Patent Description:
<CIT> describes a barbell including a rod with two tubular members respectively mounted to the two ends thereof.

<CIT> describes a barbell comprising a bar member, a first side weight assembly and a second side weight assembly.

<CIT> describes a barbell assembly includes an axle having two connection holes respectively defined in two ends thereof and two outer tubes are respectively mounted to the two ends of the axle.

Aspects of the disclosure relate to a barbell that includes a bar having a first end portion and a second end portion, a first sleeve assembly including a first sleeve having a first axial bore with a first proximal bore portion, a first distal bore portion, and a first central bore portion extending between the first proximal bore portion and the first distal bore portion, where the first end portion of the bar is received through the first axial bore and extends through the first proximal bore portion and the first central bore portion to the first distal bore portion, a first proximal bushing received in the first proximal bore portion of the first sleeve, and a first distal bushing received in the first distal bore portion of the first sleeve. The first proximal bushing is fixed against axial movement with respect to the first sleeve assembly and has a first axial passage receiving the bar therethrough, where the first proximal bushing has a first outer surface engaging the first sleeve and a first inner surface engaging the bar within the first axial passage. The first distal bushing is fixed against axial movement with respect to the first sleeve assembly and has a first cavity. The barbell also includes a first barrel fixed to the first end portion of the bar, the first barrel having a cylindrical outer shape and received within the first cavity of the first distal bushing. The first barrel is both axially and rotationally fixed to the bar. The first distal bushing has a second outer surface engaging the first sleeve and a second inner surface engaging the first barrel within the first cavity. The first proximal bushing and the first distal bushing permit the first sleeve assembly to be freely rotatable around the bar and the first barrel, and the first outer surface and the first inner surface, the second outer surface, and the second inner surface are polymer surfaces.

According to one aspect, the bar further includes a first threaded projection extending outward from the first end portion. In one embodiment, the first barrel is fixed to the first end portion of the bar by a first fastener threaded onto the first threaded projection.

According to another aspect, the first axial bore has a first proximal opening and a first distal opening, and the first proximal bore portion extends inward from the proximal opening, and the first distal bore portion extends inward from the distal opening.

According to another aspect, the first sleeve assembly is freely rotatable with respect to the bar by the first proximal bushing rotating around the bar and the first distal bushing rotating around the first barrel.

According to another aspect, the first central bore portion has a first inner diameter that is smaller than the first proximal bore portion and the first distal bore portion.

According to a further aspect, the first barrel is fixed against axial movement with respect to the first distal bushing and against axial movement with respect to the bar, such that the bar is thereby also fixed against axial movement with respect to the first distal bushing.

According to yet another aspect, the first outer surface, the first inner surface, the second outer surface, and the second inner surface are formed of a same polymer material.

According to a still further aspect, the first axial bore has a first proximal opening and a first distal opening, and the first proximal bore portion is proximate to the proximal opening, and the first distal bore portion is proximate to the first distal opening.

According to an additional aspect, the barbell also includes a second sleeve assembly including a second sleeve having a second axial bore with a second proximal bore portion, a second distal bore portion, and a second central bore portion extending between the second proximal bore portion and the second distal bore portion, wherein the second end portion of the bar is received through the second axial bore and extends through the second proximal bore portion and the second central bore portion to the second distal bore portion, a second proximal bushing received in the second proximal bore portion of the second sleeve, and a second distal bushing received in the second distal bore portion of the second sleeve. The second proximal bushing is fixed against axial movement with respect to the second sleeve assembly and has a second axial passage receiving the bar therethrough, where the second proximal bushing has a third outer surface engaging the second sleeve and a third inner surface engaging the bar within the second axial passage. The second distal bushing is fixed against axial movement with respect to the second sleeve assembly and has a second cavity. The barbell further includes a second barrel fixed to the second end portion of the bar, the second barrel having a cylindrical outer shape and received within the second cavity of the second distal bushing. The second distal bushing has a fourth outer surface engaging the second sleeve and a fourth inner surface engaging the second barrel within the second cavity. The second sleeve assembly is freely rotatable with respect to the bar by the second proximal bushing rotating around the bar and the second distal bushing rotating around the second barrel, and the third outer surface, the third inner surface, the fourth outer surface, and the fourth inner surface are polymer surfaces.

According to another aspect, the first distal bushing includes a first bushing portion and a second bushing portion in abutting contact with each other. The first bushing portion has a first cylindrical wall with a first annular flange extending inward from the first cylindrical wall to define the first axial passage at a proximal end of the first distal bushing, and the second bushing portion is positioned at a distal end of the first distal bushing. The first and second bushing portions combine to define the first cavity of the first distal bushing. In one configuration, the second bushing portion has a second cylindrical wall with a second annular flange extending inward from the second cylindrical wall to define a second axial passage at the distal end of the first distal bushing, and the first cylindrical wall of the first bushing portion and the second cylindrical wall of the second bushing portion combine to define the second outer surface and the second inner surface, and to further define the first cavity as a cylindrical cavity. In another configuration, the first barrel engages the first annular flange and further engages the second bushing portion to resist axial movement of the first barrel with respect to the first distal bushing. In a further configuration, the second bushing portion is identical to the first bushing portion and is positioned in reverse orientation relative to the first bushing portion.

According to another aspect, the barbell includes a retaining member engaging a distal end of the first distal bushing to retain the first distal bushing in the first distal bore portion.

According to an additional aspect, the first sleeve has a first groove within the first proximal bore portion, and the first proximal bushing has a first engaging surface received within the first groove and engaging a surface of the first groove to retain the first proximal bushing within the first proximal bore portion.

According to yet another aspect, the polymer surfaces are all formed of polymer materials having a durometer hardness of <NUM> Shore A to <NUM> Shore A.

Additional aspects of the disclosure relate to a barbell that includes a first rotational body including a bar having a first end portion and a second end portion, a second rotational body mounted on the first end portion of the bar, a first rotational engagement structure connecting the first rotational body to the second rotational body to permit the second rotational body to be freely rotatable with respect to the first rotational body, such that the first rotational engagement structure constitutes all structures engaging both the first rotational body and the second rotational body, a third rotational body mounted on the second end portion of the bar, and a second rotational engagement structure connecting the first rotational body to the third rotational body to permit the third rotational body to be freely rotatable with respect to the first rotational body, such that the second rotational engagement structure constitutes all structures engaging both the first rotational body and the third rotational body. The second rotational body includes a first sleeve having a first bore receiving the first end portion of the bar, and the third rotational body includes a second sleeve having a second bore receiving the second end portion of the bar. All surfaces of the first rotational engagement structure engaging at least one of the first rotational body and the second rotational body and all surfaces of the second rotational engagement structure engaging at least one of the first rotational body and the third rotational body are formed of one or more polymer materials.

According to one aspect, the first rotational engagement structure includes at least a first bushing having a first surface engaging the first rotational body and a second surface engaging the second rotational body to permit rotation of the second rotational body relative to the first rotational body, and at least one of the first and second surfaces are formed of the one or more polymer materials. Additionally, the second rotational engagement structure includes at least a second bushing having a third surface engaging the first rotational body and a fourth surface engaging the third rotational body to permit rotation of the third rotational body relative to the first rotational body, and at least one of the third and fourth surfaces are formed of the one or more polymer materials. In one configuration, the first bushing is a first distal bushing located proximate to a distal end of the second rotational body and the first end portion of the first rotational body, and the second bushing is a second distal bushing located proximate to a distal end of the third rotational body and the second end portion of the first rotational body. In another configuration, the first bushing is a first proximal bushing located proximate to a proximal end of the second rotational body and spaced from the first end portion of the first rotational body, and the second bushing is a second proximal bushing located proximate to a proximal end of the third rotational body and spaced from the second end portion of the first rotational body. In a further configuration, the first rotational body includes a first cylindrical barrel connected to the first end portion of the bar and a second cylindrical barrel connected to the second end portion of the bar, the first and second cylindrical barrels having larger diameters than the bar. In this configuration, the first cylindrical barrel is engaged with the second surface of the first bushing to permit rotation of the second rotational body relative to the first cylindrical barrel, and the second cylindrical barrel is engaged with the fourth surface of the second bushing to permit rotation of the third rotational body relative to the second cylindrical barrel.

According to another aspect, the first rotational engagement structure includes at least a first proximal bushing formed of a first polymer material of the one or more polymer materials and a first distal bushing formed of a second polymer material of the one or more polymer materials, the first proximal bushing and the first distal bushing engaging the first rotational body and the second rotational body to permit rotation of the second rotational body relative to the first rotational body. Additionally, the second rotational engagement structure includes at least a second proximal bushing formed of a third polymer material of the one or more polymer materials and a second distal bushing formed of a fourth polymer material of the one or more polymer materials, the second proximal bushing and the second distal bushing engaging the first rotational body and the third rotational body to permit rotation of the third rotational body relative to the first rotational body.

According to a further aspect, the first rotational engagement structure includes a first rotor fixed to the first end portion of the bar and having a first cylindrical outer surface engaging an inner surface of the first bore to permit rotation of the second rotational body relative to the first rotational body, and the second rotational engagement structure includes a second rotor fixed to the second end portion of the bar and having a second cylindrical outer surface engaging an inner surface of the second bore to permit rotation of the third rotational body relative to the first rotational body.

According to yet another aspect, the first polymer material, the second polymer material, the third polymer material, and the fourth polymer material are the same.

According to a still further aspect, the one or more polymer materials each have a durometer hardness of <NUM> Shore A to <NUM> Shore A.

Further aspects of the disclosure relate to a barbell including a bar having a first end portion and a second end portion, a first sleeve assembly comprising a first sleeve having a first axial bore with a first proximal opening and a first distal opening, the first axial bore having a first proximal bore portion extending inward from the proximal opening, a first distal bore portion extending inward from the distal opening, and a first central bore portion extending between the first proximal bore portion and the first distal bore portion, a first proximal bushing received in the first proximal bore portion of the first sleeve, a first distal bushing received in the first distal bore portion of the first sleeve, a first barrel having a cylindrical outer shape and received within the first cylindrical cavity of the first distal bushing, a second sleeve assembly comprising a second sleeve having a second axial bore with a second proximal opening and a second distal opening, the second axial bore having a second proximal bore portion extending inward from the proximal opening, a second distal bore portion extending inward from the distal opening, and a second central bore portion extending between the second proximal bore portion and the second distal bore portion, a second proximal bushing received in the second proximal bore portion of the second sleeve, a second distal bushing received in the second distal bore portion of the second sleeve, and a second barrel having a cylindrical outer shape and received within the second cylindrical cavity of the second distal bushing. The bar has a first threaded projection extending outward from the first end portion and a second threaded projection extending outward from the second end portion. The first central bore portion has a first inner diameter that is smaller than the first proximal bore portion and the first distal bore portion, and the first end portion of the bar is received through the first axial bore and extends through the first proximal bore portion and the first central bore portion to the first distal bore portion. The second central bore portion has a second inner diameter that is smaller than the second proximal bore portion and the second distal bore portion, and the second end portion of the bar is received through the second axial bore and extends through the second proximal bore portion and the second central bore portion to the second distal bore portion. The first proximal bushing is fixed against axial movement with respect to the first sleeve assembly and has a first axial passage receiving the bar therethrough, and the first proximal bushing is formed of a first polymer material. The first distal bushing is fixed against axial movement with respect to the first sleeve assembly and has a first cylindrical cavity and a first aperture extending to the first inner cavity and receiving the first end portion of the bar therethrough, and the first distal bushing is formed of a second polymer material. The second proximal bushing is received in the second proximal bore portion of the second sleeve and fixed against axial movement with respect to the second sleeve assembly and has a second axial passage receiving the bar therethrough, and the second proximal bushing is formed of a third polymer material. The second distal bushing is received in the second distal bore portion of the second sleeve and fixed against axial movement with respect to the second sleeve assembly and has a second cylindrical cavity and a second aperture extending to the second inner cavity and receiving the second end portion of the bar therethrough, and the second distal bushing is formed of a fourth polymer material. The first barrel is fixed to the first end portion of the bar by a first fastener threaded onto the first threaded projection, and the first barrel is fixed against axial movement with respect to the first distal bushing and is fixed against axial and rotational movement with respect to the bar. The second barrel is fixed to the second end portion of the bar by a second fastener threaded onto the second threaded projection, and the second barrel is fixed against axial movement with respect to the second distal bushing and is fixed against axial and rotational movement with respect to the bar. The first sleeve assembly is freely rotatable with respect to the bar by the first proximal bushing rotating around the bar and the first distal bushing rotating around the first barrel, and the second sleeve assembly is freely rotatable with respect to the bar by the second proximal bushing rotating around the bar and the second distal bushing rotating around the second barrel.

According to one aspect, the first proximal bushing is formed entirely of the first polymer material, the first distal bushing is formed entirely of the second polymer material, the second proximal bushing is formed entirely of the third polymer material, and the second distal bushing is formed entirely of the fourth polymer material.

According to another aspect, the first polymer material, the second polymer material, the third polymer material, and the fourth polymer material are the same.

According to a further aspect, the first distal bushing includes a first bushing portion and a second bushing portion in abutting contact with each other, the first bushing portion having a first cylindrical wall with a first annular flange extending inward from the first cylindrical wall to define the first axial passage at a proximal end of the first distal bushing, and the second bushing portion is positioned at a distal end of the first distal bushing, such that the first and second bushing portions combine to define the first cylindrical cavity of the first distal bushing. In one configuration, the second bushing portion has a second cylindrical wall with a second annular flange extending inward from the second cylindrical wall to define a second axial passage at the distal end of the first distal bushing, and the first cylindrical wall of the first bushing portion and the second cylindrical wall of the second bushing portion combine to define the first cylindrical cavity. In another configuration, the second bushing portion is identical to the first bushing portion and is positioned in reverse orientation relative to the first bushing portion, and the first bushing portion and the second bushing portion are both formed of the second polymer material.

According to yet another aspect, the first sleeve has a first groove within the first proximal bore portion, and the first proximal bushing has an annular shoulder defining a first engaging surface received within the first groove and engaging a first surface of the first groove to retain the first proximal bushing within the first proximal bore portion and to resist axial movement of the first proximal bushing toward the first proximal opening with respect to the first sleeve. A distal end of the first proximal bushing engages a second surface of the first groove to resist axial movement of the first proximal bushing toward the first distal opening with respect to the first sleeve.

According to a still further aspect, the first polymer material, the second polymer material, the third polymer material, and the fourth polymer material each have a durometer hardness of <NUM> Shore A to <NUM> Shore A.

Still further aspects of the disclosure relate to a barbell that includes a bar assembly including a bar having a first end portion and a second end portion, a first sleeve assembly including a first sleeve having a first axial bore with a first proximal opening, a first proximal bore portion extending inward from the first proximal opening, a first distal bore portion, and a first central bore portion extending between the first proximal bore portion and the first distal bore portion, and a first proximal bushing received in the first proximal bore portion of the first sleeve and fixed against axial movement with respect to the first sleeve assembly. The first end portion of the bar is received through the first axial bore and extends through the first proximal bore portion and the first central bore portion to the first distal bore portion, the first central bore portion has a first inner diameter that is smaller than the first proximal bore portion, and the first proximal bore portion has a first groove spaced distally from the first proximal opening. The first proximal bushing has a first axial passage receiving the bar therethrough, a first outer surface engaging the first sleeve, and a first inner surface engaging the bar within the first axial passage. The first proximal bushing further has a first engaging surface received within the first groove and engaging a first surface of the first groove to retain the first proximal bushing within the first proximal bore portion and to resist axial movement of the first proximal bushing toward the first proximal opening with respect to the first sleeve. The first proximal bushing permits the first sleeve assembly to be freely rotatable with respect to the bar, and the first outer surface and the first inner surface are polymer surfaces.

According to one aspect, the first groove is an annular groove, and the first proximal bushing has an annular shoulder defining the first engaging surface.

According to another aspect, the first sleeve assembly is freely rotatable with respect to the bar by the first proximal bushing rotating around the bar.

According to a further aspect, a distal end of the first proximal bushing engages a second surface of the first groove to resist axial movement of the first proximal bushing toward the first distal bore portion with respect to the first sleeve.

According to yet another aspect, the barbell also includes a first distal bushing received in the first distal bore portion of the first sleeve and having a first cavity receiving a portion of the bar assembly, the first distal bushing further having second outer surface engaging the first sleeve and a second inner surface engaging the portion of the bar assembly. The first sleeve assembly is further freely rotatable with respect to the bar by the first distal bushing rotating around the portion of the bar assembly, and the second outer surface and the second inner surface are polymer surfaces.

Yet additional aspects of the disclosure relate to a barbell that includes a bar having a first end portion and a second end portion, a first sleeve assembly including a first sleeve having a first axial bore with a first proximal bore portion, a first distal bore portion, and a first central bore portion extending between the first proximal bore portion and the first distal bore portion, a first distal bushing received in the first distal bore portion of the first sleeve and fixed against axial movement with respect to the first sleeve assembly, the first distal bushing having a first cylindrical cavity and a first aperture extending to the first cavity, and a first barrel removably fixed to the first end portion of the bar, the first barrel having a cylindrical outer shape and received within the first cavity of the first distal bushing. The first end portion of the bar is received through the first axial bore and extends through the first proximal bore portion and the first central bore portion to the first distal bore portion, the first central bore portion having a first inner diameter that is smaller than the first distal bore portion. The first barrel has a larger outer diameter than the bar, and the first distal bushing has a first outer surface engaging the first sleeve and a second inner surface defining the first cylindrical cavity and engaging the first barrel within the first cylindrical cavity. The first distal bushing further engages the first barrel to fix the first barrel against axial movement with respect to the first distal bushing, and the first sleeve assembly is freely rotatable with respect to the bar by the first distal bushing rotating around the first barrel. The first outer surface and the first inner surface are polymer surfaces.

According to one aspect, the bar further includes a first threaded projection extending outward from the first end portion, and the first barrel is fixed to the first end portion of the bar by a first fastener threaded onto the first threaded projection.

According to another aspect, the first distal bushing includes a first bushing portion and a second bushing portion in abutting contact with each other, the first bushing portion having a first cylindrical wall with a first annular flange extending inward from the first cylindrical wall to define the first axial passage at a proximal end of the first distal bushing. The second bushing portion is positioned at a distal end of the first distal bushing, and the first and second bushing portions combine to define the first cylindrical cavity of the first distal bushing. In one configuration, the second bushing portion has a second cylindrical wall with a second annular flange extending inward from the second cylindrical wall to define a second axial passage at the distal end of the first distal bushing. In this configuration, the first cylindrical wall of the first bushing portion and the second cylindrical wall of the second bushing portion combine to define the first outer surface and the first inner surface, and to further define the first cylindrical cavity. In another configuration, the first barrel engages the first annular flange and further engages the second bushing portion to resist axial movement of the first barrel with respect to the first distal bushing. In a further configuration, the second bushing portion is identical to the first bushing portion and is positioned in reverse orientation relative to the first bushing portion.

Other aspects of the disclosure relate to a barbell that includes a first rotational body including a bar having a first end portion and a second end portion, a second rotational body mounted on the first end portion of the bar and including a first sleeve having a first bore receiving the first end portion of the bar, and a first rotational engagement structure connecting the first rotational body to the second rotational body to permit the second rotational body to be freely rotatable with respect to the first rotational body. The first rotational body, the second rotational body, and the first rotational engagement structure have a plurality of surface pairs engaging each other in surface-to-surface engagement with clearances greater than <NUM> inch (<NUM>), and each of the plurality of surface pairs engaging each other in surface-to-surface engagement with clearances greater than <NUM> inch (<NUM>) includes at least one polymer surface.

According to one aspect, the first rotational engagement structure includes at least a first bushing engaging the first rotational body to form a first surface pair of the plurality of surface pairs engaging each other in surface-to-surface engagement with clearances greater than <NUM> inch (<NUM>) and engaging the second rotational body to form a second surface pair of the plurality of surface pairs engaging each other in surface-to-surface engagement with clearances greater than <NUM> inch (<NUM>). At least one surface of the first surface pair and at least one surface of the second surface pair are polymer surfaces.

According to another aspect, the first rotational engagement structure includes at least a first proximal bushing and a first distal bushing. The first proximal bushing has a first surface engaging the first rotational body to form a first surface pair of the plurality of surface pairs engaging each other in surface-to-surface engagement with clearances greater than <NUM> inch (<NUM>), and a second surface engaging the second rotational body to form a first surface pair of the plurality of surface pairs engaging each other in surface-to-surface engagement with clearances greater than <NUM> inch (<NUM>). The first distal bushing has a third surface engaging the first rotational body to form a third surface pair of the plurality of surface pairs engaging each other in surface-to-surface engagement with clearances greater than <NUM> inch (<NUM>), and a fourth surface engaging the second rotational body to form a fourth surface pair of the plurality of surface pairs engaging each other in surface-to-surface engagement with clearances greater than <NUM> inch (<NUM>). The first surface, the second surface, the third surface, and the fourth surface are polymer surfaces.

According to a further aspect, each of the polymer surfaces is formed of a polymer material having a durometer hardness of <NUM> Shore A to <NUM> Shore A. In one configuration, the polymer materials of all of the polymer surfaces are the same.

According to yet another aspect, the barbell also includes a third rotational body mounted on the second end portion of the bar, the third rotational body including a second sleeve having a second bore receiving the second end portion of the bar, and a second rotational engagement structure connecting the first rotational body to the third rotational body to permit the third rotational body to be freely rotatable with respect to the first rotational body. The first rotational body, the third rotational body, and the second rotational engagement structure have a second plurality of surface pairs engaging each other in surface-to-surface engagement with clearances greater than <NUM> inch (<NUM>), and wherein each of the second plurality of surface pairs engaging each other in surface-to-surface engagement with clearances greater than <NUM> inch (<NUM>) includes at least one polymer surface.

According to a still further aspect, the first rotational engagement structure includes a first rotor fixed to the first end portion of the bar and having a first cylindrical outer surface engaging an inner surface of the first bore to permit rotation of the second rotational body relative to the first rotational body. The first cylindrical outer surface and the inner surface of the first bore form a first surface pair of the plurality of surface pairs engaging each other in surface-to-surface engagement with clearances greater than <NUM> inch (<NUM>), and at least one of the first cylindrical outer surface and the inner surface of the first bore is a polymer surface.

Other aspects of the disclosure relate to a barbell that includes a bar having a first end portion and a second end portion, a first sleeve assembly including a first sleeve having a first axial bore with a first proximal bore portion, a first distal bore portion, and a first central bore portion extending between the first proximal bore portion and the first distal bore portion, a first proximal bushing received in the first proximal bore portion of the first sleeve and fixed against axial movement with respect to the first sleeve assembly, and a first rotor received in the first distal bore portion of the first sleeve and fixed against axial movement with respect to the first sleeve assembly, the first rotor fixed to the first end portion of the bar. The first end portion of the bar is received through the first axial bore and extends through the first proximal bore portion and the first central bore portion to the first distal bore portion. The first proximal bushing has a first axial passage receiving the bar therethrough and a first outer surface engaging the first sleeve and a first inner surface engaging the bar within the first axial passage. The first rotor has a cylindrical outer surface engaging the first sleeve, where the cylindrical outer surface is a polymer surface, and the first proximal bushing and the first rotor permit the first sleeve assembly to be freely rotatable around the bar and the first barrel.

Additional aspects of the disclosure relate to a barbell that includes a first rotational body including a bar having a first end portion and a second end portion, a first sleeve assembly including a first sleeve having a first axial bore with a first proximal bore portion and a first distal bore portion, a first proximal bushing received in the first proximal bore portion of the first sleeve, and a first distal bushing received in the first distal bore portion of the first sleeve and having a first cavity receiving a portion of the first rotational body located at the first end portion of the bar. The first end portion of the bar is received through the first axial bore and extends through the first proximal bore portion to the first distal bore portion. The first proximal bushing has a first axial passage receiving the bar therethrough and a first outer surface engaging the first sleeve and a first inner surface engaging the bar within the first axial passage. The first distal bushing has a second outer surface engaging the first sleeve and a second inner surface engaging the portion of the first rotational body within the first cavity. The first proximal bushing and the first distal bushing permit the first sleeve assembly to be freely rotatable around the first rotational body. At least one of the first outer surface and the first inner surface of the first proximal bushing and at least one of the second outer surface and the second inner surface of the first distal bushing are polymer surfaces.

Other aspects of the disclosure relate to a bushing that includes a cylindrical bushing body having cylindrical inner and outer surfaces, with the inner surface defining an axial passage through the bushing body, where the bushing body is configured to be inserted into a bore, and an engaging surface extending outward from the outer surface of the bushing body. The engaging surface is configured to be received within a groove in the bore when the bushing body is inserted into the bore, such that the engaging surface is configured to engage a surface of the groove to retain the bushing body within the bore.

According to one aspect, at least the inner surface and the outer surface are polymer surfaces. According to another aspect, the bushing is formed of a polymer material.

Other aspects of the disclosure relate to a bushing that includes a first bushing portion having a first cylindrical wall surrounding a first cavity, with a first annular flange extending inward from the first cylindrical wall to define a first axial passage, and a second bushing portion having a second cylindrical wall surrounding a second cavity, with a second annular flange extending inward from the second cylindrical wall to define a second axial passage. The second bushing portion is in abutting contact with the first bushing portion, such that the second bushing portion is positioned distally with respect to the first bushing portion, wherein the second annular flange is positioned at a distal end of the bushing, and the first annular flange is positioned at a proximal end of the bushing. The first cavity and the second cavity combine to define an inner cavity.

According to one aspect, the second bushing portion is identical to the first bushing portion and is positioned in reverse orientation relative to the first bushing portion.

According to another aspect, the bushing has an inner surface surrounding the cavity and an outer surface opposite the inner surface, and the inner surface and the outer surface are polymer surfaces. According to a further aspect, the bushing is formed of a polymer material.

Still other aspects of the disclosure relate to a method of assembling a barbell according to any configuration, aspect, or embodiment described above, including inserting a proximal bushing and/or a distal bushing into a bore of a sleeve, inserting a bar through the bore, and connecting the sleeve to the bar using a connecting structure, where the connecting structure and the proximal and/or distal bushings permit the bar to rotate with respect to the bar.

Other features and advantages of the disclosure will be apparent from the following description taken in conjunction with the attached drawings.

To allow for a more full understanding of the present disclosure, it will now be described by way of example, with reference to the accompanying drawings in which:.

While this invention is susceptible of embodiments in many different forms, there are shown in the drawings and will herein be described in detail example embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. In the following description of various example structures according to the invention, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example devices, systems, and environments in which aspects of the invention may be practiced. It is to be understood that other specific arrangements of parts, example devices, systems, and environments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention, which is defined by the appended set of claims.

General aspects of the present disclosure relate to a barbell that includes structures for reducing noise and vibration when the barbell is dropped from an elevated position. <FIG> illustrate one example embodiment of a barbell <NUM> according to aspects of the disclosure that includes a bar or bar member <NUM> having two opposed end portions <NUM>, <NUM> with first and second sleeve assemblies <NUM>, <NUM> positioned at the opposed end portions <NUM>, <NUM> of the bar <NUM>. The sleeve assemblies <NUM>, <NUM> each include a sleeve or sleeve member <NUM> configured to hold one or more weights <NUM> (see <FIG>), such as weight plates having a center hole configured to receive a portion of the sleeve <NUM> therethrough. Removable barbell collars <NUM> or other retaining devices may also be mounted on the sleeve assemblies <NUM>, <NUM> to hold the weight(s) <NUM> in place. The barbell <NUM> also includes a connection assembly <NUM> that connects the bar <NUM> to the sleeve assemblies <NUM>, <NUM> without any direct contact between the bar <NUM> and the sleeve <NUM> and without any metal parts directly contacting both the sleeve <NUM> and the bar <NUM>. As used in this application: the term "axial" refers to the direction along the elongated length of the bar <NUM>; the term "radial" refers to any direction perpendicular to the axial direction, e.g., along any radius of a cross-section of the bar <NUM> taken perpendicular to the axial direction; and the terms "proximal" and "distal" are relative terms referring to structures located toward the center of the bar <NUM> (proximal) or toward the ends of the bar <NUM> (distal), respectively, in the axial direction. These terms are intended for illustrative purposes only and do not limit the embodiments in any way.

The bar <NUM> has end portions <NUM>, <NUM> that are connected to the sleeve assemblies <NUM>, <NUM> and are received within the sleeves <NUM> of the sleeve assemblies <NUM>, <NUM>, as described in greater detail herein and a center portion <NUM> extending between the sleeve assemblies <NUM>, <NUM>. The bar <NUM> is configured for connection to fasteners <NUM> or other retaining members to the end portions <NUM>, <NUM>, and the bar <NUM> in <FIG> has cylindrical posts or projections <NUM> extending axially outward from the end portions <NUM>, <NUM> at the distal ends <NUM> of the bar <NUM>. Each of the projections <NUM> in this embodiment has a threaded portion <NUM> configured for connection to a threaded fastener <NUM>, as shown in <FIG> and <FIG>, but the projections <NUM> may have different connecting structure for connection to a different type of fastener or other retaining member (e.g., a retaining ring, a snap ring, a pin, a clip, etc.) in another embodiment. In a further embodiment, the fastener <NUM> may be a male fastener, such as a bolt, that extends into a female receiver on the bar <NUM> for connection, and the bar <NUM> may not include projections <NUM> in this configuration. The bar <NUM> in <FIG> further has cylindrical shoulders <NUM> extending axially outward from the end portions <NUM>, <NUM>, such that the projections <NUM> each extend outward from the shoulders <NUM>. The shoulders <NUM> have a peripheral dimension (e.g., diameter) and cross-sectional area that is larger than that of the end portions <NUM>, <NUM> of the bar <NUM> but smaller than that of the projections <NUM>. The shoulders <NUM> and the projections <NUM> in <FIG> are illustrated as being cylindrical with a circular outer periphery, but either or both of these structures may have a different peripheral shape in another embodiment. The bar <NUM> is generally formed of metal, and in the embodiment of <FIG>, the bar <NUM> is formed of a single piece of steel.

The center portion <NUM> and the end portions <NUM>, <NUM> of the bar <NUM> in this embodiment have a circular cross-section shape and a substantially constant diameter and cross-sectional area over the entire combined axial length of the center portion <NUM> and the end portions <NUM>, <NUM>. It is understood that the projections <NUM> in <FIG> have a smaller diameter and cross-sectional area, and in one embodiment, the projections <NUM> may have a non-circular peripheral shape. The center portion <NUM> may further include structures to enhance gripping of the bar <NUM>, such as knurling (not shown), and the bar <NUM> may be configured with or without knurling at the centermost portion of the bar <NUM>. The end portions <NUM>, <NUM> of the bar <NUM> in one embodiment have smooth outer surfaces to reduce friction on the outer surface. While the bar <NUM> is illustrated as a straight cylindrical member, it is understood that portions of the bar <NUM> may not be straight and/or cylindrical. For example, the bar <NUM> may include curves or bends or more complicated gripping structure, such as for use as a curl bar, a tricep bar, a deadlift bar, etc..

<FIG> illustrate the connection of the sleeve assemblies <NUM>, <NUM> to the bar <NUM> using the connection assembly <NUM>. It is noted that <FIG> illustrate only one of the sleeve assemblies <NUM> and the associated portions of the bar <NUM> and connection assembly <NUM>, with the understanding that the other sleeve assembly <NUM> is constructed in a similar or identical manner in this embodiment. Each of the sleeve assemblies <NUM>, <NUM> includes a sleeve <NUM> having an axial bore <NUM> with proximal and distal openings <NUM>, <NUM> and a removable end cap <NUM> configured to cover the distal opening <NUM> of the sleeve <NUM>. The bore <NUM> of each sleeve <NUM> is configured to receive one of the end portions <NUM>, <NUM> of the bar <NUM> therein, such that the end portions <NUM>, <NUM> enter the bore <NUM> of the respective sleeve <NUM> through the proximal opening <NUM>. Each sleeve assembly <NUM>, <NUM> also includes a collar <NUM> positioned at the proximal end of the sleeve <NUM>. The collar <NUM> has a larger width/diameter than the outer surface of the sleeve <NUM>, so the collar <NUM> can act as a stop to prevent any weights mounted on the sleeve <NUM> from sliding off of the sleeve <NUM> and onto the bar <NUM>. In the embodiment of <FIG>, the collar <NUM> is integrally connected to the sleeve <NUM> and provided as a single piece with the sleeve <NUM>. However, in another embodiment, the collar <NUM> may be separately connected to the sleeve <NUM> and/or the bar <NUM>. The sleeve <NUM> and the collar <NUM> are generally formed of metal, and in <FIG>, these parts are formed as a single piece of steel. The inner surface <NUM> of each sleeve <NUM> has a circumferentially positioned annular abutment surface <NUM> with a smaller width/diameter than the distal opening <NUM>, such that the end cap <NUM> is inserted into the bore <NUM> through the distal opening <NUM> and abuts the abutment surface <NUM>. An annular groove <NUM> is positioned adjacent the abutment surface that receives a C-shaped snap ring <NUM> to secure the end cap <NUM> to close the distal opening <NUM>. Each end cap <NUM> is a plate member formed of stamped steel with a cushion member <NUM> on the inner side, which may be a single-sided rubber tape in one embodiment.

In the embodiment of <FIG>, the minimum inner diameter ID1 of the bore <NUM> is defined by a central portion <NUM> of the bore <NUM> that extends over a majority of the axial length of the sleeve <NUM>. The minimum inner diameter ID1 of the passage <NUM> is greater than the maximum outer diameter OD of the end portions <NUM>, <NUM> of the bar <NUM>, such that the end portions <NUM>, <NUM> of the bar <NUM> are received in the passages <NUM> of the sleeve <NUM> without contacting the inner surface <NUM> at any point. The connection assembly <NUM> includes bushings and/or other spacing structures spacing the end portions <NUM>, <NUM> of the bar from the inner surface <NUM> of the sleeve <NUM>, and the inner surface <NUM> of the sleeve <NUM> includes structures for engaging components of the connection assembly <NUM>. Each connection assembly <NUM> includes at least a proximal bushing <NUM> engaging the sleeve <NUM> and the bar <NUM> at or proximate to the proximal opening <NUM> of the bore <NUM>, a barrel <NUM> fixedly connected to the distal end <NUM> of the bar <NUM> using a fastener <NUM> or other retaining structure, and a distal bushing <NUM> engaging the sleeve <NUM> and the barrel <NUM> at or proximate the distal end <NUM> of the bar <NUM>. All of these components of the connection assembly <NUM> are partially or entirely received in the bore <NUM> of the sleeve <NUM>. In another embodiment, either or both of the proximal bushing <NUM> and the distal bushing <NUM> may be replaced by a bearing or a bushing/bearing combination. If a bearing is used, the bearing may be partially encapsulated or lined with a polymer material as discussed herein.

The proximal bushing <NUM> in the embodiment of <FIG> is shown in greater detail in <FIG> and <FIG>. In this embodiment, the proximal bushing <NUM> has a bushing body <NUM> that is generally tubular with circular cylindrical outer and inner surfaces <NUM>, <NUM>, with the inner surface <NUM> defining an axial passage <NUM> extending through the bushing body <NUM> from a proximal end <NUM> to a distal end <NUM>. The proximal bushing <NUM> is positioned such that the outer surface <NUM> engages the inner surface <NUM> of the sleeve <NUM>, and one of the end portions <NUM>, <NUM> of the bar <NUM> passes through the passage <NUM> and engages the inner surface <NUM> of the proximal bushing <NUM>. The engagement between the proximal bushing <NUM> and the bar <NUM> is not fixed in the embodiment of <FIG>, and the inner surface <NUM> of the proximal bushing <NUM> is a smooth, low-friction surface such that the sleeve <NUM> and the proximal bushing <NUM> can rotate together freely and smoothly with respect to the bar <NUM>.

The proximal bushing <NUM> has an engaging surface <NUM> extending outward from the outer surface <NUM> proximate the distal end <NUM>, which is provided in the form of an annular shoulder in the embodiment of <FIG>. The proximal bushing <NUM> in the embodiment of <FIG> also has a ramped surface <NUM> located between the engaging surface <NUM> and the distal end <NUM>. The ramped surface <NUM> is arranged as an annular structure that is angled with respect to the axial direction AD and with respect to the outer surface <NUM> of the proximal bushing <NUM>. The sleeve <NUM> has a first bore portion or proximal bore portion <NUM> extending inwardly/distally from the proximal opening <NUM> of the sleeve <NUM>, having a larger inner width/diameter ID2 than the inner diameter ID1 of the central portion <NUM> (see <FIG>). The first bore portion <NUM> may be considered to be an annular recess with respect to the central portion <NUM> of the bore <NUM>. The proximal bushing <NUM> is received in the first bore portion <NUM>, which is dimensioned similarly to the outer surface <NUM> of the proximal bushing <NUM> to achieve tight engagement. The first bore portion <NUM> further has an engagement surface <NUM> that is defined by an annular groove <NUM> that is spaced inwardly/distally from the proximal opening <NUM>. When the proximal bushing <NUM> is received in the first bore portion <NUM>, the engaging surface <NUM> and the ramped surface <NUM> of the bushing <NUM> are received in the groove <NUM>, and the engaging surface <NUM> abuttingly engages the engagement surface <NUM> of the sleeve <NUM> to retain the bushing <NUM> within the recess <NUM>. The proximal bushing <NUM> may be inserted by pushing the distal end <NUM> of the bushing <NUM> into the proximal opening <NUM> of the sleeve <NUM>, and the ramped surface <NUM> assists in this insertion, such as by causing the bushing body <NUM> to flex slightly inwardly. The proximal opening <NUM> of the sleeve <NUM> may be beveled or chamfered in order to further assist this insertion, such as shown in <FIG>. Once inserted, the proximal end <NUM> of the proximal bushing <NUM> is exposed within the proximal opening <NUM> of the sleeve <NUM>. In other embodiments, the engaging surface <NUM> and/or the ramped surface <NUM> may have a different structure, such as an intermittent structure including a plurality of tabs, ridges, or shoulders extending outwardly from the outer surface <NUM>, and the engaging surface <NUM> may be positioned closer to or further from the distal end <NUM> and/or may not include the ramped surface <NUM>. It is understood that the engaging surface <NUM> of the proximal bushing <NUM> and the engagement surface <NUM> of the sleeve <NUM> may be transposed in a further embodiment, so that the sleeve <NUM> has a radially projecting tab or ridge that is received in a notch in the bushing <NUM>.

Additionally, in the embodiment of <FIG>, the axial passage <NUM> of the proximal bushing <NUM> has an inner diameter ID4 defined by the inner surface <NUM>, and the inner diameter ID4 is smaller than the inner diameter ID1 of the central portion <NUM>, as shown in <FIG>. In this configuration, one of the end portions <NUM>, <NUM> of the bar <NUM> engages the inner surface <NUM> of the proximal bushing <NUM> within the axial passage <NUM> but is spaced from the inner surface <NUM> of the sleeve <NUM> at the central portion <NUM>. The sleeve <NUM> in <FIG> is configured such that the distal end <NUM> of the first bore portion <NUM> is defined at the distal end of the groove <NUM>, and the bore <NUM> has a step change in diameter from the larger diameter of the groove <NUM> to the minimum inner diameter ID <NUM> defined at the central portion <NUM> of the bore <NUM>.

The barrel <NUM> is fixedly connected to the distal end <NUM> of the bar <NUM> using a fastener <NUM> in the embodiment of <FIG>, and the barrel <NUM> and fastener <NUM> in this embodiment are illustrated in greater detail in <FIG> and <FIG>. In general, the barrel <NUM> is configured to engage the distal end of the bar <NUM> and the distal bushing <NUM> to permit relative rotation between the bar <NUM> and the distal bushing <NUM>. In the embodiment of <FIG>, the barrel <NUM> fixedly engages the distal end <NUM> of the bar <NUM> and engages the distal bushing <NUM> in a manner that permits the barrel <NUM> and the bar <NUM> to rotate with respect to the distal bushing <NUM>, although this configuration may be different in other embodiments. For example, the connection between the bar <NUM> and the barrel <NUM> may permit the barrel <NUM> to rotate with respect to the bar <NUM>, such as by including a bearing or other structure to facilitate rotation. The fastener <NUM> is illustrated as a locking nut, but other fasteners may be used in other embodiments, and it is understood that the bar <NUM> and the fastener <NUM> may have complementary structures for connection. The barrel <NUM> in this embodiment has a cylindrical outer surface <NUM> and an axial passage <NUM> formed by a distal cavity <NUM> extending inward from the distal end <NUM>, a proximal cavity <NUM> extending inward from the proximal end <NUM>, and an aperture <NUM> extending between and connecting the proximal and distal cavities <NUM>, <NUM>. The aperture <NUM> is smaller in width/diameter than the distal cavity <NUM> and the proximal cavity <NUM>. Additionally, the distal cavity <NUM> has a larger width/diameter than the proximal cavity <NUM> to provide room for manipulation of the fastener <NUM>, but this structure may not be used in other embodiments. The barrel <NUM> is fixedly connected to the end portions <NUM>, <NUM> of the bar <NUM> by one of the projections <NUM> extending axially through the aperture <NUM> and into the distal cavity <NUM>, with the fastener <NUM> being positioned in the distal cavity <NUM> and connected to the projection <NUM>. In this configuration, the shoulder <NUM> of the bar <NUM> is received in the proximal cavity <NUM>, and the surfaces <NUM> of the distal end <NUM> of the bar <NUM> surrounding the shoulder <NUM> abut the end of the barrel <NUM>. Both the proximal and distal cavities <NUM>, <NUM> are cylindrical in the embodiment of <FIG>, and it is understood that the shape of the proximal cavity <NUM> may be configured to match the shape of the shoulder <NUM> of the bar <NUM> in order to resist relative movement of the barrel <NUM> and the bar <NUM>. The outer width/ diameter of the barrel <NUM> is greater than the width/diameter of the end portion <NUM>, <NUM> of the bar <NUM>, such that portions of the proximal end <NUM> of the barrel <NUM> extend radially outward of the bar <NUM>. In another embodiment, the bar <NUM> may not include the shoulder <NUM>, and the proximal cavity <NUM> may receive the distal end <NUM> of the bar <NUM>, or no proximal cavity <NUM> may be provided.

The distal bushing <NUM> engages the barrel <NUM> and the sleeve <NUM> from both axial directions in order to limit axial movement of the barrel <NUM> with respect to the sleeve <NUM>, and thereby limit axial movement of the sleeve <NUM> with respect to the bar <NUM>. The sleeve <NUM>, the distal bushing <NUM>, the barrel <NUM>, and the bar <NUM> in the embodiment of <FIG> may be fixed against axial movement by these structures. In the embodiment of <FIG>, the distal bushing <NUM> is formed of two separate bushing pieces or portions (also referred to as first and second bushing portions or proximal and distal bushing portions) <NUM>, <NUM> that are similar or identical to each other and abuttingly engage each other in the axial direction. In another embodiment, the distal bushing <NUM> may be a single piece or multiple pieces that are not identical to each other. The identical first and second bushing portions <NUM>, <NUM> are shown in greater detail in <FIG> and <FIG>. Each bushing portion <NUM>, <NUM> in the embodiment of <FIG> is a cup-shaped piece that includes a cylindrical wall <NUM> having a cylindrical outer surface <NUM> and a cylindrical inner surface <NUM> defining a cylindrical inner cavity <NUM> and a flange <NUM> positioned around an aperture <NUM> extending to the inner cavity <NUM>. The two bushing portions <NUM>, <NUM> are positioned so the ends of the cylindrical walls <NUM> face and abut each other and the inner cavities <NUM> are contiguous with each other to define a single cavity that receives the barrel <NUM>, with the bushing portions <NUM>, <NUM> thereby combining to form the distal bushing <NUM> that surrounds the barrel <NUM>. In this configuration, the inner surface <NUM> of the cylindrical wall <NUM> confronts and engages the outer surface <NUM> of the barrel <NUM>, and the flanges <NUM> of the bushing portions <NUM>, <NUM> abuttingly engage the distal and proximal ends <NUM>, <NUM> of the barrel <NUM>, such that axial and radial movement of the barrel <NUM> relative to the distal bushing <NUM> is limited. The barrel <NUM> and the distal bushing <NUM> may be fixed against relative axial and radial movement by this structure.

The end portion <NUM>, <NUM> of the bar <NUM> extends through the aperture <NUM> of the first bushing portion <NUM> to connect to the barrel <NUM>. The distal bushing <NUM> and the barrel <NUM> are not fixed against rotation relative to each other, and the barrel <NUM> can rotate together with the bar <NUM> within the cavities <NUM> of the distal bushing <NUM>. It is noted that the flanges <NUM> of the bushing portions <NUM>, <NUM> are formed as annular structures in the embodiment of <FIG>, and in other embodiments, one or both of the flanges <NUM> may be formed as a different structure that functions to abuttingly engage the distal and proximal ends <NUM>, <NUM> of the barrel <NUM>, including a plurality of intermittently spaced inwardly extending walls. It is understood that the first and second bushing portions <NUM>, <NUM> may not be identical to each other in another embodiment, and that the bushing portions <NUM>, <NUM> may be configured to match the shapes of the barrel <NUM> and/or adjacent portions of the sleeve <NUM>.

Additionally, in the embodiment of <FIG>, the diameter of the aperture <NUM> defined by the flange <NUM> of the first bushing portion <NUM> is smaller than the inner diameter ID1 of the central portion <NUM> of the bore <NUM>, as shown in <FIG>. In this configuration, the flange <NUM> of the first bushing portion <NUM> may engage the bar <NUM> or may be spaced from the bar <NUM>. If the flange <NUM> is spaced from the bar <NUM> around the aperture <NUM>, such space is smaller than the space between the bar <NUM> and the inner surface <NUM> of the sleeve <NUM> at the central portion <NUM> of the bore <NUM>.

In other embodiments, the barbell <NUM> may not include a barrel <NUM> that is separate from the bar <NUM> on one or both end portions <NUM>, <NUM>. For example, the bar <NUM> may include integrally formed barrels <NUM> or similar structures, or a combination of one integrally formed barrel <NUM> and one separate barrel <NUM> at the two end portions <NUM>, <NUM>. As another example, the distal bushing <NUM> may be configured to engage the bar <NUM> directly, and another structure (e.g., a retaining ring, split washer, end cap, etc.) may be used for axially fixing the bar <NUM> with respect to the sleeve <NUM>. Still further embodiments may be used, such as the embodiment of <FIG> disclosed herein.

The sleeve <NUM> has a second bore portion or distal bore portion <NUM> extending inwardly/proximally from the distal opening <NUM> of the sleeve <NUM>, having a larger inner width/diameter ID3 than the inner diameter ID <NUM> of the central bore portion <NUM> (see <FIG>). The second bore portion <NUM> may be considered to be an annular recess with respect to the central portion <NUM> of the bore <NUM>. The distal bushing <NUM> and the barrel <NUM> are received in the second bore portion <NUM>, which is dimensioned similarly to the outer surface <NUM> of the distal bushing <NUM> to limit radial movement of the distal bushing <NUM> with respect to the sleeve <NUM> and/or to fix the distal bushing <NUM> against radial movement with respect to the sleeve <NUM>. An abutment surface <NUM> is positioned at the proximal end of the second bore portion <NUM>, and in this embodiment, the abutment surface <NUM> is formed as a shoulder that creates a change in diameter between the second bore portion <NUM> and the central bore portion <NUM>. The abutment surface <NUM> abuts the first bushing portion <NUM> at the proximal end of distal bushing <NUM>, e.g., at the end of the cylindrical wall <NUM> and/or the outer surface of the flange <NUM>. The sleeve assembly <NUM>, <NUM> also includes a retaining member to abut the second bushing portion <NUM> at the distal end of the distal bushing <NUM>, and the retaining member in the embodiment of <FIG> is a C-shaped snap ring <NUM> that is received in an annular groove <NUM>. The abutment surface <NUM> and the snap ring <NUM> abuttingly engage the proximal and distal ends of the distal bushing <NUM> to limit axial movement of the distal bushing <NUM> with respect to the sleeve <NUM>. In the embodiment of <FIG>, these structures fix the distal bushing <NUM> against axial movement with respect to the sleeve <NUM>, which thereby fixes the barrel <NUM> and the bar <NUM> against axial movement with respect to the sleeve <NUM>. In this configuration, the entire axial load between the bar <NUM> and the sleeves <NUM> is exerted on the barrel <NUM> and the distal bushing <NUM>. The distal bushing <NUM> in <FIG> permits the sleeve <NUM> to be rotatable relative to the barrel <NUM> and the bar <NUM>, which are fixed against rotation with respect to each other. The inner and outer surfaces <NUM>, <NUM> of the distal bushing <NUM> are smooth, low-friction surfaces such that the sleeve <NUM> can rotate freely and smoothly with respect to the bar <NUM> and the barrel <NUM>, and both the sleeve <NUM> and the barrel <NUM> are rotatable with respect to the distal bushing <NUM>. In another embodiment, the distal bushing <NUM> may be fixed against rotation with respect to either the barrel <NUM> or the sleeve <NUM>, such that the distal bushing <NUM> rotates together with either the sleeve <NUM> or the barrel <NUM>.

In an example embodiment, the proximal bushings <NUM> and the bushing portions <NUM>, <NUM> of the distal bushings <NUM> are all made from polymer materials, which includes pure and mixed polymer materials, as well as polymer-matrix composite materials. These components may be manufactured using any of a variety of techniques or combinations of such techniques, including molding, casting, thermoforming, extrusion, machining, etc. The proximal bushings <NUM> and the bushing portions <NUM>, <NUM> may all be made from the same polymer material, or some or all of these components may be made from different polymer materials, in various embodiments. The polymer material may be selected based on desirable properties, including strength, durability, low friction properties (e.g., coefficient of friction), and vibration/sound absorption or damping properties. In one embodiment, the polymer material may have a durometer hardness of <NUM> Shore A to <NUM> Shore A. One example of a suitable material that provides advantageous performance in this application is a urethane or polyurethane material. Other polymer materials may provide suitable and/or advantageous performance as well. Further, one or more surfaces of the barbell <NUM>, including the inner and outer surfaces <NUM>, <NUM> of the portions <NUM>, <NUM> of the distal bushings <NUM>, the inner surfaces <NUM> of the proximal bushings <NUM>, the outer surface <NUM> of the barrel <NUM>, and/or the outer surfaces of the end portions <NUM>, <NUM> of the bar <NUM>, may have a lubricant applied thereto in order to further reduce friction during rotation of the sleeves <NUM> with respect to the bar <NUM>. The polymer material(s) of the bushings <NUM>, <NUM> may be selected for lubricity properties and compatibility with potential lubricants, in such a configuration.

It is understood that the polymer bushings <NUM>, <NUM> may have inserts, cores, or other internal components or portions made from other materials, such as metal, in one embodiment. For example, either or both of the bushings <NUM>, <NUM> and/or components thereof may be made from metal pieces coated with a polymer material on one or more surfaces, e.g., a polymer piece with a metal core. Such bushings <NUM>, <NUM> and/or components thereof are still considered to be formed of a polymer material as discussed herein. The advantages described herein are achieved in part by configuring the barbell so that, for each pair of surfaces of the barbell <NUM> that engage each other (particularly in moveable engagement) with clearances that are greater than or equal to a specific threshold, at least one of the pair of surfaces is a polymer surface, i.e., a surface formed of a polymer material. The specific threshold may be at least <NUM> inch (<NUM>) in one embodiment, or <NUM> inch (<NUM>) in another embodiment. In the embodiment of <FIG>, the pairs of surfaces that engage each other with clearances of at least <NUM>" (<NUM>) include at least the following: the outer surface <NUM> of the proximal bushing <NUM> and the inner surface <NUM> of the sleeve <NUM>; the inner surface <NUM> of the proximal bushing <NUM> and the bar <NUM>; the outer surface <NUM> of the distal bushing <NUM> and the inner surface <NUM> of the sleeve <NUM>; the inner surface <NUM> of the distal bushing <NUM> and the outer surface <NUM> of the barrel <NUM>; the abutment surface <NUM> and the proximal end of the distal bushing <NUM>; the snap ring <NUM> and the distal end of the distal bushing <NUM>; the distal flange <NUM> of the distal bushing <NUM> and the distal end <NUM> of the barrel <NUM>; the proximal flange <NUM> of the distal bushing <NUM> and the proximal end <NUM> of the barrel <NUM>; and the abutting surfaces of the first and second bushing portions <NUM>, <NUM> of the distal bushing <NUM>. In one embodiment, each of these pairs of surfaces includes at least one polymer surface. This can be accomplished, in one embodiment, by having all outer surfaces of the proximal and distal bushings <NUM>, <NUM> formed of a polymer material.

In the embodiment of <FIG>, at least the outer and/or inner surfaces <NUM>, <NUM>, <NUM>, <NUM> of the bushings <NUM>, <NUM> are polymer surfaces (i.e., the surfaces that engage the bar <NUM>, the barrel <NUM>, and/or the sleeve <NUM>). This configuration avoids metal-on-metal contact between the bar <NUM>, the barrel <NUM>, the sleeve <NUM>, and other connecting and retaining structures, as disclosed herein. Thus, the bushings <NUM>, <NUM> may have at least their outer and/or inner surfaces <NUM>, <NUM>, <NUM>, <NUM>, or any other surfaces that engage metallic components such as the bar <NUM>, the barrel <NUM>, the sleeve <NUM>, and/or the snap rings <NUM>, formed of a polymer material. Portions of a metallic insert or core may be exposed in one or more locations, which may be a location that does not engage other metallic components, e.g., the bar <NUM>, the barrel <NUM>, the sleeve <NUM>, the snap rings <NUM>, etc. In another embodiment, the bushings <NUM>, <NUM> may have a polymer material on only one surface, such as the inner surface engaging the bar <NUM> or barrel <NUM>, to avoid metal-on-metal contact between the bushings <NUM>, <NUM> and the bar <NUM> or barrel <NUM>. For example, one or more of the bushings <NUM>, <NUM> may have a metal outer surface that is interference fit within the bore <NUM> (a fixed connection with a clearance of less than <NUM>" (<NUM>) and an inner polymer layer for contacting the bar <NUM>, the barrel <NUM>, or other portions that rotate within the bushings <NUM>, <NUM>. In a further embodiment, a portion of the bar <NUM> and/or the end portions <NUM>, <NUM> thereof, may be coated in a polymer material instead of, or in addition to, the bushings <NUM>, <NUM> being formed of polymer materials as described herein.

It is also understood that components described herein as being formed of a polymer material, e.g., the bushings <NUM>, <NUM> and/or components thereof, may be formed of different polymer materials. Accordingly, components described herein as being "formed of a polymer material" may be considered to be formed of one or more polymer materials, such that a first component is formed of a first polymer material, a second component is formed of a second polymer material, etc., which materials may be the same or different.

In the configuration shown in <FIG> and described above, the barbell <NUM> includes a first rotational body <NUM> that includes the bar <NUM>, the barrels <NUM>, and the fasteners <NUM>, a second rotational body <NUM> that includes the first sleeve assembly <NUM> (i.e., the sleeve <NUM> and the end cap <NUM>), and a third rotational body <NUM> that includes the second sleeve assembly <NUM>, where all three of the rotational bodies <NUM>, <NUM>, <NUM> are freely rotatable relative to each other. The three rotational bodies <NUM>, <NUM>, <NUM> are fixed or limited in axial and radial movement with respect to each other in one embodiment, such as using the connection assemblies <NUM> described herein. The second and third rotational bodies <NUM>, <NUM> are configured to support weights <NUM>. Additionally, the second and third rotational bodies <NUM>, <NUM> are connected to the first rotational body <NUM> such that there is no metal-on-metal contact between the first rotational body <NUM> and the second and third rotational bodies <NUM>, <NUM>. The connection assembly <NUM> of the barbell <NUM> may also include a first rotational engagement structure <NUM> engaging the first rotational body <NUM> and the second rotational body <NUM> and a second rotational engagement structure <NUM> engaging the first rotational body <NUM> and the third rotational body <NUM>. The first rotational engagement structure <NUM> constitutes all structures and components engaging both the first rotational body <NUM> and the second rotational body <NUM>, and this engagement is configured to connect the first rotational body <NUM> and the second rotational body <NUM> and to permit rotation of the second rotational body <NUM> with respect to the first rotational body <NUM>. The second rotational engagement structure <NUM> constitutes all structures and components engaging both the first rotational body <NUM> and the third rotational body <NUM>, and this engagement is configured to connect the first rotational body <NUM> and the third rotational body <NUM> and to permit rotation of the third rotational body <NUM> with respect to the first rotational body <NUM>. In this configuration, the surfaces of the rotational engagement structures <NUM> that engage at least one of the first rotational body <NUM>, the second rotational body <NUM>, and/or the third rotational body <NUM> may be polymer surfaces formed of a polymer material as described herein. In particular, any surfaces of the rotational engagement structures <NUM> that moveably engage at least one of the first rotational body <NUM>, the second rotational body <NUM>, and/or the third rotational body <NUM> may be polymer surfaces formed of a polymer material as described herein.

In the embodiment of <FIG>, each of the second and third rotational bodies <NUM>, <NUM> is separated from the first rotational body <NUM> by the respective proximal bushing <NUM> and distal bushing <NUM>, which are made from a polymer material as described herein. The proximal and distal bushings <NUM>, <NUM> in this embodiment permit free rotation of the rotational bodies <NUM>, <NUM>, <NUM>. In this configuration, the proximal bushings <NUM> form proximal portions of the first and second rotational engagement structures <NUM>, and the distal bushings <NUM> form distal portions of the first and second rotational engagement structures <NUM>. The engagement of the proximal and distal bushings <NUM>, <NUM> with the first, second, and third rotational bodies <NUM>, <NUM>, <NUM> also fixes the second and third rotational bodies <NUM>, <NUM> against axial and radial movement with respect to the first rotational body <NUM>. In this configuration, the metal components of the first, second, and third rotational bodies <NUM>, <NUM>, <NUM> are therefore fixed against axial and radial movement with respect to each other by polymer components (e.g., the bushings <NUM>, <NUM>). It is understood that components that are "fixed against" movement (such as axial or radial movement) with respect to each other as described herein may include some small clearance for slight movement. For example, as described herein, such a clearance may be at least <NUM>" (<NUM>) or <NUM>" (<NUM>).

To assemble the barbell <NUM> in the embodiment of <FIG>, the proximal bushings <NUM> are first inserted into the proximal openings <NUM> of the sleeves <NUM> and are locked into the first bore portions <NUM> by engagement between the engaging surfaces <NUM> of the proximal bushings <NUM> and the engagement surfaces <NUM> of the sleeves <NUM>. The end portions <NUM>, <NUM> of the bar <NUM> are inserted into the bores <NUM> of the sleeves <NUM>, through the proximal bushings <NUM>, so that the distal ends <NUM> of the bar <NUM> extend into the second bore portions <NUM> of the sleeves <NUM>. The first bushing portions <NUM> are then inserted into the second bore portions <NUM> through the distal openings <NUM> of the sleeves <NUM> such that the end portions <NUM>, <NUM> of the bar <NUM> are received through the apertures <NUM>. The barrels <NUM> are then inserted into the cavities <NUM> of the first bushing portions <NUM> such that the projection <NUM> of each end portion <NUM>, <NUM> is received through the aperture <NUM> of the respective barrel <NUM>, and the fasteners <NUM> are connected to the projections <NUM>. The second bushing portions <NUM> are then inserted into the second bore portions <NUM> through the distal openings <NUM> of the sleeves <NUM>, and the snap rings <NUM> are inserted into the annular grooves <NUM> to lock the distal bushings <NUM> and the barrels <NUM> in place. Assembly may be simplified by inserting first bushing portion <NUM>, the barrel <NUM>, and the second bushing portion <NUM> into the second bore portions <NUM> and locking the components in place axially via the snap rings <NUM> prior to inserting the end portion <NUM>, <NUM> of the bar <NUM> into the bore <NUM> of the respective sleeve <NUM>. The fastener <NUM> can then be inserted through the aperture <NUM> of the respective second bushing portion <NUM> and connected to the respective projection <NUM>. The end caps <NUM> are then inserted into the bores <NUM> through the distal opening <NUM> such that the cushion members <NUM> and abut the abutment surfaces <NUM>, and the snap rings <NUM> are inserted into the annular grooves <NUM> to secure the end cap <NUM> to close the distal opening <NUM>. Removal or disassembly of these components can be accomplished by reversing the steps discussed above. Removal of the proximal bushings <NUM> may be accomplished, for example, by prizing out with an appropriate tool (e.g., a flat head screwdriver), cutting and then removing, or exerting force on the distal end <NUM>.

<FIG> illustrates another embodiment of a barbell <NUM> according to aspects of the disclosure that includes a bar or bar member <NUM> having two opposed end portions <NUM>, <NUM> with first and second sleeve assemblies <NUM>, <NUM> positioned at the opposed end portions <NUM>, <NUM> of the bar <NUM>. The barbell <NUM> of <FIG> is similar or identical to the barbell <NUM> in <FIG>, and similar reference numbers are used in <FIG> to reference such similar components, which may not be described again in detail for the sake of brevity. The barbell <NUM> of <FIG> differs from the barbell <NUM> of <FIG> in that the barbell <NUM> of <FIG> does not include a barrel <NUM> and distal bushing <NUM>. Instead, each sleeve assembly <NUM>, <NUM> in <FIG> includes a rotor <NUM> fixedly connected to the distal end <NUM> of the bar <NUM> using a fastener <NUM> or other retaining structure. The rotor <NUM> has a cylindrical outer surface <NUM> and an axial passage <NUM> formed by a distal cavity <NUM> extending inward from the distal end <NUM>, a proximal cavity <NUM> extending inward from the proximal end <NUM>, and an aperture <NUM> extending between and connecting the proximal and distal cavities <NUM>, <NUM>. The aperture <NUM> is smaller in width/diameter than the distal cavity <NUM> and the proximal cavity <NUM>. Additionally, the distal cavity <NUM> has a larger width/diameter than the proximal cavity <NUM> to provide room for manipulation of the fastener <NUM>, but this structure may not be used in other embodiments. The rotor <NUM> is fixedly connected to the end portions <NUM>, <NUM> of the bar <NUM> by one of the projections <NUM> extending axially through the aperture <NUM> and into the distal cavity <NUM>, with the fastener <NUM> being positioned in the distal cavity <NUM> and connected to the projection <NUM>. In this configuration, the abutment surface <NUM> and the snap ring <NUM> abuttingly engage the proximal and distal ends of the rotor <NUM> to limit axial movement of the rotor <NUM> with respect to the sleeve <NUM>, thereby fixing the sleeve <NUM> against axial movement with respect to the bar <NUM>. The rotor <NUM> is rotatable with respect to the sleeve <NUM> within the distal bore portion <NUM> to permit rotation of the sleeve <NUM> with respect to the bar <NUM>. The rotor <NUM> in this configuration may be considered to be a distal portion of the first and/or second rotational engagement structure <NUM> as described herein. In one embodiment, the rotor <NUM> may be formed of a polymer material as described herein. For example, at least the cylindrical outer surface <NUM> and any other surfaces of the rotor <NUM> contacting metal components of the sleeve assembly <NUM>, <NUM>, e.g., the abutment surface <NUM>, the snap ring <NUM>, and the inner surface <NUM> of the sleeve <NUM>, may be formed of a polymer material. In one embodiment, the portion of the rotor <NUM> connecting to the bar <NUM> may be formed of a metal material, with a polymer portion connected to the metal portion (e.g., by coating, molding, etc.), such that the polymer portion forms all surfaces that engage the sleeve <NUM> or other structures (e.g., the snap ring <NUM>). In another embodiment, the entire rotor <NUM> may be formed of a polymer material, or at least all outer surfaces of the rotor <NUM> are polymer surfaces (e.g., having a metal core). The barbell <NUM> of <FIG> may include any other components and features described herein, including alternate embodiments. Assembly of the barbell <NUM> in <FIG> may be accomplished substantially as described above, but without insertion of the distal bushings, and the rotor being.

<FIG> illustrates another embodiment of a barbell <NUM> that is identical to the barbell <NUM> of <FIG>, with a sound absorbing material <NUM> positioned within an open space in the bore <NUM> of the sleeve <NUM>. In this embodiment, the sound absorbing material <NUM> is positioned within the central portion <NUM> of the bore <NUM>, between the bar <NUM> and the inner surface <NUM> of the sleeve <NUM>. In this position, the sound absorbing material <NUM> may have a thickness that is sufficiently small to fit in the space provided and to not unduly interfere with rotation of the sleeve <NUM>, e.g., <NUM>/<NUM> inch (<NUM>). The sound absorbing material <NUM> may extend over a portion of the distance, or substantially the entire distance, between the proximal and distal bushings <NUM>, <NUM>. In other embodiments, the sound absorbing material <NUM> may be additionally or alternately positioned within other open spaces within the bore <NUM>, e.g., proximate the distal opening <NUM>. The sound absorbing material <NUM> may be, for example, a rubber or neoprene material, a foam material, a batting material, or other materials that serve to damp and/or absorb sound. In various embodiments, the sound absorbing material <NUM> may be connected to either the sleeve <NUM> or the bar <NUM> (or another structure), or may be loose within the open space. In one embodiment, the sound absorbing material <NUM> may only contact one of the bar <NUM> or the sleeve <NUM>, in order to reduce friction.

Various embodiments of barbells and components thereof have been described herein, which include various components and features. In other embodiments, the barbell may be provided with any combination of such components and features. It is also understood that in other embodiments, the various devices, components, and features of the barbell described herein may be constructed with similar structural and functional elements having different configurations, including different ornamental appearances.

The barbells and components thereof described herein provide benefits and advantages over existing barbells. For example, the barbells <NUM> shown in <FIG> exhibit significantly smaller noise emission and vibration when dropped from an elevated position onto a variety of different surfaces, as compared to existing barbells. For example, the barbell <NUM> shown in <FIG> has exhibited at least a <NUM> dB reduction in sound volume as compared to existing barbells that include metal-on-metal contact between rotational bodies, when dropped from a fixed, consistent height with equal loading. When combined with the frequency of sound emission from dropping a loaded barbell from an elevated position, the barbell <NUM> of <FIG> creates a perception of a <NUM>% reduction in noise. It is contemplated that the barbell <NUM> in <FIG> may produce similar performance. It is also contemplated that this vastly improved performance is due to the use of polymeric bushings and/or polymer surfaces, and the resultant lack of metal-on-metal contact. This benefit is particularly advantageous in smaller gyms located in residential areas, where the sound of dropping weights throughout the day may disturb residents. Additionally, the barbell structures described herein provide good durability and product life, and bushings or other components can be easily replaced if they are damaged. Further, the low friction surfaces provided by the bushings allow free rotation of the sleeve assemblies (and any weights mounted thereon) with respect to the bar, providing superior performance. It is contemplated that the use of low friction polymer structures (i.e., the bushing portions <NUM>, <NUM> of the distal bushing) to axially locate the sleeves with respect to the bar reduce friction and resistance against rotation of the sleeves with respect to the bar. Still further, the construction of the barbell permits the bushings <NUM>, <NUM> to be removed, interchanged, or replaced easily and quickly with simple tools, providing a consumer the ability to perform these actions at home. The consumer would also be able to interchange bushings with other bushings made of other materials with different properties (e.g., hardness, noise/vibration damping, lubricity, friction, color/design, etc.) as desired by the consumer to "tune" or customize performance or appearance of the barbell, such as spin, noise/vibration damping, appearance, etc. The use of a sound absorbing material <NUM> as described herein may further reduce the noise produced when the barbell <NUM> is dropped. Still other benefits and advantages are recognized by those skilled in the art.

Claim 1:
A barbell (<NUM>) comprising:
a bar (<NUM>) having a first end portion (<NUM>) and a second end portion (<NUM>);
a first sleeve assembly (<NUM>) comprising a first sleeve (<NUM>) having a first axial bore (<NUM>) with a first proximal bore portion (<NUM>), a first distal bore portion (<NUM>), and a first central bore portion (<NUM>) extending between the first proximal bore portion and the first distal bore portion, wherein the first end portion (<NUM>) of the bar is received through the first axial bore and extends through the first proximal bore portion and the first central bore portion to the first distal bore portion;
a first proximal bushing (<NUM>) received in the first proximal bore portion of the first sleeve and fixed against axial movement with respect to the first sleeve assembly, the first proximal bushing having a first axial passage (<NUM>) receiving the bar therethrough, wherein the first proximal bushing has a first outer surface (<NUM>) engaging the first sleeve and a first inner surface (<NUM>) engaging the bar within the first axial passage;
a first distal bushing (<NUM>) received in the first distal bore portion of the first sleeve and fixed against axial movement with respect to the first sleeve assembly, the first distal bushing having a first cavity; and
a first barrel (<NUM>) fixed to the first end portion of the bar, the first barrel having a cylindrical outer shape and received within the first cavity of the first distal bushing, wherein the first barrel is both axially and rotationally fixed to the bar,
wherein the first distal bushing has a second outer surface (<NUM>) engaging the first sleeve and a second inner surface (<NUM>) engaging the first barrel within the first cavity,
wherein the first proximal bushing and the first distal bushing permit the first sleeve assembly to be freely rotatable around the bar and the first barrel, and
wherein the first outer surface and the first inner surface, the second outer surface, and the second inner surface are polymer surfaces.