# Patent

## Title
Exercise device

## Abstract

A exercise device, for example, and exercise ball device. The exercise device includes a frame and at least one panel or multiple panels.

## Background
RELATED APPLICATION(S)
This U.S. patent application claims benefit under 35 U.S.C. 119(e) of U.S. Provisional Application No. 61/822,678, filed on May 13, 2013, the content of which is hereby incorporated by reference in its entirety.


FIELD
An exercise device, in particular a composite exercise device comprising a frame and at least one panel defining an outer surface of the exercise device. For example, a ball or sphere-shaped exercise device.
BACKGROUND
In the past, various types of balls are used as exercise balls. The exercise balls are typically deformable and filled with air. A person can exercise using the exercise ball in many different ways.
SUMMARY
An improved exercise device.
An improved exercise ball device.
A composite exercise device.
A composite exercise ball device.
An exercise device comprising or consisting of a frame supporting at least one panel.
An exercise ball device comprising or consisting of a frame supporting at least one panel.
An exercise device comprising or consisting of a three dimensional space frame supporting at least one panel.
An exercise ball device comprising or consisting of a three dimensional space frame supporting at least one panel.
An exercise device comprising or consisting of a frame supporting multiple panels.
An exercise ball device comprising or consisting of a frame supporting multiple panels.
An exercise device comprising or consisting of a frame supporting multiple same size and shape panels.
An exercise ball device comprising or consisting of a frame supporting multiple same size and shape panels.
An exercise device comprising or consisting of a substantially rigid frame supporting multiple resiliently deformable panels.
An exercise ball device comprising or consisting of a substantially rigid frame supporting multiple resiliently deformable panels.
An exercise device comprising or consisting of a substantially rigid frame comprising multiple frame members connected together supporting multiple resiliently deformable panels.
An exercise ball device comprising or consisting of a substantially rigid frame comprising multiple frame members connected together supporting multiple resiliently deformable panels.
An exercise device comprising or consisting of a substantially rigid frame comprising multiple frame members connected together at one or more nodes supporting multiple resiliently deformable panels.
An exercise ball device comprising or consisting of a substantially rigid frame comprising multiple frame members connected together at one or more nodes supporting multiple resiliently deformable panels.
An exercise device comprising or consisting of a substantially rigid frame comprising multiple frame members connected together at one or more nodes and one or more cross members, the substantially rigid frame supporting multiple resiliently deformable panels.
An exercise ball device comprising or consisting of a substantially rigid frame comprising multiple frame members connected together at one or more nodes and one or more cross members, the substantially rigid frame supporting multiple resiliently deformable panels.
An exercise device comprising or consisting of a substantially rigid frame defining at least one opening, the rigid frame comprising a flange surrounding at least a portion of the opening for supporting a resiliently deformable panel.
An exercise ball device comprising or consisting of a substantially rigid frame defining at least one opening, the rigid frame comprising a flange surrounding at least a portion of the opening for supporting a resiliently deformable panel.
An exercise device comprising or consisting of a substantially rigid frame defining at least one opening, the rigid frame comprising a flange surrounding the opening for supporting a resiliently deformable panel.
An exercise ball device comprising or consisting of a substantially rigid frame defining at least one opening, the rigid frame comprising a flange surrounding the opening for supporting a resiliently deformable panel.
A method of making an exercise device, comprising or consisting of providing a frame, and connecting one or more panels to the frame.
A method of making an exercise ball device, comprising or consisting of providing a frame, and connecting one or more panels to the frame.
A method of making an exercise device, comprising or consisting of providing a frame, and connecting one or more resilient panels to the frame.
A method of making an exercise ball device, comprising or consisting of providing a frame, and connecting one or more resilient panels to the frame.
A method of making an exercise device, comprising or consisting of molding a frame, and connecting one or more panels to the frame.
A method of making an exercise ball device, comprising or consisting of molding a frame, and connecting one or more panels to the frame.
A method of making an exercise device, comprising or consisting of molding a frame, molding one or more panels each comprising two or more layers; and connecting the one or more panels to the frame.
A method of making an exercise ball device, comprising or consisting of molding a frame, molding one or more panels each comprising two or more layers; and connecting one or more panels to the frame.
A method of making an exercise device, comprising or consisting of molding a frame, insert molding one or more panels each comprising two or more layers; and connecting the one or more panels to the frame.
A method of making an exercise ball device, comprising or consisting of molding a frame, insert molding one or more panels each comprising two or more layers; and connecting one or more panels to the frame.
A method of making an exercise device, comprising or consisting of molding a frame, insert molding one or more panels each comprising multiple layers; and connecting the one or more panels to the frame.
A method of making an exercise ball device, comprising or consisting of molding a frame, insert molding one or more panels each comprising multiple layers; and connecting one or more panels to the frame.
A method of making an exercise device, comprising or consisting of molding a frame, molding one or more panels each comprising an inner layer; overmolding an outer layer over the inner layer of each panel; and connecting the one or more panels to the frame.
A method of making an exercise ball device, comprising or consisting of molding a frame, molding one or more panels each comprising an inner layer; overmolding an outer layer over the inner layer of each panel; and connecting one or more panels to the frame.
A method of making an exercise device, comprising or consisting of molding a frame, molding one or more panels each comprising an inner layer; overmolding a softer outer layer over the inner layer of each panel; and connecting the one or more panels to the frame.
A method of making an exercise ball device, comprising or consisting of molding a frame, molding one or more panels each comprising an inner layer; overmolding a softer outer layer over the inner layer of each panel; and connecting one or more panels to the frame.
A method of making an exercise device, comprising or consisting of injection molding a frame, injection molding one or more panels each comprising an inner layer; overmolding an outer layer over the inner layer of each panel; and connecting the one or more panels to the frame.
A method of making an exercise ball device, comprising or consisting of injection molding a frame, molding one or more panels each comprising an inner layer; overmolding an outer layer over the inner layer of each panel; and connecting one or more panels to the frame.
An exercise device comprising or consisting of a frame and at least one panel. For example, the exercise device is an exercise ball device. Further, for example, the exercise device comprises or consists of a frame and multiple panels. The panels can be of the same size and shape, or can be of different size and/or shape. The shape of the exercise device can be spherical-shaped (i.e. ball shaped), or can be other shapes (e.g. pyramid, cube, cylindrical, octahedron, torus, etc.). Further, the panels can comprise or be made of multiple layers, for example, a stiffer inner layer supporting a softer or more resilient outer layer. The outer layer can be overmolded on the inner layer.
The frame, for example, can be a substantially rigid frame. The frame, for example, can comprise multiple frame members connected together. For example, the multiple frame members are connected together at nodes. Further, one or more cross-members can connect frame members together to further increase the rigidity of the frame. For example, the frame is a three (3) dimensional space frame the same or similar in shape to a sphere or ball. As a further, example, the outer frame members are curved and connect together at nodes, and one or more cross-members connect opposed outer frame members through an inner space defined by the outer curved frame members.
The frame can be molded, extruded, and/or machined (e.g. injection molded) as a single piece, or separate frame members can be made and then connected or assembled together. The frame can be made of plastic (e.g. nylon, polyethylene, polypropylene, ABS, or other suitable plastic), plastic material (e.g. plastic composition or material), composite material (e.g. fiberglass, carbon fiber, Kevlar, boron fiber), metal (e.g. aluminum, titanium, metal composite), or other suitable structural material. Again, the frame can have a one piece construction (e.g. molded, extruded, formed, or machined from a pre-form or block of material), or a multiple piece construction where the pieces of the frame are made and then connected or assembled together.
The frame can be configured to define one or more openings. For example, the frame comprises multiple openings (e.g. same size and shaped openings symmetrically spaced about the frame, e.g. four (4) openings). The frame can support one or more panels. The one or more panels can be connected (e.g. mechanically fastened, thermally connected, molded, overmolded, using adhesive, or combination thereof) to secured or anchor the one or more panels to the frame.
The frame can comprise a flange surrounding at least a portion of the perimeter of each opening, or the entire perimeter of each opening. The flange can connect with and structurally support the edges of the one or more panels when the panels are assembled onto the frame.
The panels can be each be made as a single piece construction, or can be made of multiple pieces joined together (e.g. molded, overmolded, layered, adhered, mechanically coupled, or combination thereof). For example, the panels can each be made with an inner support panel (e.g. made of nylon and stiffer than outer cover panel) and an outer cover panel made of resilient deformable material (e.g. soft and/or resilient plastic or thermoplastic elastomer). The outer panels can be smooth or textured (e.g. provided with textured pattern, projections, indents, spikes, grooves, different surface textures).
The panels can be made with an inner support panel (i.e. inner layer of panel) comprising a plurality of through holes (e.g. a distributed pattern of through holes) so that when the outer cover panel (i.e. outer layer of panel) is molded or overmolded thereto, the hot plastic material flows and enters the through holes, and then hardens to form a plurality of mechanical anchors. The through holes can be beveled or chamfered (e.g. on inner side of inner support panel) to create mechanical anchors when material from overmolding the outer cover panel flows, enters, and sets in the beveled or chamfered through hole portion providing even a greater retaining strength due to the beveled or chamfered configuration of the through holes.



BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of an exercise ball device.
FIG. 2 is a front elevational view of the exercise ball device shown in FIG. 1.
FIG. 3 is a back elevational view of the exercise ball device shown in FIG. 1.
FIG. 4 is a top planar view of the exercise ball device shown in FIG. 1.
FIG. 5 is a bottom planar view of the exercise ball device shown in FIG. 1.
FIG. 6 is a left side elevational view of the exercise ball device shown in FIG. 1.
FIG. 7 is a right side elevational view of the exercise ball device shown in FIG. 1.
FIG. 8 is an exploded perspective view of the exercise ball device shown in FIG. 1.
FIG. 9 is a perspective view of the frame of the exercise ball device shown in FIG. 8.
FIG. 10 is a perspective view of one (1) panel of the exercise ball device shown in FIGS. 1 and 8.
FIG. 11 is another perspective view of the panel shown in FIG. 10.
FIG. 11A is a further perspective view of the panel shown in FIG. 10.
FIG. 12 is a partial detailed cross-sectional view through a frame member of the exercise ball device shown in FIG. 1.
FIG. 13 is a partial detailed cross-sectional view through a panel of the exercise ball device shown in FIG. 1.
FIG. 14 is a partial detailed cross-sectional view through a frame member of another exercise ball device.
FIG. 15 is a diagrammatic side view of the exercise ball device shown in FIG. 1 located under the leg of the user.
FIG. 16 is a diagrammatic rear view of the exercise ball device shown in FIG. 1 located under the right side of the user's back.
FIG. 17 is a diagrammatic side view of the exercise ball device shown in FIG. 1 located under the left ankle of the user.
FIG. 18 is a diagrammatic side view of the exercise ball device shown in FIG. 1 under the right thigh of the user.



DETAILED DESCRIPTION
An exercise ball device 10 is shown in FIGS. 1 thru 13. The exercised ball device 10 comprises or consists of a frame 12 (e.g. self-supporting frame member) comprising multiple frame members 14 connecting together at multiple nodes (e.g. six (6) frame members 14 connected together at four (4) nodes).
A frame cross-member 18 connects together two (2) opposed frame members 14 to increase the rigidity and strength of the frame 12. The frame 12 can be a three (3) dimensional space frame that can be spherical-shaped like a ball. The frame 12 can be substantially rigid to rigid and made, for example, by forming (e.g. extruding, molding, injection molding), or machining a pre-form or block of material. The frame 12 can be made of plastic material (e.g. nylon, polyethylene, polypropylene, acrylonitrile butadiene styrene (ABS), or suitable plastic material, fiberglass, carbon fiber, boron fiber, Kevlar, or other suitable composite material). Alternatively, the frame can be made of metal (e.g. aluminum, titanium, metal composite), or made of multiple materials (e.g. metal frame overmolded with plastic material, frame constructed of metal and/or plastic parts.
The frame 12 can comprise six (6) frame members 14 connecting together at four (4) nodes defining four (4) openings 20 to into an interior (i.e. interior space) of the frame 12. The frame members 14 define and surround the openings 20, and support and accommodate the four (4) panels 22. The panels 22 can be the same size and shape. For example, each panel 14 can be approximately one-quarter of an outer surface layer of a sphere (i.e. four (4) quadrants). Further, the panels 22 are sized and shaped to fit into the openings 20 between the frame members 14 (i.e. the perimeter edges of the panels 22 dimensionally fit between the frame members 14 defining the openings 20).
The frame 12 can comprise one or more flanges 24 provided around a perimeter of each of the openings 20 (e.g. continuous flange). Alternatively, the flanges 24 can be provided at portions or sections of each opening (e.g. discontinuous flange members or sections). As shown in FIG. 8, the flanges 24 are continuous, except for a portion or section of the frame adjacent the attachment points of the frame cross member 18 with the frame members 14. Further, the flanges 24 (e.g. side flanges 24) extend outwardly from the sides of the frame members 14. In addition the flanges 24 can be located below the outer surfaces of each frame members 14. This arrangement results in the panels 22 being at least partially located below the outer surface of the frame members 14 (i.e. the panels recessed below outer surface of frame members 14). For example, the base of the panels (i.e. the lower base or base layers) are recessed below or flush with the outer surfaces of the frame members while the spikes 32 extend above the outer surfaces of the frame members.
The exercise ball device 10, comprises a three-dimensional space frame comprising multiple frame members 14 defining multiple the openings 20 into the interior (i.e. interior space) of the frame 12. The multiple panels 22 connect to the frame members 12, and the panels 12 are disposed within the openings 20 and located between the frame members 12. The panels 22 can be recessed below an outer surface of the frame members 14, and the frame members 14 together with the panels 22 defining an outer surface of the exercise ball device 10. Alternatively, the height of the side flanges 26 on the frame members 14 can be adjusted (e.g. raise) so that the outer surface of the frame member 14 are flush with the outer surfaces of the panels 22.
The flanges 24 can cooperate with, connect to, and support the edges of the panels 22, in particular with the inner surface of the panels 22 located adjacent to the perimeter edges thereof. As shown in FIG. 12, two (2) adjacent panels 22 are connected to the frame 12, for example, by adhesive applied (e.g. adhesive layer 25) to the flanges 24, which adhesive bonds with the respective edges of the panels 22. Alternatively, the panels 22 can be heat welded, molded, overmolded, fastened, taped (e.g. double sided tape), or connected to the frame by other suitable devices and/or methods.
The construction of the panel 22 is shown in detail in FIGS. 10, 11, and 13. The panel 22 can comprise an inner support panel 22a connected to an outer cover panel 22b. For example, the inner support panel 22a can be molded, and the outer cover panel 22b can be overmolded onto the inner support panel 22a. 
The inner support panel 22a comprises a flange 26 (i.e. raised or increased thickness portion) provided around a perimeter of the inner support panel 22a. The flange 26 of the inner support panel 22a can cooperate with and be connected (e.g. adhered) to the flange 24 of the frame 12. All four (4) panels 22 can be connected to the frame 22 in this manner to complete the construction or assembly.
The inner support panel 22a (FIG. 13) can be provided with multiple through holes 28, as shown in FIG. 11A, for example, as seen on the cross-sectioned edge of the panel 22, as shown in FIG. 13. The through holes 28 can be provided in a pattern (e.g. through holes 28 spaced apart by equal distances from each other in a geometrical pattern, matrix or grid). The anchoring heads 30 of the outer support panel 22b extend into and anchor within the through holes 28.
As shown in FIG. 13, the through holes 28 can widen (e.g. by beveling, tapering, stepping) in a radial direction towards a center of the exercise ball device 10 (i.e. the through holes become wider in a direction from the outer surface towards the inner surface of the inner support panel 22a). This arrangement results in an anchoring head 30 being formed during molding inside the through hole 28 when the outer cover panel 22b is overmolded onto the inner support panel 22a. 
The panels 22 can each be made by first injection molding the inner support panel 22a, for example, made of nylon material. Then each molded inner support panel 22a is overmolded (e.g. by insert molding) with the outer cover layer 22b made of soft plastic or thermoplastic elastomer material. This can result in the inner support panel 22a being bonded to the outer cover layer 22b. Further, the molded thermoplastic elastomer material when being molded flows and enters into the plurality of through holes 28 creating multiple anchors for mechanically fastening the outer cover layer 22b to the inner support layer 22a. 
The outer cover layer 22b of the panels 22 can be textured (e.g. by molding). For example, a plurality of spikes 32 can be provided when molding the outer cover layer 22b. For example, the spikes 32 can protrude above the outer surfaces of the frame members, as shown in FIG. 12.
The exercise ball device 10 can be made by making the frame 12 (e.g. injection molding) and the panels 22 (e.g. injection molding), and then assembling these parts or components together. For example, the panels 22 can be connected or attached to the flanges 24 of the frame 12, for example, using adhesive material resulting in an adhesive layer 25 being located between each flange 24 and each panel 22. Specifically, the adhesive layer 25 is provided between the upper surface of each flange 24 and the lower surface adjacent the edge of each panel 22.
Optionally, the exercise ball device 10, for example, can be filled with a resilient material (e.g. shredded rubber) to add weight thereto.
In the exercise ball device 10 shown in FIGS. 1 thru 13, an outer surface of each frame member 14 is exposed when assembled. Further, as shown in FIG. 13, the outer surface of each frame member 14 is recessed (i.e. located below the height of the outer surface of the protrusions 32).
Further, the base or base layer of the panels 32 can be located below (i.e. recessed below) the outer surfaces of the frame members 14, as shown in FIG. 12, or alternatively, can be flush therewith.
Another exercise ball device 110 is shown in FIG. 14. The panels 122 can be configured to abut each other and cover each frame member 122. For example, the flanges 124 can be raised on each frame member 114, and the panels 122 can be made to extend inwardly so as to cover each frame member 122 and abut each other. In this manner, the frame 112 is completely hidden under the panels 22 compared with the construction of the exercise ball shown in FIGS. 1 and 8.
Use
The exercise ball device 10 can be can be positioned under the leg of a user, as shown in FIG. 15. The user can move his or her leg back and forth over the exercise ball device 10 to cause the exercise ball device 10 to roll on the ground while rolling on and manipulating the tissue (e.g. skin, muscle, bone, tendons, ligaments) of the user's leg.
Alternatively, the user can position the exercise ball device 10 under the user's back, as shown in FIG. 16. The user can move his or her body back and forth over the exercise ball device 10 to cause the exercise ball device 10 to roll on the ground while manipulating the tissue of the user's back.
As a further alternative, the user can position the exercise ball device 10 under the user's thigh, as shown in FIG. 17. The user can move his or her leg back and forth over the exercise ball device 10 to cause the exercise ball device 10 to roll on the ground while manipulating the tissue of the user's thigh.

## Claims

1. An exercise ball device, comprising:
a self-supporting rigid three-dimensional space frame comprising multiple frame members defining multiple openings into an interior of the frame; and
multiple panels connected to the frame members, the panels disposed within the openings and extending between the frame members, and outer surfaces of the frame members together with outer surfaces of the panels defining an outer surface of the exercise ball device,
wherein the frame is a spherical-shaped three-dimensional space frame consisting essentially of six (6) frame members connected together at four (4) nodes and defining four (4) equally sized and shaped quadrants each having an opening, the frame members each comprising one or more flanges extending outwardly from the sides of each frame member and into each respective opening.

2. The device according to claim 1, wherein the openings are of the same size and shape.

3. The device according to claim 2, wherein the panels are sized and shaped to fit into the openings.

4. The device according to claim 2, wherein a portion of each panel is sized and shaped to fit into the openings.

5. The device according to claim 2, wherein the panels are shaped as quadrants of a sphere.

6. The device according to claim 1, wherein the panels are shaped as portions of a sphere.

7. The device according to claim 6, wherein the panels are same size and shape sphere portions.

8. The device according to claim 1, wherein a perimeter of each panel fits into each opening in the respective frame member.

9. The device according to claim 1, wherein the panels are deformable resulting in a deformable exercise device.

10. The device according to claim 9, wherein the frame is made of plastic material.

11. The device according to claim 1, wherein a base of each panel is recessed below or flush with the outer surfaces of the frame members.

12. The device according to claim 11, wherein each panel comprises spikes, and the spikes protrude above the outer surfaces of the frame members.

13. The device according to claim 1, further comprising one or more cross members connecting together opposed frame members.

14. An exercise ball device, comprising:
a spherical-shaped three-dimensional space frame consisting essentially of six (6) frame members connected together at four (4) nodes and defining four (4) equally sized and shaped quadrants each having an opening, the frame members each comprising one or more flanges extending outwardly from respective sides of each frame member and into each respective opening, the one or more flanges being located below an outer surface of each frame member;
one or more cross members connecting together opposed frame members; and
four (4) equally shaped and sized quadrant panels connected to the frame members and covering each opening and defining an outer surface of the exercise ball device,
wherein the outer surface of each frame member is recessed below the outer surface of the exercise ball device.

15. The device according to claim 14, wherein the frame is a self-supporting rigid frame.

16. A method of making an exercise ball device comprising:
making a self-supporting rigid spherical-shaped three-dimensional space frame defining multiple openings;
making multiple panels configured to fit into the multiple openings, the multiple panels being made of resilient material; and
connecting the multiple panels to the frame to make an assembled exercise ball device,
wherein the frame is a spherical-shaped three-dimensional space frame consisting essentially of six (6) frame members connected together at four (4) nodes and defining four (4) equally sized and shaped quadrants each having an opening, the frame members each comprising one or more flanges extending outwardly from the sides of each frame member and into each respective opening.

17. An exercise ball device, comprising:
a self-supporting rigid three-dimensional space frame comprising multiple frame members defining multiple openings; and
multiple deformable panels connected to the frame members, the panels covering at least the openings in the space frame,
wherein the frame is a spherical-shaped three-dimensional space frame consisting essentially of six (6) frame members connected together at four (4) nodes and defining four (4) equally sized and shaped quadrants each having an opening, the frame members each comprising one or more flanges extending outwardly from the sides of each frame member and into each respective opening.

18. The device according to claim 17, wherein outer surfaces of the frame members and outer surfaces of the multiple panels define an outer surface of the exercise ball device.

19. The device according to claim 18, wherein the outer surfaces of the frame members are recessed below the outer surfaces of the multiple panels.

20. The device according to claim 19, wherein the one or more flanges are recessed below the outer surfaces of the frame members to accommodate and connect with an outer perimeter of each respective deformable panel.

21. The device according to claim 20, further comprising one or more cross members connecting together opposed frame members.