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  Weight assembly and method of manufactureUSPTO Application #: 20070027007Title: 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. (end of abstract)
Agent: Sheppard, Mullin, Richter & Hampton LLP - Los Angeles, CA, US Inventor: Scott J. Frasco USPTO Applicaton #: 20070027007 - Class: 482106000 (USPTO) Related Patent Categories: Exercise Devices, User Manipulated Force Resisting Apparatus, Component Thereof, Or Accessory Therefor, Utilizing Weight Resistance, Handheld Bar With Weight At Each End (e.g., Barbell, Dumbbell, Etc.) Or Component Thereof The Patent Description & Claims data below is from USPTO Patent Application 20070027007. Brief Patent Description - Full Patent Description - Patent Application Claims
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. Continue reading... Full patent description for Weight assembly and method of manufacture Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Weight assembly and method of manufacture patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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