Dumbbell handle bar assembly and method of production is presented, wherein the traditional way of

machining down the thickness (exterior diameter) of a handle bar from that of the collar is avoided,
resulting in substantial saving of material, such as steel or any metal alloy, and saving of time needed to
machine off the amount of material, by using collar-nuts having inner threadlines that can be snugly fit to
the threaded junction areas defining the central grip portion.
Claims:
1. Dumbbell handle bar assembly, comprising:a. A bar having a central grip portion;b. Two threaded
junction areas made to the two ends of said central grip portion;c. Two stub portions coaxially connected
to the two said threaded junction areas and the diameter of said stub is made slightly smaller than that of
the threaded junction area; and,d. Two collar-nuts having inner diameter with thread lines fitted to said
junction areas.

2. The dumbbell handlebar assembly of claim 1, wherein the diameter of threaded junction areas is made
to be slightly smaller than that of the central grip portion, and the stub portion is made to be slightly
smaller than that of the threaded junction areas.

3. Method of producing dumbbell handle bar, comprising:a. Take a cylindrical bar of suitable material and
machine down the diameter of the two stub portions;b. Machine and produce two threaded junction areas
between the central grip portion and the two stub portion; and,c. Attach two collar-nuts having inner
threadlines fitted to the threadlines on the junction area on the handle bar.

4. The method of producing dumbbell handle bar of claim 3, further having the step of making the
diameter of the threaded junction area slightly smaller than that of the central grip portion, and making the
diameter of the stub portion slightly smaller than that of the junction area, with the collar-nuts having inner
diameter of its threadline fitting to the threadline of the junction area.
Description:
FIELD AND BACKGROUND OF THE INVENTION

[0001]The present invention relates generally to construction of dumbbell handle and the method
of such construction used on fitness training equipment.

[0002]The handle bar of traditional dumbbells that can load variable weights contains two collars
flanking a central grip portion, with two outer stub portions capable of attaching variable weight
heads or weight discs.

[0003]The production of such traditional handle bar is done by taking a length of cylindrical bar of
proper material such as metal or steel, and proceed to machine off the thickness (diameter on the
exterior of such bar), until the two collars are formed, defining the central grip in between and the
two loading ends, referred to as "stub" in present application.

[0004]A lot of material waste is produced in such process, which is also time-consuming.

[0005]Present invention substantially reduces the wasted material due to the old machining down
process, and also saves a lot of time.

OBJECTS AND SUMMARY OF THE INVENTION

[0006]Present invention takes a cylindrical bar of proper material and machines down just a little
bit of the thickness (exterior diameter) on the two stub portions and by creating threadlines for
inserting two color-nuts, resulting in substantial saving in the material and the time needed to
produce such a handle bar.

DESCRIPTION OF THE DRAWINGS

[0007]The accompanying drawings, which are incorporated in and constitute a part of this
specification, illustrate the preferred embodiments of the invention and together with the
description, serve to explain the principles of the invention.

[0008]A brief description of the drawings is as follows:

[0009]FIG. 1 shows a traditional dumbbell handle bar having drilled/tapped holes on the two
stubs.

[0010]FIG. 2 shows a traditional dumbbell handle bar having threaded end on the two stubs.

[0011]FIG. 3 shows the dumbbell handle bar of present invention, with the two collar-nuts spread
out.

[0012]FIG. 4 shows an assembled view of the dumbbell handle bar of present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0013]In FIG. 1, a traditional dumbbell handle bar is shown.

[0014]To make this type of handle bar, a length of bar having the diameter of 1-b, the place of the
collars, is fed into a machine wherein the thickness (exterior diameter) of the central grip portion
1-a and the two stubs 1-c are machined off and down to the desired size. A lot of the metal
material is wasted as a result of the machining down. It is also time-consuming.

[0015]Depending on the chosen configuration, the end of the two stubs can be made to a drilled
hole with inner thread, as in FIG. 1, or made to contain outer threadline, as in FIG. 2, for attaching
locking nuts to keep the selected weight heads or weight discs in place.

[0016]With present invention, a handle bar is slightly machined down on the two stub 3c, as
shown in FIG. 3, so that weight heads and weight discs can be inserted from the two stubs 3c.

[0017]The two junction areas 3b between central grip portion 3a and stubs 3c will be made into
thread line configuration for receiving two collar-nuts 3d. Essentially, 3b will maintain the same
diameter as that of grip portion 3a.

[0018]Alternatively, diameter of the threaded portion 3b can also be made to be slightly smaller
than that of central grip portion 3a, producing a stop-action when the collar-nuts 3d are inserted
(screwed) in place.

[0019]The inner diameter of collar-nuts 3d is the same as the junction 3b thread line, so that when
the two collar-nuts 3d are screwed in and assembled in place, they form a snug fig collar to define
and guard the central grip portion 3a, as shown in FIG. 4, the assembled view of present
invention.

[0020]Actual production showed that the handle bar made pursuant to the disclosure of present
invention substantially reduces the waste material and saves a lot of the time needed for
machining down the thickness/diameter for the central grip portion and the two stub portions.


Our Manufacturing Process for Steel
Products
Ma
xwod prides itself on offering products with innovative designs, attention to detail and a strict quality
control process to ensure that every product is just perfect. Perfection is pursued in the design of the
product, the manufacturing process, and the packaging and shipping of the equipment. All of our
Maxwod products are made right here in the US by US workers. Our goal at Maxwod is to provide
you with the highest quality product that will last you a lifetime.
Design Process- Before a product is manufactured it is designed by our team of engineers who use
the same software program that Boeing uses to design commercial aircraft. In addition to 3-D
renderings, the software gives us the ability to test the equipment for potential design flaws with the
welds, uprights, pull-up bars and bolts. The software can apply weight, force or movement to a
specific part of the equipment to see if it can handle the load or force. Once the design process is
complete, a proto-type is manufactured and further changes to the design are made.
Manufacturing Process- Maxwod uses the highest quality and most durable materials to manufacture
our equipment. Below is an overview of our manufacturing process.
Cutting of the Steel- The manufacturing process begins with a fiber laser cutting machine, with state
of the art technology. These massive machines are extremely precise and achieve a high level of
accuracy. Once the cutting process is complete, the steel undergoes a quality control check by two
workers to ensure all cuts and holes are accurate.







Welding- All of our welding is done in the US by US Workers. US welds are considerably stronger
than welds by overseas manufacturers. Our factory is in the process of being accredited by ISO
International Standards. Manufacturers certified by the ISO must display that their products are safe,
reliable and of good quality, and that the manufacturing process contributes to preserving the
environment and health of the citizens & workers. Once the welds are complete, every weld is
inspected and signed off on by our floor supervisor.
Shot Blasting- Following welding, all steel is shoot blasted to remove any substrates from the metal
before the powder coating process. Shot Blasting is a process where metal abrasive, similar to little
metal pellets, are rapidly blasted at high velocity toward the steel. The metal abrasive strikes the
surface and rebounds removing any/all contaminants from the steel caused by the laser cutting or
welding process. The shot blasting process leaves the surface ready for powder coating and
produces the highest bonding character between the power coat and the steel. This process will
prevent rusting or chipping (powder coating) of your CrossFit pull-up rig or rack. Most other
manufacturers do not include shot blasting in their manufacturing process, and overtime their
products begin to chip along the corners of the uprights, rust along the laser cut holes and floor
plates, as well as bubbling of the powder coating along the weld lines. The benefit to this process is
that your rig will always look new.
Po
wder Coating- This is a three step process which includes: Automated washing and pretreatment of
the steel, application of the powder coating by hand and drying of the steel in large ovens.
Washing and Pre-Treatment- Before the steel is powder coated, it undergoes a final process of
washing, along with the application of an iron phosphate coating.
Benefits of the washing and coating process are:
Powder Coating will have good adhesive and cohesive strength to the steel
Finish will look more consistent
Iron phosphate coating provides a weather resistant protection against deterioration such as rust,
chemicals and corrosive agents. Steel and Powder Coating are two reactive materials, so the thin film
separating them provides a corrosion free product.
Powder Coating- All of our products are powder coated by hand using high quality Dupont paint.
After the steel is placed in the drying ovens, once again it undergoes a quality control check by the
floor supervisor.
Assembly & Packaging- Products are assembled and tested to ensure that they meet our standards
of a high quality product. We have put careful consideration into the packaging of our equipment so
that when you receive your pull up rig, power rack, sled or storage rack, it will not be scratched or
damaged.



Coated weight plates, dumbbells and method of manufacture
US 20050054496 A1
ABSTRACT
The present invention is a clear coating on a weight for a dumbbell, a dumbbell having weights having a
clear coating, and the process for coating a weight on a dumbbell with a clear coating. The invention
includes the painting or other coloration of the weights before placing the clear coating on the dumbbell.
Also, the invention includes the use of decals on the weight before the clear coating is placed on the
dumbbell. In addition, the invention is a method of advertising on a weight plate.
IMAGES(8)

















CLAIMS(20)
1. A weight assembly for a dumbbell, comprising:
a weight plate;
a first coating applied to at least a portion of the weight plate; and
an at least partially transparent second coating applied over the first coating.
2. The assembly of claim 1, wherein the first coating comprises a coloring agent.
3. The assembly of claim 1, wherein the second coating is substantially clear, whereby the first coating is
at least partially visible through the second coating.
4. The assembly of claim 1, wherein the second coating comprises polyurethane.
5. The assembly of claim 3, wherein the first coating is adapted to provide advertising.
6. The assembly of claim 5, wherein the advertising is a corporate logo.
7. The assembly of claim 1, wherein the first coating is one or more of the following: paint and powder
coat.
8. The assembly of claim 1, wherein the second coating further comprises a UV protection chemical
element.
9. The assembly of claim 1, wherein the second coating is adapted for receiving a dumbbell handle.
10. The assembly of claim 9, wherein the weight plate is adapted for receiving a dumbbell handle.
11. A weight assembly for a dumbbell, comprising:
a weight plate;
a decal applied to at least a portion of the weight plate; and
an at least partially transparent second coating applied over the decal.
12. The assembly of claim 11, wherein the decal is comprised of a vinyl material.
13. The assembly of claim 11, wherein the second coating is substantially clear, whereby the decal is at
least partially visible through the second coating.
14. The assembly of claim 11, wherein the second coating comprises polyurethane.
15. The assembly of claim 11, wherein the second coating is adapted for receiving a dumbbell handle.
16. A dumbbell comprising:
a handle; and
a plurality of weight assemblies, each assembly comprising:
a weight plate;
a first coating applied to at least a portion of the weight plate; and
an at least partially transparent second coating applied over the first coating.
17. A dumbbell comprising:
a handle; and
a plurality of weight assemblies, each assembly comprising:
a weight plate;
a decal applied to at least a portion of the weight plate; and
an at least partially transparent second coating applied over the decal.
18. A method for forming a weight assembly for a dumbbell, comprising the steps of:
providing a weight plate;
coating the weight plate with an at least partially transparent material;
providing means for attaching the coated weight plate to a handle.
19. The method of claim 18, further comprising the step of applying a decal to the weight plate before the
step of coating the weight plate.
20. The method of claim 19, wherein a design is placed on the weight plate before the step of coating the
weight plate.
DESCRIPTION
THIS APPLICATION CLAIMS PRIORITY TO PROVISIONAL PATENT-APPLICATION SERIAL No.
60/449,886, FILED ON FEB. 25, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of weights and dumbbells. The invention especially relates to
decoration and advertising placed upon a weight plate and the addition of an at least partially clear
coating to the weight.
2. Description of Related Art
In the prior art, logos were placed on dumbbells in a variety of expensive ways. Logos or advertising
could not be placed on the weights as decals, since the decals would be abused by the use of the
exercise equipment. Also, the decals would not stick to a preferred polyurethane coating. In addition, if a
manufacturer wanted to color the weight heads, or paint them, the coloring would be dirtied, faded or torn
by the use of the weights.
SUMMARY OF THE INVENTION
In standard practice in the industry, the dumbbell is created with a thin coating of black polyurethane on
the weight plates. Next, a logo is applied. Because of the wax-paper surface characteristics of
polyurethane, it is difficult to place decals, silk-screening, paint or similar materials on the surface of the
weight plates. Thus, a logo could only be placed on a weight head by having the logo in the mold or by
having it machined or engraved on the plate.
It is known to inject or fill a void with white or colored urethane to form letters on a weight plate. However,
in using this process, it is important to remove all mold release from the voids after each use. Otherwise,
the colored letters will not adhere to the black urethane. Alternatively, a weight plate may be machined
so-that a logo is in a void. Then a different color urethane is injected or filled into the void to form a logo.
Also, in the industry it is known to simply machine a logo directly into the weight plate using one or more
steps of machining for each color of urethane. This method is extremely expensive and time consuming.
Furthermore, it is limiting in the amount of detail which may be included in a logo. Furthermore, it would
be extremely difficult to apply the logo on the inside face of a weight plate on a dumbbell.
In addition, colored dumbbells with a polyurethane surface in the prior art are prohibitively expensive.
Each time a colored dumbbell is desired a manufacturer would have to purge its injection machines and
insert the desired colors, consuming valuable manufacturing time.
It is the object of the present invention to make it possible to have detailed, colorful logos on weight plates
and dumbbells.
It is a further object of this invention to allow the inexpensive production of colored dumbbells.
It is a further object of this invention to make colored dumbbells with a protective coating.
It is a further objective of this invention to have weight plates and dumbbells with decals that are
permanently affixed, protected and visible.
In accordance with these and other objectives which will be apparent hereinafter, the instant invention will
now be described with particular reference to the accompanying drawings. The drawings constitute a part
of this specification and include exemplary embodiments of the present invention and illustrate various
objects and features thereof.
DESCRIPTION OF THE FIGURES
FIG. 1 is a cut away perspective view of the preferred embodiment of the invention.
FIG. 1 a is a cut away perspective view of the preferred embodiment having a dark colored weight plate.
FIG. 2 is a perspective view of a prior art invention.
FIG. 3 is a perspective view of a prior art invention and a typical prior art logo for the prior art invention.
FIG. 4 is a perspective view of alternative embodiments of the invention next to a prior art invention.
FIG. 5 is a perspective view of an alternative embodiment of the invention.
FIG. 6 is a perspective view of an alternative embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a clear coating on a weight on a dumbbell, a dumbbell having weights having a
clear coating, and the process for coating a weight on a dumbbell with a clear coating. The invention
includes the painting or other coloration of the weights on a dumbbell before placing the clear coating on
the dumbbell. Also, the invention includes the use of decals on the weight before the clear coating is
placed on the dumbbell. In addition, the invention is a method of advertising on a weight plate.
In the preferred embodiment, a dumbbell of the preferred embodiment is shown in FIGS. 1 and 1 a at 10.
The weight plate 12is provided, and may be colored in a preferred hue. The coloring is preferred to be a
powder coat or paint but may be some other agent known in the art. The paint is preferably sprayed onto
the plate 12. Optionally, the plate may be covered with a clear paint. In an alternative embodiment, a
design or logo is painted onto the weight plate itself. The weight plate is preferred to be metal which has
been forged, cast or machined. However, other manufacturing methods and appropriate materials may be
used as is known in the art. Also, it is preferred that the weight is in a generally round shape as shown
in FIGS. 1-6. A weight plate 12 is placed on either end of a handle 14. The handle may be of any useful
shape and texture, but the Tri-Bar handle used by TKO Sports, Inc. is preferred. The handle is preferably
welded to the weight plates. However, it may also be threaded, pinned or press fit to the plates 12, or
attached in other methods known in the art.
Then, if desired, one or more decals 16 are placed on the weight plate. It is preferred that the decals are
on the far end 18 of the plate 12 so it can be viewed easily. However, as shown in FIGS. 1 and 1 a,
decals 16 may also be placed on the inside surface 20 or on the perimeter 22 of the weight plate 12. The
decals are preferred to be of a vinyl material, but any other generally heat resistant material may also be
used. Also, it is preferred that the decal material keeps the colors on the decal from running.
The weight plates 12 are then covered with a clear coating 24. The coating protects the weight
plate 12 and allows the decals16 to be seen. Also, if the weight plate is colored, or if there is a painted
design on the weight plate it may be seen through the clear coating. While it is preferred that the coating
is clear; however, the coating may be translucent and colored if desired. It may also be preferred to
include a UV protection chemical element into the polyurethane.
The coating is preferred to be polyurethane, such as that manufactured by Anderson Development
Company, Inc., Uniroyal or Airproducts. The polyurethane is preferably placed on the weight plate using a
low-pressure polyurethane dispensing machine, such as one produced by Ureflex-Baule. The urethane
may alternatively be placed on the weight plates using an injection molding system, using a mold that
does not use an injection system, or using a spray method directly spraying the coating onto the weight
plates. In using a mold system wherein the polyurethane is poured directly into a mold containing the
weight plate to be covered, it is preferred that the polyurethane is poured at a temperature of
approximately 150-200 degrees Fahrenheit. Equivalent polyurethane may be used which cures at a lower
temperature such as room temperature. Either weight plates 12 may be covered simultaneously, or each
plate 12 may be covered individually.
In one embodiment a weight plate is covered with polyurethane before the handle is attached. The weight
plate 12 has a threaded internal bore and a threaded plug member having threads which extend beyond
the threading within the plate 12 is placed within the bore. The polyurethane is then poured over the
weight plate 12 and at least a portion of the plug member. When the polyurethane has cooled, the plug is
removed, and threading is left within the polyurethane extending above the threading within the bore of
the weight plate a threaded handle is then placed through the threading in the polyurethane and
preferably through the threading in the weight plate. However, other equivalent methods of molding the
polyurethane onto the weights before the handle is attached are known in the art.
FIG. 2 reveals a prior art dumbbell 26 without clear coating. The text written on the weight plates may be
marred by normal use. Furthermore, if the weights were merely painted, the plates could be marked, or
the colors could rub off onto surfaces in the gymnasium.
FIG. 3 reveals an expensive design 28 painted on a dumbbell of the prior art 26. Each color of the
design 28 was placed on the weight plate 26 using a separate step. However, using the current invention,
the design may be placed on a decal. The decal process is much less expensive; and more highly
detailed designs may be placed on the decal. After it is covered with polyurethane, the decal may be seen
through the protective coating.
FIG. 4 illustrates three dumbbells, including one prior art dumbbell 26 and one dumbbell embodying the
present invention 10. As shown, the painting applied to the weight plate 12 as well as decals 16 can bee
seen clearly through the polyurethane coating.
FIGS. 5 and 6 reveal the finished product of the present invention. As shown, the clear coating improves
the ability to design or decorate a weight plate whether it is a traditional dark color 30 or a bright
color 32 underneath.
Alternatively, the steps for creating a dumbbell pursuant to the present invention are as follows. First the
handle is selected. The handle is preferred to be steel, and may be knurled, flats, chromed, black oxide,
or be of any other useful shape or finish known in the art. Next, the dumbbell head is created. The head is
preferred to be metal and manufactured as described above. Next, the head is prepared for coating. It
can be powder coated or otherwise painted, chromed or sandblasted, with or without a clear finish. Other
finished known in the art may also be used.
In the next step, a decal, if desired, is placed on the head. The decal can be of any desired image. The
decal can be of any color or mix of colors, high resolution graphics or actual pictures. It may be preferred
that the image is a computer image which is placed on a decal using known printing techniques. If
needed, the decal is then cut before it is placed on the dumbbell head.
Next, clear polyurethane is applied to the weight with the decal as described above. If necessary, the
polyurethane is then trimmed after the dumbbell is removed from the mold.
Thus, the number of steps and the labor needed to make a design on a weight plate is minimized.
Furthermore, a dumbbell is now available having a high quality design which can be seen though a
protective coating.
The instant invention has been shown and described herein in what is considered to be the most practical
and preferred embodiment. It is recognized, however, that departure may be made therefrom within the
scope of the invention and that obvious modifications will occur to a person skilled in the art.