 1-5 show three handle openings 24, any number of
equiangularly spaced handle openings, including but not limited to,
two or more handle openings, may be used. The handle openings 24
are disposed extending through body 11 and through at least a
portion of the outer periphery 20 (best illustrated in FIGS. 3-5).
Although the size of these handle openings 24 may vary depending on
the size, weight, and other design particulars of a specific weight
plate, each handle opening should be less than about 20%, and more
preferably less than about 10%, of the total area of the weight
plate body plate, which is calculated as the area of each opening
extending through plate body 11 as a percentage of the area of the
plate body 11. For clarity, the area of plate body 11 if the plate
were circular as shown in FIGS. 1-5 would be simply .pi.*D.sup.2/4,
where D is the diameter of plate body 11. For non-circular plates,
the total area of the plate body is would be calculated in an
analogous manner.
[0021] A recess 26 having a defined axial thickness is formed
between each handle opening 24 and the adjacent raised flange
member 22. Each recess 26 in conjunction with the corresponding
handle opening 24 and the raised flange member 22 form a handle 28
that is dimensioned in such a way that is sufficient for a human
hand to grip. For example, handle 28, opening 24, and recess 26 may
be sized to receive at least a portion of one or more fingers of a
human hand extending therethrough. The axial thickness of recess 26
may be controlled by many means known in the art, including but not
limited to increasing or decreasing the size of the flange member
22 at the locations corresponding to handle openings 24. Recess 26
may be of any axial thickness, but is preferably less than about
one inch, and more preferably less than about 0.5 inch.
[0022] Sharp edges may be eliminated by rounding the edges of the
handle openings 24. Likewise, the raised flange member 22 may be
rounded to avoid scratching or gouging the floor or harming the
user in the event that the weight plate 10 is brushed against the
user's body. The handles 28 can be reinforced by reinforcements
(not shown) formed on the first side 12 and on each side of the
handle openings 24.
[0023] One of ordinary skill should appreciate that the handle 28
may be grasped in several ways, including but not limited to: (1)
placing one or more fingers through recess 26 first, then wrapping
the fingers about handle 28 through opening 24 while wrapping the
thumb around the outer periphery 20 to secure the grip, or (2)
placing one or more fingers through opening 24 first, then wrapping
the fingers about handle 28 through recess 26 while wrapping the
thumb around the outer periphery 20 to secure the grip.
[0024] Another aspect of the present disclosure is the
substantially flat nature of second surface 14 of the weight plate
10. Accordingly, manufacturing costs are reduced by providing a
second surface 14 that is substantially flat and contains no
integral features that would be difficult or expensive to mill. No
support collar or support ribs are required as with first surface
12. No flange member is required on the second side since the
handles 28 are formed using the first flange member 22. It will be
apparent to one of skill in the art that what is described herein
is a novel weight plate having integrally formed handles.
[0025] The substantially flat second surface or side 14 offers
significant advantages for manufacturing the disclosed weight
plates 10. For example, the second side 14 does not require
expensive tooling or molds. The substantially flat second side 14
also allows the weight of the initially manufactured weight plate
10 to be adjusted by using any convenient technique for removing
plate material from the flat side 14 of the weight plate 10. For
example, the flat side 14 of the weight plate 10 can be filed or
milled to reduce the weight of the weight plate 10 in small or
large increments. This type of filing or milling can be performed
before applying any coating, cover, rubberization, or other finish
(not shown) to the weight plate 10. Of course, with attention to
the finishing type and filing or milling technique used, the
finishing can also be applied prior to any filing or milling.
[0026] Therefore, with respect to the disclosed weight plate 10,
the following manufacturing technique can be used to make a more
precisely weighted plate 10. A weight plate 10 can be formed by
casting, molding, or other manufacturing technique. The weight
plate 10 will have one flat side 14 as disclosed, thereby reducing
the difficulty or producing such a plate 10. Furthermore, depending
upon the technique to be used for removing plate material from the
flat side 14, the formation of the "flat" side 14 need not
necessarily be precisely flat. Rather, the side 14 can be
approximately or relatively flat and thereby allow for less
expensive manufacturing techniques. Furthermore, the target
manufacturing weight for the initial step of manufacturing the
weight plate 10 can be heavier than the target weight for the
finally manufactured weight plate 10. At some point after the
creation of the initial "flat" sided weight plate 10, a plate
reduction process can be employed to reduce plate material from the
"flat" side 14. For example, the "flat" side 14 of the weight plate
10 can be filed or milled to reach an ultimate target weight with
greater accuracy. This plate reduction process can also serve to
reduce or eliminate defects on the "flat" side 14 of the weight
plate 10, if the initial manufacturing technique yielded less than
ideal results on the "flat" side 14 (e.g., if the flat side 14 was
not quite flat).
[0027] Reducing the flat side 14 of the weight plate 10 by filing
or milling can be performed in one or more increments in between
weighing steps. Alternatively, the weight plate 10 can be weighed
during the weigh reduction steps. In the former case, reduction can
be performed in time or weight (or mass) increments between
weighing. In the later case, the reduction technique can simply be
stopped when the weight plate 10 reaches the target weight (or a
desired weight in view of any coating or finishing that may be
applied later to the plate).
[0028] Referring to FIGS. 6A-6C, an embodiment interlocking weight
plate 50 according to certain teachings of the present disclosure
is illustrated. The weight plate 50 has a plate body 52 having a
first side 54 and a second side 56. The plate body 52 defines a
central bore 51 for mounting on a bar and defines at least one
cutaway 58 in a periphery 53 of the plate body 52. In the present
embodiment, the plate body 52 has three cutaways 58 defined at the
periphery 53. The second side 56 of the plate body 52 is
substantially flat such that material can be removed from the
second side 56 of the plate body 52 to adjust weight of the weight
plate 50 according to the techniques disclosed herein. For example,
the material is removable from the second side 56 of the plate body
52 by milling or filing at least a portion of the substantially
flat second side 52 of the plate body 52.
[0029] The weight plate 50 also includes a raised lip 60 formed
about the periphery 53 of the plate body 52 and formed on the first
side 54 of the plate body 52. As best shown in FIG. 6B, portions 62
of the raised lip 60 extend across the cutaways 58 defined in the
plate body 52 such that recesses 63 are formed from the second side
56 of the plate body 52. As best shown in FIG. 6A, interlocks 64
are positioned on the raised lip 60 and protrude beyond the raised
lip 60. The protruding interlocks 64 can be formed on the portions
62 of the raised lip 60 that extend across the cutaways 58,
although this is not strictly necessary as the interlocks can be
positioned elsewhere on the raised lip 60. As best shown in FIG.
6C, the interlocks 64 of one weight plate 50' are capable of
positioning in the recesses 63 formed in another weight plate 50
when the weight plates 50 and 50' are positioned together.
[0030] As shown in FIGS. 6A-6B, the cutaway 58 can define an open
portion 59 in the plate body 52 that extends toward the interior of
the plate body 52. This open portion 59 can accommodate the hand of
a person to hold the weight plate 50. In this regard, the portions
62 of the raised lip 60 extending across the cutaways 58 in the
plate body 52 form handles for a person to handle the weight plate
50 in a manner similar to previous embodiments disclosed
herein.
[0031] Referring to FIGS. 7A-7B, another embodiment of an
interlocking weight plate 50 according to certain teachings of the
present disclosure is illustrated. The weight plate 50 is
substantially similar to those disclosed in previous embodiments.
The weight plate 50 has interlocks 70 formed adjacent the open
portions 59 of the cutaways 58 defined in the plate body 52. The
interlocks 70 are pairs of protrusions that extend away from the
first side 54 of the plate body 52 and that slant inward toward the
open portions 59 of the cutaways 58. The size and position of the
slanted protruding interlocks 70 preferably still allows a person
to use the open portions 59 and handle portions 62 to pick up the
weight plate 50. As best shown in FIG. 7C, portions of the slanted
protruding interlocks 70 extend beyond the raised lip 60 of the
weight plate 50. When similar weight plates 50 and 50' are
positioned together, first sides of the slanted protruding
interlocks 70 on one weight plate 50' are capable of fitting
against second sides of the interlocks 70 on the other weight plate
50.
[0032] Referring to FIGS. 8A-8B, another embodiment of a weight
plate 50 according to certain teachings of the present disclosure
is illustrated. Again, the weight plate 50 of FIGS. 8A-8B is
substantially similar to those disclosed in previous embodiments
with the exception that the weight plate 50 in the present
embodiment has a plurality of pocks 80 for adjusting the weight of
the weight plate 50. As best shown in the plan view of FIG. 8A, the
weight plate 50 has a plurality of pocks 80 formed in the plate
body 52. Although three pocks 80 are shown in the present
embodiment, it will be appreciated that more or fewer pocks 80 can
be provided.
[0033] As best shown in FIG. 8B, the pocks 80 are pockets or holes
defined in the material of the weight plate 50. Preferably, the
pocks 80 are formed with an opening 82 in the first side 54 of the
plate body 52. Sides 84 of the pocks 80 may or may not extend
beyond the first side 54. Preferably, the pocks 80 are formed
during the casting of the weight plate 50, but they can also be
formed by machining the weight plate 50 after casting. Should the
weight plate 50 exceed a desired weight after casting, the raised
sides 84 of the pocks 80 can be milled or filed down to reduce the
resultant weight of the cast weight plate 50 to the desired
weight.
[0034] The pocks 80 can also receive and hold additional material
90 therein to add weight to the weight plate 50 in the event that
the cast weight plate 50 does not initially meet a desired weight.
The additional material 90 can be any suitable material that can be
filled into the pocks 80 to add additional weight. Examples of
suitable materials 90 include packed sand, malleable metals (such
as lead), steel pellets, or various aggregate materials. Various
techniques can be used to hold the additional material 90 into the
pocks 80. In the case of a malleable metal or like material, simply
packing the pock 80 with the material 90 may be sufficient to keep
the material 90 in the pock 80. For aggregate materials 90, such as
steel pellets or the like, the material can be positioned in the
pocks 80, and the pocks 80 can be filled with thermoplastic or
other resin to keep the aggregate material 90 in the pocks 80.
Alternatively, coatings or coverings (not shown) may be used to
cover the opening 82 of the pock 80 and thereby keep aggregate
material 90 in the pock. In another alternative, an additional
plate or cover (not shown) can be affixed to the weight plate 50 to
cover the pock 80 and keep the aggregate material 90 therein.
[0035] While the disclosure has been described with references to
specific preferred embodiments, it is not limited to these
embodiments. For example, aspects of the various embodiments can be
interchanged with one another. Thus, the disclosure may be modified
or varied in many ways and such modifications and variations as
would be obvious to one of skill in the art are within the scope
and spirit of the disclosure and are included within the scope of
the following claims.
* * * * *