Patent Publication Number: US-9885376-B1

Title: Rotary connector devices, connector assemblies and method of use

Description:
FIELD AND BACKGROUND 
     The present disclosure relates to connector devices and assemblies. The illustrated embodiments relate to exercise equipment and connector devices and assemblies for connecting components of exercise equipment. This disclosure is applicable to other types of apparatus in addition to exercise equipment. 
     U.S. Pat. No. 8,807,898 which is herein incorporated by reference in entirety, discloses a connector assembly comprising a base part that defines a throughhole for receiving a bolt and also defines an aperture for receiving a device having a first end that fits through the aperture in the base part and a second end that does not fit through the aperture in the base part. The first end of the device defines a bolt hole for engaging with a bolt extending through the throughhole in the base part. The second end of the device comprises opposing outer surfaces that engage the base part and thereby prevent the device from passing completely through the aperture, and also align the bolt hole in the device with the throughhole in the base part when the first end of the device is inserted into the aperture. 
     SUMMARY 
     The summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. 
     In some examples, connector assemblies comprise a connector device and a base part that defines a throughhole having a forming wall structure for receiving a bolt and for receiving the connector device. The connector device has a rear portion that fits through the throughhole in the base part, and a front portion which does not fit through the throughhole in the base part. The rear portion of the connector device defines a bolt hole for engaging with the bolt extending through the throughhole in the base part, and the front portion of the connector device defines an access opening aligned with the bolt hole in the rear portion for receiving the bolt. The rear portion is configured with engagement surface structure aligned with and engaged in abutting relationship with the forming wall structure upon movement of the connector device relative to the throughhole in the base part. 
     In other examples, connector devices are provided for connecting an element to a base pan via a bolt. The connector devices each comprise a body having a width extending in a lateral direction, a height extending in a vertical direction perpendicular to the lateral direction, and a depth extending in a transverse direction perpendicular to the lateral direction and perpendicular to the vertical direction. The body includes a rear portion integrally joined to a front portion. The rear portion is configured to fit through a throughhole defined by forming wall structure and formed in the base pan, and the front portion is configured with a rear face for engaging an outer surface of the base part lying outside the throughhole. The rear portion extends between upper and lower surfaces in the lateral direction, between first and second side surfaces in the vertical direction, and between front and rear walls in the transverse direction. The rear portion has a core portion extending between the front wall and the rear face of the front portion. The core portion is formed with engagement surface structure for engaging the forming wall structure of the throughhole to retain the body relative to the base part when the rear portion is inserted through the throughhole and the body is rotated relative to the base part. The body is formed with a hole extending completely through the front portion and the rear portion in the transverse direction in alignment with the throughhole for receiving the bolt and engaging the bolt in a threaded connection within the rear portion. 
     In further examples, there is disclosed a method of connecting an element via a bolt to a base part having throughhole formed in a mounting face thereof and defined by forming wall structure. The method includes the steps of a) providing a connector device having a rear portion that fits through the throughhole in the base part, and a front portion which does not fit through the throughhole and engages an outer surface of the mounting face lying outside the throughhole, wherein the rear portion defines a bolt hole and the front portion defines an access opening aligned with the bolt hole, the bolt hole and the access opening being aligned with the throughhole, and wherein the rear portion is configured with engagement surface structure; b) rotating the connector device when the rear portion is inserted through the throughhole such that the engagement surface structure is brought into abutting relationship with the forming wall structure of the throughhole to prevent further rotation of the connector device relative to the base part; and c) inserting the bolt through the element and the access opening and turning the bolt into threaded connection with the bolt hole to secure the element to the base part. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
       Examples of connector devices and assemblies are described with reference to the following figures. The same numbers are used throughout the figures to reference like features and components. 
         FIG. 1  is a perspective view of exercise equipment having a connector assembly according to the present disclosure. 
         FIG. 2  is a partially exploded view of the connector assembly. 
         FIG. 3  is a sectional view of the connector assembly taken on line  3 - 3  of  FIG. 1 . 
         FIG. 4  is a left front perspective view of a rotary connector device for connecting an element to a base part via a bolt and a washer. 
         FIG. 5  is a right front perspective view of the connector device shown in  FIG. 4 . 
         FIG. 6  is a front view of the connector device shown in  FIGS. 4 and 5 . 
         FIG. 7  is a top view of the connector device shown in  FIG. 6 . 
         FIG. 8  is a right side view of the connector device shown in  FIG. 6 . 
         FIG. 9  is a partial sectional view taken on line  9 - 9  of  FIG. 2  showing insertion of the connector device into the base part. 
         FIG. 10  is a view similar to  FIG. 9  showing a rotary orientation of the connector device in the base part. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     In the present description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be inferred therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes only and are intended to be broadly construed. The different devices and assemblies described herein may be used alone or in combination with other devices and/or assemblies. Various equivalents, alternatives and modifications are possible within the scope of the appended claims 
       FIG. 1  depicts exercise equipment  10  including among other things, a weight rack  10  and a weight bar  12 . The weight rack  10  and the weight bar  12  are exemplary and provide only one of many examples of uses for the present invention. The present invention is applicable to other apparatuses and/or structural assemblies in addition to the weight rack  10  shown in  FIG. 1 . The weight bar  12  is shown supported on the weight rack  10  via a pair of cross support members  14  which are releasably fixable to different vertical locations (e.g.  16 ) to thereby allow a user to select the vertical height at which the weight bar  12  is supported above the ground. The cross support members  14  are attached to respective front and rear support columns  18 ,  20  which vertically extend above and are supported by base frame members  22 . First auxiliary support members  24  are attached to support columns  18  for attachment of additional exercise apparatus (not shown) such as, for example, chin up assemblies. The auxiliary support members  24  are connected to the support columns  18  such as by connector assemblies as disclosed in U.S. Pat. No. 8,807,898. In the example shown, a second auxiliary support member  26  in the form of a plate is attached to support column  20  for further attachment of additional exercise apparatus (not shown) by a connector assembly according to the present disclosure. Again, the weight rack  10  shown in the figures is exemplary, and the present invention can be used to connect structural members in other types of structural apparatus besides the exercise equipment shown in  FIG. 1 . 
       FIG. 2  depicts a connector assembly  28  according to the present disclosure including a base part  30  which in the exemplary embodiment is a rectangular tube that is part of the rear support column  20  shown in  FIG. 1 . It should be noted that the support column  20  may have a different cross sectional configuration other than the rectangular tube shown. The connector assembly  28 , in this example, connects the support column  20  and the auxiliary support member  26 . The configuration and function of the base part  30  and member  26  can vary. In other examples, the base part  30  can form part of the base frame member  22  or other portions of the weight rack  10 . The base part  30  defines at least one throughhole  32  shaped and sized for receiving and retaining a connector device  34  relative to forming walls  32   a ,  32   b ,  32   c .  32   d  of the throughhole  32 . A bolt  36  extends through a throughhole  38  formed in a washer  40  and then passes through an opening  42  configured through the support member  26 . In the example shown, the washer  40  has a circular front portion  40   a  designed to overlie the opening  42  and a circular rear portion  40   b  configured with a smaller diameter than the diameter of the front portion  40   a  such that the rear portion  40   b  is received by the walls forming the opening  42 . According to the present disclosure, the connector device  34  receives a threaded end  44  of the bolt  36  to thereby connect the support member  26  and the base part  30 . 
     In the example shown in  FIG. 2 , the connector assembly  28  includes a pair of identical spaced apart throughholes  32 , each of which receives one of the connector devices  34  which is coupled to one of the bolts  36 , washers  40 , and the supporting member  26  as described above. The throughholes  32  are formed through a sidewall and mounting face  46  of the base part  30 . As seen in  FIG. 3 , an additional pair of throughholes  32  are formed in an opposing sidewall and mounting face  48  of the base part  30  to permit further connection of an auxiliary support member to an opposite side of the support column  20 . If desired, throughhole  32  could also be formed on opposing end walls and mounting faces  50 ,  52  of the base part  30 . It should be appreciated that each throughhole  32  is located between and away from the adjacent corners of the base part  30  so as not to weaken the structural integrity thereof. 
       FIGS. 4-8  depict the connector device  34  in further detail. The device  34  has a body  54  integrally formed with a front portion  56  and a rear portion  58 . The body  54  has a width w extending in a lateral direction W, a height h extending in a vertical direction V perpendicular to the lateral direction W and a depth d extending in a transverse direction D which is perpendicular to the lateral direction W and the vertical direction V. The front portion  56  is sized and shaped so that it does not fit through the throughhole  32  in the base part  30 . The rear portion  58  is sized and shaped to fit through the throughhole  32  in the base part  30 . 
     The front portion  56  is formed with a circular shape, and includes a circular planar front face  60  having a first diameter, and a circular planar rear face  62  ( FIGS. 7-8 ) having a diameter which is larger than the diameter of the first face  60 . The front face  60  and the rear face  62  are connected by a peripheral rim  64  which diverges in the transverse direction D from the front of face  60  towards the rear face  62 . A central area of the front portion  56  is formed completely therethrough with an unthreaded access opening  66 . In the example shown, the access opening  66  has a hexhead configuration defined by six forming walls  68  which are designed to receive a complementary-shaped hexhead of a driving tool (not shown) used during installation of the connector device  34 . However, it should be understood that the access opening  66  may be otherwise configured to matingly receive a driving tool for installation of the connector device  34  as will be explained below. 
     The rear portion  58  is constructed with various surfaces which form a clearance space behind the front portion  56 , and are designed to lie behind and within the forming walls  32   a ,  32   b ,  32   c ,  32   d  of the throughhole  32 . The rear portion  58  has a planar upper surface  70  and a planar lower surface  72 , both of which extend laterally in the direction W. The rear portion  58  also includes a first planar side surface  74  and a second planar side surface  76  extending in the vertical direction V. The upper and lower surfaces  70 ,  72  and the side surfaces  74 ,  76  are connected by rounded corners  78 . The upper and lower surfaces  70 ,  72 , the side surfaces  74 ,  76  and the rounded corners  78  define a generally rectangular periphery which is sized slightly smaller than the size of the throughhole  32  formed in the base part  30 . As best seen in  FIGS. 4, 5 and 7 , the upper planar surface  70  includes an upper planar segment  70   a  which is connected to an upper end of the rear face  62  of the front portion  56 . The lower planar surface  72  includes a lower planar segment  72   a  which is connected to a lower end of the rear face  62  of the front portion  56 . The rear portion  58  has a planar rear wall  80  ( FIGS. 7-8 ) which lies parallel to the rear face  62  of the front portion  56 . A left side front wall of the rear portion  58  further includes a planar lower front surface  82 , and a ramped upper front surface  84  which extends upwardly in the vertical direction V and rearwardly in the transverse direction D. A right side front wall of the rear portion  58  includes a planar upper front surface  86 , and a ramped lower front surface  88  which extends downwardly in the vertical direction V and rearwardly in the transverse direction D. Together, the planar front surfaces  82 ,  86  and the ramped front surfaces  84 ,  88  define a front wall of the rear portion  58 . 
     Further referring to  FIGS. 9 and 10 , the rear portion  58  additionally includes a core portion  90 ) which extends in the transverse direction D between the front surfaces  82 ,  84 ,  86 ,  88  and the rear face  62  of the front portion  56 . As seen in  FIG. 4 , the core portion  90  has a first lobe  92  which extends from the upper planar segment  70   a  and merges smoothly into an outwardly facing first planar engagement surface  94  having a first beveled edge  96  joined to the lower planar segment  72   a . The first lobe  92  has a width extending in the transverse direction D which gradually decreases as it extends along the ramped front surface  84  towards the first planar engagement surface  94 . 
     As seen in  FIG. 5 , the core portion  90  also has an outwardly facing second lobe  98  which extends from the lower planar segment  72   a  and uniformly transitions with an outwardly facing second planar engagement surface  100  having a beveled edge  102  joined to the upper planar segment  70   a . The second lobe  98  has a width extending in the transverse direction D which gradually decreases as it extends along the ramped front surface  88  towards the second planar engagement surface  100 . 
     As seen in  FIGS. 4 and 5 , the rear portion  58  of the connector device  34  is formed therethrough with an internally threaded throughhole  104  which is aligned with the throughhole  66  formed through the front portion  56 . 
     In use, the hexhead of an installation tool is first inserted into mating engagement with the walls  68  of the access opening  66  formed in the front portion  56  of the connector device  34 . The rear portion  58  of the connector device  34  is then inserted into the throughhole  32  as shown in  FIG. 9  until the rear face  62  of the front portion  56  contacts an outer surface of the base part  30  extending outside the throughhole  32 . Next, the tool is turned in the direction of arrow A to rotate the entire connector device  34 , 90 degrees about a central axis of the throughhole  32  extending in the transverse direction D, as shown in  FIG. 10 . During this rotary motion, the first lobe  92  moves along wall  32   a  as the lower front surface  82  and the ramped front surface  84  move along an inner surface of the base part  30  above wall  32   a . Simultaneously, the second lobe  98  moves along wall  32   c  as the upper front surface  86  and the ramped front surface  88  move along the inner surface of base part  30  below wall  32   c . Such rotary movement brings first engagement surface  94  into abutting contact with wall  32   a , and second engagement surface  100  into abutting contact with wall  32   c . At this point, the connector device  34  can no longer be rotated in the direction of arrow A, and is retained in the base part  30  relative to at least the walls  32   a ,  32   c  of the throughhole  32 . 
     Thereafter, the installation tool is removed and, as shown in  FIGS. 2 and 3 , the bolt  36  is fed through the throughhole  38  in the washer  40  and the opening  42  formed in the support member  26 , and has its threaded portion  44  turned into engagement in a threaded connection with throughhole  104  formed at the rear portion  58  of the connector device  34 . Accordingly, the support member  26  can be conveniently and securely attached to the base part  30  without the need to extend the threaded shaft  44  of the bolt  36  completely through the base part  30 . If desired, the connector assembly  28  may be quickly disassembled by simply reversing the above process. 
     As should be recognized by those skilled in the art, the present disclosure provides a connector assembly that can be mass produced, and eliminates the need for tools to hold the connector device in place during connection of the support member to the base part. In comparison with prior art arrangements, the connector assembly of the present disclosure requires less laser time in forming a throughhole in a mounting face of a base part away from the corners thereof so as to maintain the strength and aesthetic appearance of the base part. In addition, the connector device can be formed so that it can be used on multiple gauge thicknesses of the base part. The connector device can be easily replaced in the field if it becomes lost or damaged, and is economical to manufacture. The examples set forth herein advantageously provide modular attachments that are independent of each other, and provide a replaceable threaded connection which is efficient and easy to use. 
     Although only a few examples have been described in detail above, those having ordinary skill in the art will readily appreciate that many modifications are possible in examples without materially departing from the invention. All such modifications are intended to be included within the scope of this disclosure as defined in the claims.