Weightlifting Rack Assembly

Abstract

A weight rack assembly may include a plurality of vertical frame members and a plurality of lateral frame members extending between the plurality of vertical frame members. The weight rack assembly may also include a first lateral frame member that includes a gusseted end bracket at one end, where the gusseted end bracket includes a base plate, a lateral extension, a vertical extension, and a top gusset that extends along a side of the first lateral frame member and where the top gusset extends from an upper edge of the lateral extension. The weight rack assembly may further include a second lateral frame member that includes a bottom end plate at one end, where the bottom end plate includes a tab that extends from a lower surface of the bottom end plate and is received in a slot on a foot plate.

What is claimed is: 
     
         1 . A weight rack assembly, comprising:
 a plurality of vertical frame members, wherein each of the plurality of vertical frame members comprises a vertical beam with a rectangular cross-sectional shape, the plurality of vertical frame members including a first vertical frame member;   a plurality of horizontal frame members connected to and extending between the plurality of vertical frame members, wherein each of the plurality of horizontal frame members comprises a horizontal beam with a rectangular cross-sectional shape, the plurality of horizontal frame members including a first longitudinal frame member and a first lateral frame member extending transverse to the first longitudinal frame member; and   a first gusseted end bracket forming a joint between the first longitudinal frame member, the first lateral frame member, and the first vertical frame member, the first gusseted end bracket comprising:
 a first base plate connected to a first end of the first longitudinal frame member and oriented transverse to the first longitudinal frame member; 
 a first lateral extension extending laterally from the first base plate along a first lateral side surface of the first lateral frame member, wherein the first lateral extension is connected to the first lateral frame member by a first fastener; 
 a first vertical extension extending vertically downward from the first base plate along a first vertical side surface of the first vertical frame member, wherein the first vertical extension is connected to the first vertical frame member by a second fastener; and 
 a first top gusset extending from an upper end of the first lateral extension along a longitudinal side surface of the first longitudinal frame member, 
 wherein the first base plate, the first lateral extension, the first vertical extension, and the first top gusset of the first gusseted end bracket are formed as a single plate, with the first top gusset joined to the first lateral extension by a first bend, such that the first top gusset extends transversely to the first base plate, the first lateral extension, and the first vertical extension. 
   
     
     
         2 . The weight rack assembly of  claim 1 , wherein the plurality of horizontal frame members further includes a second longitudinal frame member extending in line with the first longitudinal frame member and transverse to the first lateral frame member, wherein the first longitudinal frame member and the second longitudinal frame member are arranged on opposite sides of the first vertical frame member, the weight rack assembly further comprising:
 a second gusseted end bracket forming a joint between the second longitudinal frame member, the first lateral frame member, and the first vertical frame member, the second gusseted end bracket comprising:
 a second base plate connected to a second end of the second longitudinal frame member and oriented transverse to the second longitudinal frame member; 
 a second lateral extension extending laterally from the second base plate along a second lateral side surface of the first lateral frame member, wherein the second lateral extension is connected to the first lateral frame member by a third fastener; 
 a second vertical extension extending vertically downward from the second base plate along a second vertical side surface of the first vertical frame member, wherein the second vertical extension is connected to the first vertical frame member by a fourth fastener; and 
 a second top gusset extending from an upper end of the second lateral extension along a longitudinal side surface of the second longitudinal frame member, 
 wherein the second base plate, the second lateral extension, the second vertical extension, and the second top gusset of the second gusseted end bracket are formed as a second single plate, with the second top gusset joined to the second lateral extension by a second bend, such that the second top gusset extends transversely to the second base plate, the second lateral extension, and the second vertical extension. 
   
     
     
         3 . The weight rack assembly of  claim 2 , wherein the first gusseted end bracket is integrally joined to the first end of the first longitudinal frame member, and the second gusseted end bracket is integrally joined to the second end of the second longitudinal frame member. 
     
     
         4 . The weight rack assembly of  claim 1 , wherein the first gusseted end bracket is integrally joined to the first end of the first longitudinal frame member. 
     
     
         5 . The weight rack assembly of  claim 1 , wherein the first longitudinal frame member includes a second gusseted end bracket at a second end of the first longitudinal frame member opposite the first end, wherein the second gusseted end bracket includes a second base plate at the second end of the first longitudinal frame member, a second lateral extension extending laterally from the second base plate, a second vertical extension extending vertically downward from the second base plate, and a second top gusset that extends from an upper edge of the second lateral extension along the longitudinal side surface of the first longitudinal frame member. 
     
     
         6 . The weight rack assembly of  claim 1 , wherein the plurality of horizontal frame members further includes a second lateral frame member extending transverse to the first longitudinal frame member and parallel to the first lateral frame member, and the plurality of vertical frame members includes a second vertical frame member parallel to the first vertical frame member, the weight rack assembly further comprising:
 a second gusseted end bracket forming a second joint between the first longitudinal frame member, the second lateral frame member, and the second vertical frame member, the second gusseted end bracket comprising:
 a second base plate connected to a second end of the first longitudinal frame member, opposite the first end, and oriented transverse to the first longitudinal frame member; 
 a second lateral extension extending laterally from the second base plate along a second lateral side surface of the second lateral frame member, wherein the second lateral extension is connected to the second lateral frame member by a third fastener; 
 a second vertical extension extending vertically downward from the second base plate along a second vertical side surface of the second vertical frame member, wherein the second vertical extension is connected to the second vertical frame member by a fourth fastener; and 
 a second top gusset extending from an upper end of the second lateral extension along the longitudinal side surface of the first longitudinal frame member, 
 wherein the second base plate, the second lateral extension, the second vertical extension, and the second top gusset of the second gusseted end bracket are formed as a second single plate, with the second top gusset joined to the second lateral extension by a second bend, such that the second top gusset extends transversely to the second base plate, the second lateral extension, and the second vertical extension. 
   
     
     
         7 . The weight rack assembly of  claim 6 , wherein the first gusseted end bracket is integrally joined to the first end of the first longitudinal frame member, and the second gusseted end bracket is integrally joined to the second end of the first longitudinal frame member. 
     
     
         8 . The weight rack assembly of  claim 6 , wherein the first top gusset has a first angled edge extending at obtuse angles to the longitudinal side surface of the first longitudinal frame member and the first lateral side surface of the first lateral frame member, and the second top gusset has a second angled edge extending at obtuse angles to the longitudinal side surface of the first longitudinal frame member and the second lateral side surface of the second lateral frame member. 
     
     
         9 . The weight rack assembly of  claim 1 , wherein the first gusseted end bracket includes a first side gusset extending between the first vertical extension and an exterior facing surface of the first longitudinal frame member. 
     
     
         10 . The weight rack assembly of  claim 1 , wherein the first top gusset has a first angled edge extending at obtuse angles to the longitudinal side surface of the first longitudinal frame member and the first lateral side surface of the first lateral frame member. 
     
     
         11 . The weight rack assembly of  claim 1 , wherein the first top gusset does not extend above top surfaces of the first longitudinal frame member and the first lateral frame member or above a top end of the first vertical frame member. 
     
     
         12 . The weight rack assembly of  claim 1 , wherein the first longitudinal frame member, the first lateral frame member, and the first vertical frame member are arranged at 90° angles to each other, and the first bend is a 90° bend. 
     
     
         13 . The weight rack assembly of  claim 1 , wherein a lower longitudinal frame member of the plurality of horizontal frame members is positioned below the first longitudinal frame member proximate a bottom of the weight rack assembly and includes a bottom end plate at one end, wherein the bottom end plate includes a tab that extends from a lower surface of the bottom end plate, and
 wherein the tab of the bottom end plate is received in a slot on a foot plate.   
     
     
         14 . A weight rack assembly, comprising:
 a plurality of vertical frame members including a first vertical frame member, a second vertical frame member, a third vertical frame member, and a fourth vertical frame member arranged parallel to each other;   a plurality of horizontal frame members connected to and extending between the plurality of vertical frame members, the plurality of horizontal frame members including a first longitudinal frame member and second longitudinal frame member arranged parallel to each other, and a first lateral frame member and a second lateral frame member arranged parallel to each other and extending perpendicular to the first longitudinal frame member and the second longitudinal frame member, wherein the first vertical frame member, the second vertical frame member, the third vertical frame member, the fourth vertical frame member, the first longitudinal frame member, the second longitudinal frame member, the first lateral frame member, and the second lateral frame member are arranged perpendicular to each other to form a box shape;   a first gusseted end bracket forming a first joint between the first longitudinal frame member, the first lateral frame member, and the first vertical frame member, the first gusseted end bracket comprising:
 a first base plate connected to a first end of the first longitudinal frame member and oriented perpendicular to the first longitudinal frame member; 
 a first lateral extension extending laterally from the first base plate along a first lateral side surface of the first lateral frame member, wherein the first lateral extension is connected to the first lateral frame member; 
 a first vertical extension extending vertically downward from the first base plate along a first vertical side surface of the first vertical frame member, wherein the first vertical extension is connected to the first vertical frame member; and 
 a first top gusset extending from a first upper end of the first lateral extension along a first longitudinal side surface of the first longitudinal frame member; 
   a second gusseted end bracket forming a second joint between the first longitudinal frame member, the second lateral frame member, and the second vertical frame member, the second gusseted end bracket comprising:
 a second base plate connected to a second end of the first longitudinal frame member, opposite the first end, and oriented perpendicular to the first longitudinal frame member; 
 a second lateral extension extending laterally from the second base plate along a second lateral side surface of the second lateral frame member, wherein the second lateral extension is connected to the second lateral frame member; 
 a second vertical extension extending vertically downward from the second base plate along a second vertical side surface of the second vertical frame member, wherein the second vertical extension is connected to the second vertical frame member; and 
 a second top gusset extending from a second upper end of the second lateral extension along the first longitudinal side surface of the first longitudinal frame member; 
   a third gusseted end bracket forming a third joint between the second longitudinal frame member, the first lateral frame member, and the third vertical frame member, the third gusseted end bracket comprising:
 a third base plate connected to a third end of the second longitudinal frame member and oriented perpendicular to the second longitudinal frame member; 
 a third lateral extension extending laterally from the third base plate along the first lateral side surface of the first lateral frame member, wherein the third lateral extension is connected to the first lateral frame member; 
 a third vertical extension extending vertically downward from the third base plate along a third vertical side surface of the third vertical frame member, wherein the third vertical extension is connected to the third vertical frame member; and 
 a third top gusset extending from a third upper end of the third lateral extension along a second longitudinal side surface of the second longitudinal frame member; and 
   a fourth gusseted end bracket forming a fourth joint between the second longitudinal frame member, the second lateral frame member, and the fourth vertical frame member, the fourth gusseted end bracket comprising:
 a fourth base plate connected to a fourth end of the second longitudinal frame member and oriented perpendicular to the second longitudinal frame member; 
 a fourth lateral extension extending laterally from the fourth base plate along the second lateral side surface of the second lateral frame member, wherein the fourth lateral extension is connected to the second lateral frame member; 
 a fourth vertical extension extending vertically downward from the fourth base plate along a fourth vertical side surface of the fourth vertical frame member, wherein the fourth vertical extension is connected to the fourth vertical frame member; and 
 a fourth top gusset extending from a fourth upper end of the fourth lateral extension along the second longitudinal side surface of the second longitudinal frame member. 
   
     
     
         15 . The weight rack assembly of  claim 14 , wherein:
 the first base plate, the first lateral extension, the first vertical extension, and the first top gusset of the first gusseted end bracket are formed as a first single plate, with the first top gusset joined to the first lateral extension by a first bend, such that the first top gusset extends perpendicular to the first base plate, the first lateral extension, and the first vertical extension,   the second base plate, the second lateral extension, the second vertical extension, and the second top gusset of the second gusseted end bracket are formed as a second single plate, with the second top gusset joined to the second lateral extension by a second bend, such that the second top gusset extends perpendicular to the second base plate, the second lateral extension, and the second vertical extension,   the third base plate, the third lateral extension, the third vertical extension, and the third top gusset of the third gusseted end bracket are formed as a third single plate, with the third top gusset joined to the third lateral extension by a third bend, such that the third top gusset extends perpendicular to the third base plate, the third lateral extension, and the third vertical extension, and   the fourth base plate, the fourth lateral extension, the fourth vertical extension, and the fourth top gusset of the fourth gusseted end bracket are formed as a fourth single plate, with the fourth top gusset joined to the fourth lateral extension by a fourth bend, such that the fourth top gusset extends perpendicular to the fourth base plate, the fourth lateral extension, and the fourth vertical extension.   
     
     
         16 . The weight rack assembly of  claim 14 , wherein:
 the first gusseted end bracket is integrally joined to the first end of the first longitudinal frame member,   the second gusseted end bracket is integrally joined to the second end of the first longitudinal frame member,   the third gusseted end bracket is integrally joined to the third end of the second longitudinal frame member, and   the fourth gusseted end bracket is integrally joined to the fourth end of the second longitudinal frame member.   
     
     
         17 . The weight rack assembly of  claim 14 , wherein the first gusseted end bracket and the second gusseted end bracket are welded to the first longitudinal frame member, and the third gusseted end bracket and the fourth gusseted end bracket are welded to the second longitudinal frame member. 
     
     
         18 . A horizontal frame member for use in a weight rack assembly, comprising:
 an elongated beam extending along a direction of elongation between a first end and a second end and having a rectangular cross section formed by a plurality of side surfaces defining a hollow interior;   a first gusseted end bracket configured to form a first joint between the elongated beam, a first lateral frame member, and a first vertical frame member, the first gusseted end bracket comprising:
 a first base plate integrally joined to the first end of the elongated beam and oriented perpendicular to the direction of elongation of the elongated beam; 
 a first lateral extension extending laterally from the first base plate and configured to extend along a first lateral side surface of the first lateral frame member, the first lateral extension having a first fastener hole configured for receiving a first fastener for connection to the first lateral frame member; 
 a first vertical extension extending vertically downward from the first base plate and configured to extend along a first vertical side surface of the first vertical frame member, the first vertical extension having a second fastener hole configured for receiving a second fastener for connection to the first vertical frame member; and 
 a first top gusset extending from a first upper end of the first lateral extension along a first side surface of the plurality of side surfaces of the elongated beam; and 
   a second gusseted end bracket configured to form a second joint between the elongated beam, a second lateral frame member, and a second vertical frame member, the second gusseted end bracket comprising:
 a second base plate integrally joined to the second end of the elongated beam and oriented perpendicular to the direction of elongation of the elongated beam; 
 a second lateral extension extending laterally from the second base plate and configured to extend along a second lateral side surface of the second lateral frame member, the second lateral extension having a third fastener hole configured for receiving a third fastener for connection to the second lateral frame member; 
 a second vertical extension extending vertically downward from the second base plate and configured to extend along a second vertical side surface of the second vertical frame member, the second vertical extension having a fourth fastener hole configured for receiving a fourth fastener for connection to the second vertical frame member; and 
 a second top gusset extending from a second upper end of the second lateral extension along the first side surface of the plurality of side surfaces of the elongated beam. 
   
     
     
         19 . The horizontal frame member of  claim 18 , wherein the plurality of side surfaces of the elongated beam further includes a second side surface adjacent to and perpendicular to the first side surface, wherein the first gusseted end bracket includes a first side gusset extending perpendicular to the first vertical extension and along the second side surface of the elongated beam, and wherein the second gusseted end bracket includes a second side gusset extending perpendicular to the second vertical extension and along the second side surface of the elongated beam. 
     
     
         20 . The horizontal frame member of  claim 18 , wherein:
 the first base plate, the first lateral extension, the first vertical extension, and the first top gusset of the first gusseted end bracket are formed as a first single plate, with the first top gusset joined to the first lateral extension by a first bend, such that the first top gusset extends perpendicular to the first base plate, the first lateral extension, and the first vertical extension, and   the second base plate, the second lateral extension, the second vertical extension, and the second top gusset of the second gusseted end bracket are formed as a second single plate, with the second top gusset joined to the second lateral extension by a second bend, such that the second top gusset extends perpendicular to the second base plate, the second lateral extension, and the second vertical extension.