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.

1 . A weight assembly, comprising: 
 first and second weight heads spaced apart from each other, each weight head having a side wall and an end wall that together define a bore having a longitudinal axis, the side wall including 
 portion disposed about an opening to the bore and at an angle relative to the longitudinal axis of the bore, and  
 an intermediate portion disposed between the outer portion and the end wall;  
   an elongated handle having two end portions and a gripping portion between the end portions, each end portion having a diameter greater than a diameter of the gripping portion, each end portion press-fit into a corresponding bore of the first and second weight heads such that the handle extends between the first and second weight heads; and    first and second weld seams each 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 such that the weld seams are spaced apart from the gripping portion of the handle.    
   
   
       2 . A weight assembly as defined in  claim 1 , wherein the outer portion of each side wall has a prescribed curvature, as viewed in cross-section.  
   
   
       3 . A weight assembly as defined in  claim 1 , wherein each bore has a depth greater than or equal to the diameter of the corresponding end portion of the handle.  
   
   
       4 . A weight assembly as defined in  claim 1 , wherein the outer portion has a frusto-conical configuration.  
   
   
       5 . A weight assembly as defined in  claim 1 , wherein the outer portion has a notch configuration, the outer portion including 
 a first surface, adjacent to the intermediate portion, angled outwardly relative to the longitudinal axis of the bore, and    a second surface extending from the first surface, generally parallel to the longitudinal axis of the bore.    
   
   
       6 . A weight assembly as defined in  claim 1 , wherein a coating of compliant material is provided over the first and second weight heads, substantially covering the first and second weld seams.  
   
   
       7 . A method of manufacturing a weight assembly, comprising: 
 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 
 an outer portion disposed about an opening to the bore and at an angle relative to a longitudinal axis of the bore, and  
 an intermediate portion disposed between the outer portion and the end wall;  
   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;    pressing the first end portion of the handle into the bore of the first weight head;    pressing the second end portion of the handle into the bore of the second weight head;    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    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.    
   
   
       8 . A method as defined in  claim 7 , wherein the outer portion of each side wall has a prescribed curvature, as viewed in cross-section.  
   
   
       9 . A method as defined in  claim 7 , wherein the outer portion of each side wall has a notch configuration, the outer portion including 
 a first surface, adjacent to the intermediate portion, angled outwardly relative to the longitudinal axis of the bore, and    a second surface extending from the first surface, generally parallel to the longitudinal axis of the bore.    
   
   
       10 . A method as defined in  claim 7 , wherein the weight heads are covered with a compliant material.  
   
   
       11 . A method as defined in  claim 7 , wherein each bore has a depth greater than or equal to the diameter of the corresponding end portion of the handle.  
   
   
       12 . A method as defined in  claim 7 , wherein the step of providing a handle includes, 
 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.    
   
   
       13 . A method as defined in  claim 7 , wherein the step of providing first and second weight heads includes, 
 providing a first head blank and a 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 the end wall, and    removing material about the outer edge of the cylindrical hole, thereby forming the outer portion of the side wall.