RECYCLED DUMBBELL

Description

CROSS-REFERENCE TO RELATED APPLICATION

This patent application claims the benefit of priority to U.S. Provisional Application No. 63/725,303, filed on Nov. 26, 2024, the entirety of which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates generally to an article of exercise equipment, and more particularly, to a dumbbell comprised of recycled and non-recycled materials.

BACKGROUND

Dumbbells are a type of free weight used in weight training. They provide resistance training for the user and can be utilized in several different ways during exercise. For example, dumbbells are used for bench presses, shoulder presses, bicep curls, triceps kickbacks, lunges and more. Generally, dumbbells are made of a metal, such as cast iron that is covered with some type of coating. For example, cast iron dumbbells covered in synthetic rubber, such as neoprene are commonly seen in the consumer marketplace. The manufacturing process of dumbbells in the volume required to keep up with consumer demand is a costly process with environmental impacts.

Over the years, there has been an increased focus and effort to collect and recycle materials produced during the manufacturing process and materials from used products. Manufacturers in all industries continue to focus on decreasing the environmental impacts of their products through innovative sustainability programs. For example, manufacturers of sports equipment may repurpose materials, such as manufacturing scraps and unused materials, thereby reducing waste. In an effort to reduce waste and improve sustainability, developing circular waste systems to reuse and recycle material waste from manufacture and supply chains, prevents potentially reusable waste from ending up in landfills and incineration. Such recycling and reuse of manufacturing materials is aimed at working towards a zero carbon, zero waste future. However, often times, manufacturers encounter challenges in recycling and reuse of materials due to the inability to re-process such materials in a useable way.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various exemplary embodiments and together with the description, serve to explain the principles of the disclosed embodiments.

FIG. 1 is a perspective view of an exemplary dumbbell, according to aspects of the disclosure.

FIG. 2 is a top view of the exemplary dumbbell of FIG. 1.

FIG. 3 is a front view of the exemplary dumbbell of FIG. 1.

FIG. 4 is a side view of the exemplary dumbbell of FIG. 1.

Those skilled in the art will appreciate that the figures are not intended to be drawn to any particular scale; nor are the figures intended to illustrate every embodiment of the invention. The invention is not limited to the exemplary embodiments depicted in the figures or the specific components, configurations, shapes, relative sizes, ornamental aspects, or proportions as shown in the figures.

DETAILED DESCRIPTION

Both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the features, as claimed. As used herein, the terms “comprises,” “comprising,” “has,” “having,” “includes,” “including,” or other variations thereof, are intended to cover a non-exclusive inclusion such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such a process, method, article, or apparatus. In this disclosure, unless stated otherwise, relative terms, such as, for example, “about,” “substantially,” and “approximately” are used to indicate a possible variation of ±10% in the stated value.

FIGS. 1-4 depicts an exemplary dumbbell 100, the dumbbell 100 including a handle 110 and two heads 120 disposed on opposite sides of the handle 110. The handle 110 extends along a central longitudinal axis 10 that extends through a radial center of dumbbell 100. In aspects, the handle 110 is composed of a metal material, such as cast iron or machined steel. However, handle 110 may be composed of any other suitable material. Handle 110 may also have any suitable shape. For example, handle 110 may be generally cylindrical. Handle 110 also may include other shapes, recesses, protrusions, or the like to alter the handle 110, or the feel and/or the aesthetics of the handle 110. For example, handle 110 may have other cross-sectional shapes and/or may have a varied thickness or shape along its length. Handle 110 may include a textured grip 115, which may include but is not limited to polymer or rubberized grips, cast-iron texturing, or other similar textures or materials that provide increased friction for the user. In some embodiments, handle 110 is an exposed handle that does not include any polymer or rubber (e.g., neoprene or other rubber) coating. In some examples, heads 120 may be welded to handle 110.

The two heads 120 may be substantially similar to one another in shape and weight. In an exemplary embodiment, dumbbell 100 may be a hexagonal dumbbell and, thus, heads 120 may each have a generally hexagonal shape, as further described. In particular, a cross-section of head 120 taken in a plane perpendicular or orthogonal to the central longitudinal axis 10 may be generally hexagonal in shape. Heads 120 may form a generally equilateral or non-equilateral shape. The terms “hexagon” and “hexagonal” as used herein mean any six-sided polygon structure or shape, including six-sided polygon structures having sides of the same or different dimensions or lengths and the same or different sized angles between adjacent sides. Also, the terms “hexagon” and “hexagonal” as used herein include shapes and/or structures having side edges joined at rounded corners (rather than the more pronounced and sharp corners) provided that the six-sided configuration remains apparent (e.g., relatively straight side edges joined by a rounded corner and sharp).

Each head 120 includes an inner end face 130, an outer end face 140 spaced apart from the inner end face 130, and a plurality of side faces 150 disposed longitudinally between the inner end face 130 and the outer end face 140. Inner end face 130 may be disposed closer to a longitudinal center of dumbbell 100 than outer end face 140. Outer end face 140 may be the longitudinally-outermost portion of head 120 and of dumbbell 100. Outer end face 140 and inner end face 130 may each be substantially planar or flat. In other embodiments, outer end face 140 and inner end face 130 may possess some curvature.

Heads 120 each include a plurality of side faces 150. In the hexagonal dumbbell 100 shown in the figures, heads 120 each include six side faces 150, although other suitable numbers of side faces 150 are also contemplated in non-hexagonal configurations. For example, three-sided, four-sided, five-sided, eight-sided, ten-sided, twelve-sided, or other configurations of dumbbell 100 are contemplated. In some aspects, a majority of side faces 150 are substantially planar or flat, although in other embodiments, side faces 150, outer end face 140 and/or inner end face 130 may possess some curvature. In the embodiment shown in FIG. 1, head 120 may include five substantially planar or flat side faces 150, and one side face 150 having an indentation 155 in its outer surface. The indentation 155 may enable a given side face 150 to display indicia, such as a logo and/or weight of the given dumbbell 100. However, even when a given side face 150 includes an indentation 155, such side face 150 may include an outer periphery 158 that is substantially planar of flat, in order to promote the ability of a user to rest the dumbbell 100 on any of its side faces 150. The planar shapes of side faces 150 help prevent dumbbells 100 from rolling.

Adjacent side faces 150 of each head 120 are connected to one another along their respective edges at rims. In some embodiments, one or more of the rims are rounded or curved, rather than having straight, sharp, or chamfered edges. The rims may thus include a curvature extending along their respective lengths. In other words, the intersections 1) between circumferentially adjacent side faces 150 (side rims 180); 2) between a side face 150 and inner end face 130 (inner end rims 160); and 3) between a side face 150 and outer end face 140 (outer end rims 170), are curved surfaces that do not include 1) any sharp or straight edge, and do not include 2) any chamfers. In the exemplary dumbbell 100, each of the heads 120 includes six inner end rims 160 and six outer end rims 170 on opposite sides of the head 120. Each head 120 also includes six side rims 180. Interfaces, rims, or edges, between two adjacent faces of the dumbbell are round such that they have a radius or curvature. The interfaces, rims, or edges may be round and/or curved, or otherwise contain a fillet or bullnose. Thus, the interfaces are not a straight edges or straight lines formed by the direct intersection of two planar surfaces. Each of these rims have a rounded or curved shape, which may be a convex shape when viewed from a perspective exterior of the dumbbell. As stated above, in at least some embodiments, none of the linear faces of the heads 120 (e.g., the inner end face 130, the outer end face 140, or the side faces 150) intersect with another linear face directly at a straight edge, straight line, or straight corner.

As shown in FIGS. 1-4, each head 120 includes a plurality of rim intersections or corners 190 where at least three rims converge. For example, an intersection corner 190 may be formed by either 1) the intersection of two rims 160 and a side rim 180, or 2) the intersection of two rims 170 and a side rim 180. For example, in an instance where an inner end rim 160 converges with two side rims 180, the intersection point will result in a corner 190 in proximity to the handle 110. Similarly, in an instance where an outer end rim 170 converges with two side rims 180, the intersection point will result in an intersection corner 190 on the outer periphery of the head 120. Due to the various curvatures of each rim 160, 170, and 180, corners 190 are blunt. The blunt shape of corners 190 are in contrast to the sharp corners found in dumbbells where corners are formed by the intersection of straight or chamfered edges. The blunt shape of corners 190 increase user comfort during exercises where dumbbell 100 is rested or pressed onto the body (e.g., front squats, push presses, farmer carries, and the like).

In some instances, heads 120 are made of a composite material that is a mixture of recycled or unused rubber or plastic materials. Recycled rubber material discussed herein may comprise supplying, accessing and/or utilizing various materials, tools and machines needed to manufacture the dumbbell. As used herein, the term “composite material” may encompass used, excess or scrapped materials made of different compositions (e.g. rubber, plastic, textiles, EVA, etc.) that is put into the recycling stream. This is intended to include but is not limited to wholesale recycling of entire products, disassembly of products, and recycling of selected parts, recycling of manufacturing byproduct.

The process of creating the composite material may include obtaining raw materials such as pre-consumer manufacturing scraps, end-of-life footwear, samples, etc. For example, footwear is broken down into its components such as rubber from the outsole, foam from the midsole, and fabric from the upper. During the manufacturing of an article of footwear, an outsole in the shape of the footwear is created by cutting the rubber material used for the outsole in the shape of the footwear using a template. When this is done, scrap portions of the rubber are left. The outsole rubber scraps can be repurposed by processing the rubber material that can then be used to form different goods, such as the dumbbell 100. Rubber scraps are processed with virgin natural rubber to produce the composite material to be utilized. Processing includes, but is not limited to, grinding the rubber scraps into granules and then mixing the granules of rubber scraps with virgin rubber material to create the composite blend. This process allows for utilization of rubber scraps that would otherwise be discarded as waste.

Once collected, the materials have to undergo a separation process. This step in the manufacturing process ensures that the type of material can be processed correctly for reuse. In some instances, once separated, the materials are prepared for additional use. In other instances, the products are further processed into a form that can be utilized. Thereafter, the separated materials are processed and transformed into recycled rubber material. The granules of recycled rubber that can be formed are the essence of recycled rubber and may be reconstituted into several different products and materials.

Once a batch of composite material is obtained and then sorted, cleaned, or subjected to any other pre-processing steps, the composite material may be shredded, chopped, and/or ground. Substances such as rubber may be pelletized, granulated, or converted to powder form. Materials that have been grinded may then be mixed with a virgin material, such as natural rubber. As used herein, “virgin material” is any material, such as a natural rubber or plastic that has not been altered/recycled/used/etc. since formation. Following this, in some instances, the combined recycled composite material and virgin material may be treated with additives or fillers, pigments, processing aids and the like.

The composite material may also be vulcanized. Vulcanization of the composite material of the dumbbell 100 includes curing the coating of each of the two heads 120. In some instances, sheets of composite material are placed in a bottom mold piece of a two-piece vulcanization mold, and the dumbbell 100 is placed in the bottom mold on top of the sheets of composite material. Additional sheets of composite material are then placed on top of the dumbbell 100, and a top mold piece is placed on the dumbbell 100. The dumbbell 100 is then subjected to heat and pressure in the mold, which vulcanizes the sheet of the ground composite material. During vulcanization, vulcanizing agents, such as sulfur or other curing agents are used with the heat and pressure to secure the composite material to the dumbbell 100. Vulcanization of the dumbbell 100 may help increase the strength of the dumbbell 100 by hardening and strengthening the composite material.

The combination of these different materials which form the recycled rubber material produces the speckled appearance illustrated in FIG. 1. The speckled appearance is formed by a plurality of colored rubber fragments 200 that are randomly spread throughout the composite rubber material. While the speckled appearance is shown only on an outer surface of each head 120 of the dumbbell, the same speckled appearance would be seen on the inside of the dumbbell 100. In other words, the colored rubber fragments 200 are spread randomly throughout dumbbell 100 and would be seen on both the outside surfaces and inside surfaces of the heads 120. It is contemplated that there may be at least fifty different colored rubber fragments, but greater or fewer colored rubber fragments may exist within the recycled rubber material. Additionally, the colored rubber fragments 200 may comprise different shapes and sizes and be composed of different materials from the recycling process.

In embodiments, the colored rubber fragments 200 seen on dumbbell 100 may comprise one or more colors based on the different components making up the recycled rubber material. The base color of recycled rubber dumbbell can be any color, including but not limited to gray and white. Additionally, the concentration of colored rubber fragments 200 and the appearance of the colored rubber fragments 200 will vary based on what materials are used in each batch of recycled rubber material produced. Each batch of recycled rubber material is unique since each batch is comprised of a unique variety of components. In instances, the recycled rubber material may also include other components such as, but not limited to EVA foam or thermoplastics. The uniqueness of each batch of recycled rubber material produced means a limited number of dumbbells can be produced with each batch of recycled rubber material's features. As such, once a batch of recycled rubber material has been used for manufacture of the dumbbells, the appearance of dumbbells produced may be different from any future production. Additionally, each batch is unique as recycled rubber manufacturing scrap colors vary from season to season.

In the present disclosure, the heads 120 of dumbbell 100 are comprised of a composite material which includes a mixture of a virgin material (e.g. natural rubber which has not been altered/recycled/etc.), and recycled rubber material. During the manufacturing process, it is contemplated that different combinations of mixture of virgin material and recycled rubber material may be utilized to form the heads 120 of dumbbell 100 (e.g. 50 percent mixture of virgin material and 50 percent recycled rubber material). However, in the dumbbell 100 described herein, each head 120 of dumbbell 100 is comprised of at least 20% composite material based on the volume of the dumbbell (e.g. the mixture of the recycled rubber material and the virgin material). The remainder of the dumbbell 100, such as the handle 110, may be made of a metal, such as cast-iron or machined steel. Additionally, each dumbbell head 120 may comprise a cast-iron core with recycled rubber vulcanized over the top of the cast-iron core. In embodiments, the mixture of natural rubber and recycled rubber material comprising the composite material may include 55% natural rubber (e.g., polyisoprene) and 45% recycled rubber material. In other embodiments the mixture of natural rubber and recycled rubber material comprising the composite material may include a range from 45-65% natural rubber and 55-35% recycled rubber.

The recycled rubber material is mechanically ground, sulphur-cured rubber originating from various rubber outsole formulations. Ground recycled rubber material particles vary in mesh size and contain in general 70% (by weight) cured polymers (either polybutadiene, styrene butadiene, neoprene or natural rubber) along with 30% (by weight) additives (silica) and curing and processing aids. The color of the rubber particles comprising the recycled material may include a mixed color (e.g. no color separation), a solid color, or the like. Rubber outsole components are made up of cured outside materials chopped to a variety of sizes. The sizes of the rubber outsole components may include, but are not limited to about 150 mm by 80 mm by 44 mm, 30 mm by 30 mm by 30 mm, 30 mm by 30 mm by 2 mm, 50 mm by 80 mm by 2 mm, 120 mm by 100 mm by 2 mm, 120 mm by 100 mm by 30 mm). The PU foam is lightweight, compressible, shock absorbing and has cushioning characteristics, which is beneficial for the use of the dumbbell 100. The leather scraps may include a polyurethane coating and have tensile strength, fire resistance, and are resistant to mildew.

The mixture of materials used to form the recycled rubber material may include any combination of cured rubber, polyurethane (PU) foam, ethylene-vinyl acetate (EVA) foam, leather including scraps or pieces from manufacturing processes, post-industrial textiles, and thermoplastics. The cured rubber may be sourced from outsoles, flashings, and other post-consumer rubber. In aspects, the rubber is sourced from at least one of outsole components, flashings, and post-consumer rubber. Unused or scrap outsole components are chopped into a variety of sizes to be used in the recycled rubber material. Post-consumer rubber comprises a rubber material separated from end-of-life footwear components, wherein the rubber material separated from end-of-life footwear components are processed to granular sizes. The granular sizes ranges from 3-6 mm and 10-30 mm.

The recycled rubber material is further comprised of outsoles and flashings processed into a powder form. The EVA foam is comprised of one or more of EVA injections, EVA flashings, EVA components, EVA laminated scraps, and post-consumer mixed foam, wherein the post-consumer mixed foam comprises mixed EVA and PU foam components processed into granulate form. The post-industrial textiles include one or more of polyester, cotton, elastane, nylon or post-consumer fluff. Post-consumer fluff consists of ground textile material recovered from end-of-life footwear. The thermoplastics used include thermoplastic polyurethane (TPU) chips from ground up cleats. Benefits of using thermoplastics includes abrasion resistance, resistance to oil and greases, and the ability to be melted and re-extruded, which are features beneficial to the use of dumbbell 100. The TPU chips may vary in size from 1-3 mm, 3-5 mm, and 1-4 mm and have a mixed color appearance that is comprised of the different colored chips utilized. It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed system without departing from the scope of the disclosure. Other embodiments of the system will be apparent to those skilled in the art from consideration of the specification and practice of the system disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.

Items

The present disclosure includes a dumbbell comprising a handle extending along a central longitudinal axis and two heads located at opposite ends of the handle along the central longitudinal axis. The two heads are comprised of a ground composite material. Each of the two heads is comprised of at least twenty percent ground material within the composite material based on a volume of each dumbbell. The ground composite material comprising a virgin material and recycled rubber material. The ground composite material consists essentially of 35% to 55% recycled rubber material and 45% to 65% virgin material, which may be a natural rubber. While this disclosure discusses the use of recycled rubber material, it is also contemplated that non-recycled materials could be used to form a composite material as well. The recycled rubber material is comprised of a mixture of recycled materials from manufacturing processes and post-consumer use. The natural rubber found in each head of the dumbbell comprises polyisoprene and the ground composite material is comprised of a mixture of recycled materials, such as rubbers and plastics. The ground composite material is made up of the regeneration of manufacturing scrap and end-of-life footwear and other recycled and unused materials from manufacturing processes and post-consumer use. In other aspects, each head is comprised of at least twenty percent ground composite material based on volume of the dumbbell.

The mixture of recycled material and/or unused materials may include a mixture of cured rubber, polyurethane (PU) foam, ethylene-vinyl acetate (EVA) foam, leather scraps, post-industrial textiles, and thermoplastics. The cured rubber utilized may include cured rubber sourced from at least one of outsole components, flashings, and post-consumer rubber. Cured rubber comprises a rubber material separated from end-of-life footwear components, wherein the rubber material separated from end-of-life footwear components are processed to granulate sizes. The granular sizes may range from 3-6 mm and 10-30 mm. Additionally, the rubber may further be comprised of outsoles and flashings processed into a powder form.

The EVA foam is comprised of one or more of EVA injections, EVA flashings, EVA components, EVA laminated scraps, and post-consumer mixed foam, wherein the post-consumer mixed foam comprises mixed EVA and PU foam components processed into granulate form. Post-industrial textiles include one or more of polyester, cotton, elastane, nylon or post-consumer fluff, which is comprised of ground textiles material recovered from end-of-life footwear. Additionally, the thermoplastics utilized include thermoplastic polyurethane (TPU) chips from ground up cleats.

The present disclosure also includes a dumbbell comprising a metal handle having a central longitudinal axis extending through the metal handle, and two heads located at opposite ends of the metal handle having. Each of the two heads includes an outer end face, an inner end face positioned closer to the metal handle than the outer end face, a plurality of side faces disposed between the outer end face and the inner end face; and a plurality of rounded corners disposed at interfaces of circumferentially adjacent side faces of the plurality of side faces and the outer end face. The two heads are comprised of at least twenty percent ground composite material by volume. In aspects, the ground composite material comprises a plurality of colored rubber fragments. The plurality of colored rubber fragments have at least two different shapes and at least two different sizes. Additionally, each of the two heads may also comprise a metal, such as cast iron.

In some aspects the invention is in accordance with the following clauses:

Clause 1: A dumbbell comprising:

• • a handle extending along a central longitudinal axis; and
  • two heads located at opposite ends of the handle along the central longitudinal axis,
  • wherein the two heads include a ground composite material.

Clause 2: The dumbbell of clause 1, wherein each of the two heads is comprised of at least twenty percent ground composite material based on a volume of the dumbbell.

Clause 3: The dumbbell of clause 1, wherein the ground composite material comprising comprises a virgin material and recycled rubber material.

Clause 4: The dumbbell of clause 3, wherein the ground composite material consist essentially of 35% to 55% recycled rubber material and 45% to 65% percent virgin material.

Clause 5: The dumbbell of clause 4, wherein the virgin material comprises rubber.

Clause 6: The dumbbell of clause 4, wherein the recycled rubber material comprises a mixture of recycled rubber and materials from manufacturing processes and post-consumer use.

Clause 7: The dumbbell of clause 6, wherein the mixture of recycled and unused materials includes at least one of following:

• • a) cured rubber,
  • b) polyurethane (PU) foam,
  • c) ethylene-vinyl acetate (EVA) foam,
  • d) leather pieces, and
  • e) thermoplastics.

Clause 8: The dumbbell of clause 7, wherein the cured rubber is comprised of footwear outsole components.

Clause 9: The dumbbell of clause 8, wherein the footwear outsole components are granular in size, and range from 1-3 mm, 3-6 mm or 10-30 mm.

Clause 10: The dumbbell of clause 9, wherein the cured rubber is further comprised of outsole components processed into a powder form.

Clause 11: The dumbbell of clause 7, wherein the EVA foam is comprised of one or more of EVA injections, EVA flashings, EVA components, EVA laminated scraps, and post-consumer mixed foam.

Clause 12: The dumbbell of clause 11, wherein the post-consumer mixed foam comprises mixed EVA and PU foam components processed into granules.

Clause 13: The dumbbell of clause 7, wherein the thermoplastics include thermoplastic polyurethane (TPU).

Clause 14: A dumbbell comprising:

• • a metal handle having a central longitudinal axis extending through the metal handle; and
  • two heads located at opposite ends of the metal handle having, each of the two heads comprising:
  • an outer end face;
  • an inner end face positioned closer to the metal handle than the outer end face;
  • a plurality of side faces disposed between the outer end face and the inner end face; and
  • a plurality of rounded corners disposed at interfaces of circumferentially adjacent side faces of the plurality of side faces and the outer end face,
  • wherein the dumbbell includes at least twenty percent ground composite material by volume.

Clause 15: The dumbbell of clause 14, wherein the ground composite material comprises a plurality of colored rubber fragments.

Clause 16: The dumbbell of clause 15, wherein the plurality of colored rubber fragments have at least two different shapes and at least two different sizes.

Clause 17: The dumbbell of clause 14, wherein the ground composite material consists essentially of recycled rubber material and a virgin material.

Clause 18: The dumbbell of clause 17, wherein the virgin material is a natural rubber.

Clause 19: The dumbbell of clause 18, wherein each of the two heads is further comprised of metal.

Clause 20: A dumbbell comprising:

• • a metal handle having a central longitudinal axis extending through the metal handle; and
  • two heads located at opposite ends of the metal handle, wherein each head includes six outer side faces extending around a circumference of each head, and no interface between circumferentially adjacent faces has a straight edge or straight corner, and
  • wherein each of the two heads includes a ground composite material consisting of a recycled rubber material and a plurality of colored rubber fragments spread randomly throughout the ground composite material.

The present disclosure also includes a dumbbell comprising a metal handle having a central longitudinal axis extending through the metal handle; and two heads located at opposite ends of the metal handle. Each of the two heads includes six outer side faces extending around a circumference of each head, and no interface between circumferentially adjacent faces has a straight edge or straight corner. Each of the two heads are also comprised of a ground composite material consisting of a recycled rubber material and a plurality of colored rubber fragments spread randomly throughout the ground composite material.