RESISTANCE DEVICE FOR EXERCISE MACHINE

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application is a non-provisional of, and claims priority to, U.S. Provisional Application No. 63/676,320, filed Jul. 26, 2024, which is incorporated by reference in its entirety.

FIELD

The present disclosure relates generally to a resistance device for an exercise machine.

BACKGROUND

Exercise devices may utilize various types of resistance devices. Some resistance devices may be adjustable by a user to provide the correct amount of resistance. In order to provide the correct amount of resistance to the user, an adjustment device may be provided that is robust to provide the expected resistance desired by a user.

BRIEF SUMMARY

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. The Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

This disclosure may relate to a resistance device for an exercise machine that may comprise a housing having first, second, and third sidewalls defining an inner cavity, with air exhaust and inlet openings, where the second sidewall may include a recess with a flange having a protrusion extending outward from an outward facing surface. The device may include a resistance element that may rotate within the housing to create resistance for a user, along with a fixed baffle connected to the housing that may have openings allowing air into the inner cavity. A movable baffle may be rotationally connected to the second sidewall and may comprise an inner member with fins and openings, an outer member with a handle, and a mesh screen, where the inner member may include an outer flange with a guide surface. The protrusion may contact the guide surface to create a gap between the inner member and the flange to adjust the amount of air allowed to enter the inner cavity and adjust the resistance for the user. The protrusion may comprise an upper surface and a transition surface extending between the outward facing surface and the upper surface. The protrusion may comprise a plurality of protrusions positioned along the outward facing surface of the flange, and the plurality of protrusions may comprise three protrusions evenly spaced along the outward facing surface of the flange. The guide surface may be formed on a guide member that may be received in a pocket located on an inward facing surface of the outer flange. The guide surface may have a first region with a first thickness and a second region with a second thickness, where the second thickness may be greater than the first thickness, and a ramped surface may extend between the first region and the second region.

Other aspects of this disclosure may relate to an exercise machine that may comprise a frame and a resistance device connected to the frame and operatively connected to a user input mechanism. The resistance device may comprise a housing defining an inner cavity with an air inlet on a sidewall, where the sidewall may comprise a protrusion, and a resistance element that may be rotatably mounted within the inner cavity, where resistance of the resistance device may be dependent upon airflow through the air inlet. A component may be movably connected to the sidewall and may comprise a guide surface, where interaction between the protrusion and the guide surface may create a variable air gap between the sidewall and the component to adjust the resistance of the resistance device. The user input mechanism may comprise a handle connected to the resistance element through a cable. The exercise machine may be a rowing machine, an exercise bike, a skiing exercise machine, a climbing exercise machine, a stair-climbing machine, an elliptical exercise machine, a squat exercise machine or a bench press exercise machine. The movable component may comprise a rotatable baffle with fins that may selectively cover openings on the sidewall to control airflow. The variable air gap may have a width within a range of 0.1 mm and 4 mm. The guide surface may have a second region that may be positioned a first distance from an inward facing surface of the component to a second outward facing surface of the second region, and a first region that may be positioned a second distance from the inward facing surface of the component and a first outward facing surface of the first region, where the first distance may be less than the second distance, and a ramped surface may extend between the first region and the second region.

Still other aspects of this disclosure may relate to a resistance device for an exercise machine that may comprise a housing having first, second, and third sidewalls defining an inner cavity, with a first opening in the third sidewall that may serve as an air exhaust, and a second opening in the second sidewall extending into the inner cavity that may define an air inlet. The device may include a resistance element that may be rotatably mounted within the inner cavity, along with a plurality of protrusions that may extend from an outward facing surface of the second sidewall. A movable baffle for controlling airflow into the inner cavity may be connected to the housing and may comprise a plurality of guide surfaces, where a first guide surface of the plurality of guide surfaces may be positioned to interact with a first protrusion of the plurality of protrusions to create an air gap between the movable baffle and the second sidewall. The first guide surface may be located on a first guide member that may be received in a pocket located on an inward facing surface of the movable baffle. The first guide member may have a varying thickness along its length such that interaction between the first protrusion and the first guide surface may create a variable air gap between the movable baffle and the second sidewall. The first guide member may comprise a first region having a first thickness, a second region having a second thickness greater than the first thickness, and a ramped surface between the first region and the second region. The first guide surface may have a second region that may be positioned a first distance from an inward facing surface of the movable baffle to a second outward facing surface of the second region, and a first region that may be positioned a second distance from the inward facing surface of the movable baffle and a first outward facing surface of the first region, where the first distance may be less than the second distance, and a ramped surface may extend between the first region and the second region.

BRIEF DESCRIPTION OF THE DRAWINGS

The following Detailed Description, will be better understood when considered in conjunction with the accompanying drawings in which like reference numerals refer to the same or similar elements in all of the various views in which that reference number appears.

FIG. 1 depicts a perspective view of an exemplary resistance device for an exercise machine, according to one or more aspects described herein.

FIG. 2 depicts a perspective view of the exemplary exercise machine with the resistance device of FIG. 1, according to one or more aspects described herein.

FIG. 3 depicts a perspective cross-sectional view of the resistance device of FIG. 1, according to one or more aspects described herein.

FIG. 4 depicts an enlarged perspective cross-sectional view of the resistance device of FIG. 1 in a first resistance level with some components removed for clarity, according to one or more aspects described herein.

FIG. 5 depicts an enlarged perspective cross-sectional view of the resistance device of FIG. 1 in a second resistance level with some components removed for clarity, according to one or more aspects described herein.

FIG. 6 depicts a perspective view of the resistance device of FIG. 1 with some components removed for clarity, according to one or more aspects described herein.

FIG. 7 depicts an enlarged view of the perspective view of FIG. 6, according to one or more aspects described herein.

FIG. 8 depicts a perspective view of the movable baffle of the resistance device of FIG. 1, according to one or more aspects described herein.

FIG. 9 depicts a guide member of the movable baffle of FIG. 8, according to one or more aspects described herein.

FIG. 10 depicts a guide adjustment member of the movable baffle of FIG. 8, according to one or more aspects described herein.

FIG. 11 depicts an alternate portion of a movable baffle of the resistance device of FIG. 1, according to one or more aspects described herein.

Further, it is to be understood that the drawings may represent the scale of different components of various examples; however, the disclosed examples are not limited to that particular scale. Further, the drawings should not be interpreted as requiring a certain scale unless otherwise stated.

DETAILED DESCRIPTION

In the following description of the various examples and components of this disclosure, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example structures and environments in which aspects of the disclosure may be practiced. It is to be understood that other structures and environments may be utilized and that structural and functional modifications may be made from the specifically described structures and methods without departing from the scope of the present disclosure.

Also, while the terms “upper,” “base,” “lower,” “side,” “below,” and the like may be used in this specification to describe various example features and elements, these terms are used herein as a matter of convenience, e.g., based on the example orientations shown in the figures and/or the orientations in typical use. Nothing in this specification should be construed as requiring a specific three dimensional or spatial orientation of structures in order to fall within the scope of the clauses.

The term “connected” as used herein may be defined to encompass components being directly connected where the components contact each other and also encompass components being indirectly connected where the components are connected through one or more intermediary components.

This disclosure generally relates to a resistance device for an exercise machine. The resistance device may comprise a resistance element, such as a fan or impeller, that rotates within a cavity of a housing. As the resistance element rotates within the cavity it generates resistance to the user's input. The resistance element of the resistance device may be connected to the exercise machine with a shaft or other means and then connected via a plurality of cables, pulleys, or other connection members to an input device (i.e., a handle) that the user may move when exercising. One feature of the resistance device is the ability for a user to adjust the resistance provided to the user by the resistance device. The rotating resistance element within the cavity of the housing may create resistance that is transmitted to the user through the shaft connected to the resistance element. The resistance felt by the user can be modified by the amount of air that is allowed to come into the cavity. If more air is allowed into the cavity, the resistance will increase, and if less air is allowed into the cavity the resistance will decrease. Additionally, the resistance device may provide a desired amount of resistance depending on a user adjustable setting (i.e., a resistance level). The amount of resistance of each user adjustable setting may be desired to be within a predetermined range. As described in more detail below, the resistance device provides the ability to adjust the resistance of each user adjustable setting to be within a predetermined range.

FIGS. 1 and 3 illustrate an exemplary resistance device 100 of an exercise machine. The resistance device 100 may include a housing 110 comprising a first sidewall 112, a second sidewall 114 opposite the first sidewall 112, and a third sidewall 116 connecting the first sidewall 112 and the second sidewall 114. An inner cavity 118 may be defined by the first sidewall 112, the second sidewall 114, and the third sidewall 116. In some examples, the third sidewall 116 may have a substantially cylindrical shape and may include an opening 120 or plurality of openings that acts as an air exhaust. The opening 120 may be elongated and may be covered by a mesh screen 122 to prevent access into the inner cavity 118. In addition, the first sidewall 112 may include mounting components and a shaft opening where the mounting components and shaft opening are configured to connect to an exercise device. The second sidewall 114 may include a recess 124, where the recess 124 includes a flange 126 spaced below and away from an outer surface 128 of the second sidewall 114, and an opening 130 that extends through the flange 126 into the inner cavity 118. The opening 130 may define an air inlet for the resistance device 100.

As discussed above, FIG. 2 illustrates the resistance device 100 connected to a rowing exercise machine 10, where the resistance device 100 provides the resistance to the user exerts a force on the user input mechanism or handle 12 that causes the resistance element 132 to move. While the illustrated example is a rowing exercise machine 10, the exemplary resistance device 100 may be connected to and used on a variety of exercise equipment such as an exercise bike, a skiing exercise machine, a climbing exercise machine, a stair-climbing machine, an elliptical exercise machine, a squat exercise machine, a bench press exercise machine, or other exercise equipment known to one skilled in the art.

Referring to FIGS. 1 and 3, the resistance device 100 may also include a resistance element 132 (i.e., a fan, an impeller, or similar resistance element), where the resistance element 132 may comprise a base 134 configured to receive a shaft or connection member to connect to an exercise machine and a plurality of blades 136 connected to the base 134. A fixed baffle 140 and a movable baffle 150 may be located at the opening 130 that define an air inlet. The fixed baffle 140, as best shown in FIG. 6, may have a plurality of openings 142 that permit air to pass through the air inlet into the inner cavity 118. The plurality of openings 142 may be elongated openings that are arranged in a spiral shape. The fixed baffle 140 may be connected to an inner surface 115 of the second sidewall 114, where the fixed baffle 140 is located within the opening 130. In some examples, the fixed baffle 140 may be connected to an inward facing surface of the flange 126. While not shown in the illustrated examples, the fixed baffle 140 may be formed integrally with the second sidewall 114 of the housing 110. The movable baffle 150 may be located outward of and adjacent to the fixed baffle 140 and may comprise an inner member 152 that includes a plurality of fins 154 in a spiral shape with a plurality of openings 156 between the fins 154, an outer member 160 that includes an external handle 162, and a mesh screen 164 that covers the inner member 152. A portion of the inner member 152 may be located within the recess 124 of the second sidewall 114. The inner member 152 may also include an outer flange 166 that is located outboard of the plurality of fins 154. The plurality of openings 156 may allow air to flow through the movable baffle 150 and then through the openings 142 of the fixed baffle 140 into the inner cavity 118. The movable baffle 150 may be rotationally connected to the second sidewall 114 along a longitudinal axis that is coaxial with an axis of the opening 130 such that the movable baffle 150 can be rotated by a user. As the movable baffle 150 is rotated, the fins 154 may move along the plurality of openings 142 of the fixed baffle 140 to partially or fully cover the openings 142 to adjust the amount of air allowed into the inner cavity 118. The movable baffle 150 may be moved by a user rotating the external handle 162. The external handle 162 may also comprise an indicator 158 that points to a resistance level on a resistance level scale 161 located along the third sidewall 116 of the housing 110. The resistance level scale 161 may comprise a plurality of resistance levels where each resistance level corresponds with a predetermined resistance range.

To ensure the resistance device 100 provides the proper resistance within each predetermined resistance range, an adjustment mechanism 170 may ensure that when the movable baffle 150 is moved to each resistance level, the resistance is in the desired predetermined resistance range. As best shown in FIGS. 4-10, the adjustment mechanism 170 may comprise a protrusion 172 or a plurality of protrusions 172 that extend outward from an outward facing surface 127 of the flange 126 within the recess 124 that interact with a guide surface 182 that is located on the outer flange 166 of the inner member 152 of the movable baffle 150. The guide surface 182 may interacts with an upper surface 174 of the protrusion 172. The upper surface 174 of the protrusion 172 may contact the guide surface 182 of the guide member 180 when the movable baffle 150 is rotated to specific resistance level positions. This contact between the upper surface 174 and the guide surface 182 creates a mechanical interface that applies an outward force to the inner member 152 of the movable baffle 150, which causes the outer flange 166 of the movable baffle 150 to be displaced away from the flange 126 of the second sidewall 114 that. The upper surface 174 of the protrusion 172 may slide along the contoured guide surface 182 as the movable baffle 150 rotates, with the varying thickness of the guide member 180 determining the extent of contact and the resulting displacement force applied to the inner member 152 of the movable baffle 150. The guide surface 182 may be located on a guide member 180 that is fixedly connected to the movable baffle 150 such that as the movable baffle 150 is moved from a first resistance level to a second resistance level, the upper surface 174 of the protrusion 172 may selectively contact the guide surface 182 of the guide member 180 causing the inner member 152 along with the outer flange 166 to move outward creating a gap 171 between the outer flange 166 of the inner member 152 and the flange 126 of the recess 124 to allow additional air into the inner cavity 118 to further adjust the resistance to the desired predetermined range for its corresponding resistance level. The protrusion 172 may be free of contact with the guide surface 182 in some areas as the movable baffle 150 is rotated where the gap 171 may not be present. In some examples, the gap 171 may have a width within a range of 0.1 mm and 2 mm, or within a range of 0.1 mm and 4 mm. It is contemplated the gap 171 may have a different width. The guide surface 182 may vary in shape such that in some locations the guide surface 182 does not contact the protrusion 172 as shown in FIG. 4. For example, the thickness of the guide member 180 may vary along its length so that in areas that the resistance level is in the predetermined range the guide member 180 may have a smaller thickness or in areas that the resistance level may need to be increased the guide member 180 may have a larger thickness as shown in FIG. 5.

FIGS. 6 and 7 illustrate the exemplary resistance device 100 with the movable baffle 150 removed to see the protrusion(s) 172 of the adjustment mechanism 170. As shown in FIG. 6, the adjustment mechanism 170 may comprise a plurality of protrusions 172 that are evenly spaced around the flange 126. For example, the plurality of protrusions 172 may include three protrusions 172 that are evenly spaced around the flange 126. Each protrusion 172 may extend outward from the outward facing surface 127 of the flange 126 and may include an upper surface 174 and a transition surface 176 that extends between the outward facing surface 127 and the upper surface 174. The transition surface 176 may have a linear or ramped shape, or in some examples, have a curved profile. In the illustrated example, each protrusion 172 has a pair of transition surfaces 176 to help it smoothly engage and disengage from the guide surface 182. While the fixed baffle 140 is illustrated as a separate component connected to the second sidewall 114 of the housing 110, it is contemplated that the fixed baffle 140 may be formed as an integral component of the second sidewall 114.

FIGS. 8-10 illustrate the exemplary guide members 180 of the adjustment mechanism 170. FIG. 8 illustrates a perspective view of the movable baffle 150. The inner member 152 of the movable baffle 150 may include a pocket 168 that receives a guide member 180. As shown in FIG. 8, the movable baffle 150 may include a plurality of guide members 180. The number of guide member 180 may equal the number of protrusions 172. For instance, the illustrated example has three protrusions 172 and three guide surfaces 182 that are arranged at corresponding locations such that as the movable baffle 150 is rotated, each protrusion 172 may interact with a single corresponding guide surface 182. Thus, each guide member 180 may be positioned in one of a plurality of pockets 168 located on the inward facing surface 167 of the outer flange 166. As discussed above, the guide members 180 may have a varying thickness. In some examples, the guide surface 182 may be below the inward facing surface 167. However, the guide surface 182 may have a second region 190 that is positioned at a distance that closer to the inward facing surface 167 in the locations where the interaction with the protrusion 172 is needed to adjust the air allowed into the inner cavity 118 and a first region 188 positioned a distance that is further away from the inward facing surface 167 in other locations (i.e., the distance from the inward facing surface 167 to the second region 190 of the guide surface 182 is less than the distance from the inward facing surface 167 to the second region 188 of the guide surface 182) depending upon the thickness of the guide member 180. Alternatively, a guide surface 182 may be integrally formed within each pocket 168 as a part of the inner member 152 of the movable baffle 150, such that the pocket 168 have a varying depth and the guide surface 182 of the pocket 168 interacts with the protrusion 172 in the same manner as described herein. As an alternative option, the arrangement of the adjustment mechanism 170 may be reversed where the protrusion 172 may be located on outer flange 166 of the movable baffle 150 and the guide surface 182 may be located in a pocket 168 located on the flange 126.

FIG. 11 depicts an alternate inner member 152 of a movable baffle 150 as described herein. The inner member 152 shown in FIG. 11 has a guide surface 182 integrally formed in each pocket 168. In this example, the inner member 152 comprises three guide surfaces 182. The guide surfaces 182 depicted in the portion of the movable baffle 150 as shown in FIG. 11 have three regions, 194, 195, 196 with each region having a different depth or distance from the inward facing surface 167. The three regions 194, 195, 196 are connected by ramped surfaces 197, 198. In this example, a first distance (depth) from the inward facing surface 167 to the first region 194 of the guide surface 182 may be greater than a second distance from the inward facing surface 167 to the second region 195 of the guide surface 182. The second distance may be greater than a third distance from the inward facing surface 167 to the third region 196 of the guide surface 182. The ramped surface 197 may connect the first region 194 to the second region 195, and the ramped surface 198 may connect the second region 195 to the third region 196. In some examples, the ramped surfaces 197, 198 may have a linear slope, or a non-linear slope, or in some cases, the ramped surfaces 197, 198 have multiple linear sloped portions. In some examples, a difference between the first distance and the second distance may be within a range of 0.1 mm and 4 mm, and in some examples, a difference between the first distance and the third distance may be within a range of 0.1 mm and 6 mm, or larger than 6 mm. It is contemplated that the distance from the inward facing surface 167 to the first region 194 of the guide surface 182 may be less than the distance from the inward facing surface 167 to the second region 195 of the guide surface 182, and that the distance from the inward facing surface 167 to the third region 196 of the guide surface 182 is less than the distance from the inward facing surface 167 to the second region 195 of the guide surface 182. Alternatively, a first distance from the inward facing surface 167 to the first region 194 of the guide surface 182 may be less than a second distance from the inward facing surface 167 to the second region 195 of the guide surface 182. The second distance may be less than a third distance from the inward facing surface 167 to the third region 196 of the guide surface 182.

The profile of the guide surface 182 may be determined by a number of factors such as the desired resistance ranges for each designated resistance level, the interaction between the fins 154 of the movable baffle 150 with the openings 142 of the fixed baffle 140, and other variables within the overall resistance device 100 such as manufacturing tolerances of the resistance element 132, the housing 110, the baffles 140, 150, or other components as known to one skilled in the art. If at assembly of the resistance device 100, the measured resistance is not within the desired predetermined ranges for each resistance level setting an appropriate guide member 180 may be installed in the movable baffle 150. The plurality of guide surfaces 182 for a movable baffle 150 may be have the same profile, while in some instances, the plurality of guide surfaces 182 may be different for the same movable baffle 150.

While not limited to these examples, FIGS. 9 and 10 illustrate two different guide members 180 that may be used with the resistance device 100. Each guide member 180 may have a curved upper surface 184 and a curved lower surface 186, where the curvature of the upper and lower surfaces 184, 186 may be substantially the same as the radius of the corresponding upper and lower surface of their corresponding pocket 168. In addition, the length of each guide member 180 may travel through an arc length that is substantially the same as the arc length of the resistance level scale 161. Thus, each protrusion 172 may contact the guide surface 182 when the movable baffle 150 is moved to any of the resistance levels of the resistance level scale 161 depending upon the contour of the guide surface 182. In the exemplary guide member 180 of FIG. 9 has a first region 188 at one end, a second region 190 at another end, and a ramped surface 192 between the first region 188 and the second region 190. The second region 190 has a greater thickness than the first region 188. In addition, the second region 190 has a length that is greater than a length of the first region 188, which would create a gap 171 between the edges of the movable baffle 150 and the flange 126 and/or the fixed baffle 140 over a majority of the resistance levels of the resistance level scale 161. Alternatively, the guide member 180 of FIG. 10 has a first region 188 at one end, a second region 190 at another end, and a ramped surface 192 between the first region 188 and the second region 190. The second region 190 has a greater thickness than the first region 188. In addition, the second region 190 has a length that is approximately the same as a length of the first region 188, which would create a gap 171 between edges of the movable baffle 150 and the flange 126 or the fixed baffle 140 over approximately the same number of resistance levels of the resistance level scale 161.

The components of the resistance device 100 may be formed from polymeric or metallic materials. In particular the housing 110, the movable baffle 150, and the fixed baffle 140 may be formed from a polymeric material using a molding or other technique known to one skilled in the art. While the resistance element 132 may be formed from a metallic material.

The present disclosure is disclosed above and in the accompanying drawings with reference to a variety of examples. The various examples described herein may have features that can be combined to form an exemplary exercise machine. The purpose served by the disclosure, however, is to provide examples of the various features and concepts related to the disclosure, not to limit the scope of the claims. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the examples described above without departing from the scope of the present disclosure. The various dimensions described above are merely exemplary and may be changed as necessary. Accordingly, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the claims. Therefore, the embodiments described are only provided to aid in understanding the claims and do not limit the scope of the claims.