US20260021337A1

US20260021337A1 - Plate for weight training

Info

Publication number: US20260021337A1
Application number: US19/272,811
Authority: US
Inventors: Matthew David Noble; Sharon Park
Original assignee: 511 Inc
Current assignee: 511 Inc
Priority date: 2024-07-17
Filing date: 2025-07-17
Publication date: 2026-01-22
Also published as: WO2026020030A1

Abstract

A weighted plate system can include a molded panel including an array of compartments defining recesses on a first side of the molded panel and projections on a second side of the molded panel. The projections can be separated by channels that include at least a first channel and a second channel having longest dimensions extending non-parallel to one another. A set of weighted inserts can be sized for receipt in the recesses of the compartments. A cap layer can be sized to overlay the molded panel and enclose the set of weighted inserts within the compartments.

Description

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application claims the benefit of and priority to U.S. Provisional Application No. 63/672,586, filed Jul. 17, 2024, which is hereby incorporated by reference in is entirety for all purposes.

BACKGROUND OF THE INVENTION

Weighted plates are often used in exercising. In various scenarios, weighted plates are worn along the torso of a wearer, such as within a plate carrier that may be in the form factor of a vest and include panel pockets on front and rear for receiving weighted plates. Wearing a weighted plate (e.g., within a plate carrier) can allow an exerciser to include additional weight beyond body weight, and switching between different weights of weighted plate can allow adjustments to intensity of a workout. However, as weight is increased, volume of weighted plates tends to increase to accommodate added material to provide the added weight. Weighted plates accordingly are often bulky, so an exerciser using available weighted plates may encounter challenges related to restricted range of motion or other limitations of mobility or comfort in use.

BRIEF SUMMARY OF THE INVENTION

The following presents a simplified summary of some embodiments of the present disclosure in order to provide a basic understanding of the invention. This summary is not an extensive overview of the invention. It is not intended to identify key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some embodiments of the invention in a simplified form as a prelude to the more detailed description that is presented later.
In various embodiments, provided may be a weighted plate assembly. The weighted plate assembly may include a set of metal weighted inserts. The assembly may include a molded foam panel extending in a height direction, a width direction, and a depth direction. The molded foam panel may be defining a main body extending in the depth direction between a first reference face and a second reference face. The molded foam panel may be further defining an array of compartments each including a recess extending inwardly from the first reference face and each at least partially bounded by a projection extending outwardly from the second reference face. The set of metal weighted inserts may be received within the array of compartments. The projections may be separated by flexure channels. The flexure channels may include at least one vertical flexure channel having a longest dimension extending along the height direction so as to facilitate flexure of the molded foam panel about the height direction. The flexure channels may include at least one horizontal flexure channel having a longest dimension along the width direction so as to facilitate flexure of the molded foam panel about the width direction. The assembly may include a cap layer coupled with the molded foam panel and arranged so as to enclose the set of metal weighted inserts within the compartments of the molded foam panel.
In some embodiments, the weighted plate assembly may include a fabric skin layer form-fitted over the projections and into the flexure channels. The cap layer may include or may be covered by a fabric backing layer. The cap layer may include a foam board sandwiched between the molded foam panel and a fabric backing layer. The weighted plate assembly may include an edge binding included along boundaries of the molded foam panel and the cap layer. The array of compartments may include compartments having differing peripheral shapes from one another. The set of metal weighted inserts may be shaped to match the differing peripheral shapes. The at least one vertical flexure channel may include a central vertical flexure channel. The array of compartments may be symmetric from one side of the central vertical flexure channel to an opposite side of the central vertical flexure channel. The at least one horizontal flexure channel may include a middle horizontal flexure channel. The array of compartments may be asymmetric from one side of the middle horizontal flexure channel to an opposite side of the middle horizontal flexure channel. The weighted plate assembly may include stitching extending through at least some of the flexure channels so as to secure the molded foam panel with the cap layer. The weighted plate assembly may include a fabric skin layer arranged over the molded foam panel so as to obscure the stitching from view.
In various embodiments, provided may be a weighted plate system. The weighted plate system may include a molded panel including an array of compartments defining recesses on a first side of the molded panel and projections on a second side of the molded panel. The projections may be separated by channels that include at least a first channel and a second channel having longest dimensions extending non-parallel to one another. The system may include a set of weighted inserts sized for receipt in the recesses of the compartments. The system may include a cap layer sized to overlay the molded panel and enclose the set of weighted inserts within the compartments.
In some embodiments, the weighted inserts may be formed from a material having a higher density than the molded panel. The recesses may extend inward from a reference face of the molded panel. An overall depth of the molded panel relative to the reference face may be greater along the projections than along the channels. The weighted plate system may include a set of fasteners arranged for receiving straps to form the weighted plate system into a vest or other form factor for disposing along a body of a wearer for use. The molded panel may include a foam material; the set of weighted inserts may include a metal material; and/or the cap layer may include at least one of a foam material or a fabric material.
In various embodiments, provided may be a method of preparing a weighted plate assembly. The method may include accessing a molded panel including an array of compartments defining recesses on a first side of the molded panel and projections on a second side of the molded panel. The projections may be separated by channels that include at least a first channel and a second channel having longest dimensions extending non-parallel to one another. The method may include inserting a set of weighted inserts into the recesses of the compartments. The method may include securing a cap layer to the molded panel in a position enclosing the set of weighted inserts within the compartments.
In some embodiments, the securing may include stitching the cap layer to the molded panel with stitching in at least one of the channels. Inserting the set of weighted inserts may include inserting weights into less than all of the recesses. Inserting the set of weighted inserts may include inserting a selected number of slices into one of the recesses in accordance with a target weight for the weighted plate assembly. At least one spacing insert having a density at least five times less than one of the weighted inserts may be inserted into at least one of the recesses.
For a fuller understanding of the nature and advantages of the present invention, reference should be made to the ensuing detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments in accordance with the present disclosure will be described with reference to the drawings, in which:

FIG. 1 illustrates a perspective view of a weighted plate in accordance with various embodiments;

FIG. 2 illustrates an exploded view showing examples of parts that may be incorporated into the plate of FIG. 1 ; and

FIG. 3 illustrates a side cross-sectional view showing the plate of FIG. 1 in an assembled state along with examples of inserts that may be included in accordance with various embodiments;

FIG. 4 illustrates an end view and a lateral side view of an example of the plate of FIG. 1 in differing flexed states in accordance with various embodiments;

FIG. 5 is a front view illustrating an example in which the plate of FIG. 1 can be received for use within a carrier;

FIG. 6 is a perspective view illustrating examples of components that may be utilized to facilitate wearing of the plate of FIG. 1 in accordance with various embodiments;

FIG. 6A is a detail view showing an example of a construction for securing a fastener-bearing tab of the plate of FIG. 1 in accordance with various embodiments; and

FIG. 7 is a perspective view showing an example arrangement of the plate of FIG. 1 held by straps in a position of being worn along a body of a wearer in accordance with various embodiments.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, various embodiments will be described. For purposes of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the embodiments. However, it will also be apparent to one skilled in the art that the embodiments may be practiced without the specific details. Furthermore, well-known features may be omitted or simplified in order not to obscure the embodiment being described.
Reference will now be made to the drawings. It can be understood that the drawings may include ornamental and aesthetic design features as aspects of the present disclosure. While some views of the ornamental and aesthetic are shown in the drawings, further orthogonal, perspective, and cross-sectional views can be logically extrapolated and supported by these drawings. Such ornamental and aesthetic design can be appreciated as separate from, integrated with, or existing parallel to the functionality of the overall disclosure; however, the ornamental appearances shown in the drawings is not a design solely or primarily driven or dominated by the function of the disclosure. Indeed, particular contours, boundaries, or other aspects of the drawings shown herein may have no relevance or contribution to the ornamental and aesthetic design of the disclosure.
Like reference numerals refer to like elements throughout the drawings. In many instances, similar elements may be identified by the same reference numeral and differentiated by a different letter suffix in the drawings. Thus, in the following text description, elements may be referenced with suffixes (e.g., for referencing individual or specific elements such as a first channel 105A or a second channel 105B) or without suffixes (e.g., for generally or collectively referencing elements such as one or more of the channels 105). Moreover, to avoid obscuring features in the figures, leadlines from reference numerals may reach to less than all possible examples, such that it may be understood that some other depicted features may correspond to an example of a feature denoted by a reference numeral even if no explicit leadline is present between the numeral and the depicted feature(s).
FIG. 1 illustrates a plate 101, e.g., which may correspond to a weighted plate. The plate 101 can include compartments 103. The compartments 103 may correspond to weight compartments that may be suitable for holding weight, e.g., holding parts that are relatively heavier than other portions of the plate 101. Channels 105 may be defined between and/or among the compartments 103. The channels 105 may be flexure channels, for example. The channels 105 may allow the plate 101 to be flexible in use, such as being able to bend or flex away from an at-rest configuration in response to load or force application and exhibiting suitable resilience to return to the at-rest configuration upon cessation of the load. The channels 105 may correspond to areas in which an overall depth or thickness of the whole plate 101 is less than in areas that include the compartments 103. Overall, bending and/or flexing may be facilitated by the presence of the channels 105 and/or along axes 107, e.g., which may be defined by the channels 105. In operation, bending and/or flexing of the plate 101 may enable the plate 101 to better conform to the body of a user during use and/or may facilitate better range of motion and/or mobility than if the plate were all a uniform thickness and/or constructed of a block of rigid material.
The plate 101 may include various subcomponents. Some examples of suitable subcomponents are described further with respect to FIG. 2 .
FIG. 2 illustrates an exploded view showing examples of parts that may be incorporated into the plate 101. The plate 101 may be formed as a weighted plate assembly 109, which may include various constituent subcomponents. Parts of the plate 101 may be defined and/or extend in one or more of a height direction 111, a width direction 113, and/or a depth direction 115. The plate 101 may be fabricated and/or prepared by a process that may include operations and/or components described herein, although operations may be performed in different orders and/or other components, operations, and/or variations may be utilized.
Preparation of the plate 101 may include accessing a molded panel 117. The molded panel 117 may be formed to define a mold that may receive other components of the plate 101, for example. The molded panel 117 may function as a core relative to which other parts are added to form the plate 101. The molded panel 117 may be a molded foam panel or may otherwise be formed with a material of suitable workability, flexibility, resilience, and/or durability to provide the features described herein. The molded panel 117 may be constructed from ethylene-vinyl acetate (EVA) foam, for example. Additionally or alternatively, the molded panel 117 may be constructed at least in part from a rigid or semi-rigid material. In various embodiments, the molded panel 117 may be fabricated by a compression-molding process.
The molded panel 117 may define a main body 119. The main body 119 may extend in the depth direction 115 between a first reference face 121 and a second reference face 123. The first reference face 121 and the second reference face 123 may face away from each other on opposite sides of the main body 119 of the molded panel 117. For example, the first reference face 121 may correspond to a proximal or body-facing side arranged to face toward a body of a wearer in use, while the second reference face 123 may correspond to a distal or outward-facing side arranged to face away from a body of a wearer in use. A forward or backward orientation may depend along which portion of the body the plate 101 is worn in use. For example, when worn along a wearer's back, the first reference face 121 may be positioned to face forward, while the second reference face 123 may be positioned to face backward. If the plate is rotated along the height direction and worn along a wearer's chest or front, the first reference face 121 may be positioned to face backward, while the second reference face 123 may be positioned to face forward.
The main body 119 may be generally rectangular (e.g., when viewed in a plane of the width direction 113 and the height direction 111). An upper margin 120 of the main body 119 may narrow in the width direction 113 proceeding toward a top of the main body 119. Such narrowing in the width direction 113 near a top of the main body 119 may allow a top of the plate 101 to be received near a base of a wearer's neck along a front or rear of the wearer's body while avoiding substantial impingement at a wearer's shoulders on either side of the upper margin 120 of the plate 101.
The molded panel 117 may correspond to a receptacle layer or may otherwise include structure that may form (or may be formed by) features of the compartments 103. The compartments 103 may define indentations or recesses 125 on a first side of the molded panel 117 and bumps or projections 127 on a second side of the molded panel 117. For example, each compartment 103 may include a recess 125 extending inwardly from the first reference face 121. Each compartment 103 further may be each at least partially bounded by a projection 127 extending outwardly from the second reference face 123. For example, for a given compartment 103, the recess 125 may form an inner cavity within the corresponding projection 127, and/or an inner surface of the projection 127 may define chamber boundaries of the recess 125.
As may be best seen by way of example with reference back to FIG. 1 , the projections 127 extending from the second reference face 123 may be separated by the channels 105. The plate 101 in FIG. 1 is depicted with examples of different orientations of channels 105 and corresponding axes 107. A vertical channel 105A is shown with a longest dimension aligned along a vertical axis 107A, while various horizontal channels 105B are shown with longest dimensions aligned along horizontal axes 107B, and diagonal channels 105C are shown with longest dimensions along axes 107C that extend at least partially horizontally and at least partially vertically. As may be appreciated, the channels 105 may be arranged such that at least some have longest dimensions extending along axes 107 that are non-parallel to one another (e.g., which may facilitate flexing of the plate 101 in differing directions). As one example, the projections 127 in FIG. 1 are shown separated by channels 105 that include at least one vertical channel 105A (e.g., having a longest dimension along an axis 107A extending along the height direction 111 so as to facilitate flexure of the molded panel 117 about the height direction 111) and at least one horizontal channel 105B (e.g., having a longest dimension along an axis 107B extending along the width direction 113 so as to facilitate flexure of the molded panel 117 about the width direction 113). Although the vertical channel 105A and horizontal channels 105B are depicted as being perpendicular to each other, other relative non-parallel arrangements may be implemented.
The compartments 103 can be arranged to form an array. The array may include at least two columns and at least two rows. The width and/or number of columns may vary along the plate 101. For example, as shown in FIG. 1 , in a top-down progression, the width of the columns may start with an initial width near the top and may expand to a greater width while progressing downward (e.g., until reaching a transition at which the narrowed upper margin 120 reaches a full width of the plate 101). As another example, the width of the columns may narrow while progressing downward (e.g., while progressing from a lower extent of the narrowed upper margin 120 toward a lowest extremity of the plate 101 in the height direction 111). As a further example, the number of the columns may increase while progressing downward. For example, FIG. 1 shows an arrangement that progresses from two columns at a top of the plate 101 and at a lower extent of the narrowed upper margin 120, while progressing to four columns while progressing toward a lowest extremity of the plate 101 in the height direction 111. Although the rows are shown with a generally uniform height, variation may be included across the rows. Furthermore, although five rows are shown, fewer or more may be included.
More generally, although a particular number and relative arrangement of features is shown in FIG. 1 , other suitable numbers and/or relative arrangements of these or other features described herein may be utilized. As one example, although some projections 127 in FIG. 1 in the lower lateral edges of the bottom rows are shown with wedge-like form factors that involve a tapered or slanted face sloped in the depth direction 115 and others of the projections 127 are shown with form factors that involve a substantially flat or plateau-like surface spaced apart from base surfaces of the channels 105, any form of wedge-like or plateau-like or other type of form factor may be utilized for any of the projections 127. Additionally, although all of the projections 127 depicted in FIG. 1 have matching recesses 125 depicted in FIG. 2 , some projections 127 may be provided with an interior volume fully occupied and/or some recesses 125 may be provided without having corresponding projections 127 present on an opposite face (e.g., some projections 127 and/or recesses 125 may be included without forming a compartment 103 in some examples).
In some embodiments, the recesses 125, the projections 127, and/or compartments 103 can be arranged to exhibit particular symmetry or asymmetry. As one example, FIG. 1 shows an arrangement in which the vertical channel 105A is centrally located (e.g., forming a central vertical channel 105A) and the array of compartments 103 is symmetric from one side of the central vertical channel 105A to an opposite side of the central vertical channel 105A. As another example, FIG. 1 also shows an arrangement in which at least one of the horizontal channels 105B includes a middle horizontal channel 105B and the array of compartments 103 is asymmetric from one side of the middle horizontal channel 105B to an opposite side of the middle horizontal channel 105B.
As may be best seen with reference back FIG. 2 , preparation of the plate 101 may include accessing a set of weighted inserts 129 suitable for installation into the recesses 125 of the compartments 103. The set of weighted inserts 129 may be sized for receipt in the recesses 125, for example. The weighted inserts 129 may correspond to slugs or pieces of steel, other metal, ceramic, and/or other materials suitable for imparting weight to the plate 101. In various embodiments, the weighted inserts 129 may be formed from a material having a higher density than the molded panel 117. In some examples, the weighted inserts 129 have a density at least five times (or at least ten times) the density of the molded panel 117. As an illustrative example, the molded panel 117 may be constructed from EVA foam having a density of 0.1, 0.05, 0.98, or otherwise less than 1 gram per cubic centimeter, while the weighted inserts 129 may be formed of steel having a density of 7.85 or more grams per cubic centimeter.
Preparation of the plate 101 may include inserting the set of weighted inserts 129 into the recesses 125 of the compartments 103. The weighted inserts 129 may be shaped according to shapes of the compartments 103. For example, the compartments 103 may include compartments 103 having differing peripheral shapes from one another, and the set of weighted inserts 129 may be shaped to match the differing peripheral shapes. The peripheral shapes may correspond to a footprint, planform, or cross-sectional shape in a plane defined in the height direction 111 and the width direction 113, for example. The peripheral shapes may vary and narrow in width in a progression descending and/or ascending from a widest part of a shape of the plate 101, for example. The peripheral shapes may be imparted through any suitable technique, including, but not limited to casting, laser-cutting, or water-jet cutting.
Preparation of the plate 101 may include accessing a cap layer 131. The cap layer 131 may be sized as a cover to overlay the molded panel 117 and enclose the set of weighted inserts 129 within the compartments 103. For example, the cap layer 131 may form a wall of the compartments 103 in use. The cap layer 131 may include a material with suitable properties to act as a padding or backer board with sufficient rigidity to retain the weighted inserts 129 within the compartments 103. Material in the cap layer 131 may exhibit sufficient compressibility to form fit against the weighted inserts 129 and hold the weighted inserts 129 in place within the compartments 103 in use. The cap layer 131 may include a foam material, which may be different or similar to a material selection for the molded panel 117. The cap layer 131 may include closed-cell foam, for example. The cap layer 131 may additionally or alternatively include fabric or other material. Although the cap layer 131 is depicted as a single continuous layer sized for covering all of the recesses 125 of the compartments 103, the cap layer 131 (and/or any other layers described herein) alternatively may be formed of physically distinct or separate sub-portions used together in or out of contact with each other.
Preparation of the plate 101 may include accessing a backing layer 133. The backing layer 133 may correspond to an outermost layer that may be arranged to face toward a torso or body of a wearer in use. The backing layer 133 may include material that may provide suitable tactile and/or aesthetic qualities, such as a texture suitable for use against skin that may not be fully covered by other garments along a torso of a wearer during use. The backing layer 133 may include polyester, nylon, and/or other fabric, for example.
Preparation of the plate 101 may include accessing a skin layer 135. The skin layer 135 may correspond to an outermost layer that may be arranged to face away from a torso or body of a wearer in use. The skin layer 135 may include material that may provide suitable tactile and/or aesthetic qualities, such as a texture suitable for contacting arms or hands that may come into incidental contact across a front of the wearer during use. The skin layer 135 may include material with suitable flexibility and/or formability for molding over the projections 127 of the compartments 103 and/or into the channels 105 or otherwise along the second reference face 123 of the molded panel 117. The skin layer 135 may include elastane, blends (such as polyester-elastane), or other fabric, for example.
Preparation of the plate 101 may include accessing an edge binding 137 or other closure. The edge binding 137 may be suitably sized for placement along a rim of the plate 101. For example, the edge binding 137 may be of a suitable length to extend along an outer periphery of the plate 101. The edge binding 137 may correspond to webbing or other fabric, for example. The edge binding 137 may function as a closure to hold other parts together, such as holding the molded panel 117 with the cap layer 131 to retain weighted inserts 129 within the compartments 103. Additionally or alternatively, the edge binding 137 may be supplemented with or replaced with a zipper, magnets, snaps, hook and loop fasteners, and/or another form of closure (e.g., which may allow the cap layer 131 to be readily releasably detachable and attachable, such as to enable varying a configuration of weighted inserts 129 within the compartments 103).
Generally, accessed components may be combined together to form the plate. For example, structures depicted independently in FIG. 2 are also shown in an example of a combined state in FIG. 3 .
FIG. 3 depicts a side cross-sectional view of an assembled plate 101. The view of FIG. 3 may correspond to a view taken along line 3-3 in FIG. 1 , for example.
In use, the skin layer 135 may be form-fitted over the projections 127 and/or into the channels 105. For example, the skin layer 135 may extend outwardly along the projections 127 and/or inwardly along the channels 105.
The weighted inserts 129 may be positioned within the compartments 103 of the molded panel 117. The cap layer 131 may be arranged along the molded panel 117 so as to enclose the set of weighted inserts 129 within the compartments 103. The cap layer 131 may be coupled with the molded panel 117 to remain in position enclosing the weighted inserts 129.
The cap layer 131 may include or may be covered by the backing layer 133. For example, the cap layer 131 may include a foam board that is sandwiched between the molded panel 117 and the backing layer 133.
Preparation of the plate 101 may include securing the cap layer 131 to the molded panel 117 in a position enclosing the set of weighted inserts 129 within the compartments 103. The cap layer 131 may be secured in a position shown in FIG. 3 , for example.
More generally, preparation of the plate 101 may include arranging suitable structure to hold or secure parts of the plate 101 together. As one example, the edge binding 137 may be included along boundaries of the molded panel 117 and the cap layer 131. For example, the edge binding 137 may be arranged extending over boundaries of the molded panel 117 and the cap layer 131 and/or over boundaries of other layers (such as the backing layer 133 and/or the skin layer 135) that may contain or enclose the molded panel 117 and the cap layer 131. The edge binding 137 may be correspond to an elongate member that has been folded and/or doubled about its longitudinal axis to form a U-shape or may be otherwise arranged to form a trough that may receive edges of other layers to hold layers together. In use, the edge binding 137 may provide a finished edge of the plate 101.
Additionally or alternatively parts of the plate 101 may be secured together by stitching 139. For ease of viewing, stitching 139 in FIG. 3 is depicted as lines extending fully through and beyond outer bounds of the stack of all layers of the plate 101, although stitching 139 in use may extend through fewer than all layers and/or may be arranged to not extend appreciably beyond outer bounds of the combined layers.
Stitching 139 may extend through the edge binding 137. For example, stitching 139 extending through the edge binding 137 may secure edges of layers received within the edge binding 137 and/or may provide and/or secure a finished edge of the plate 101.
Stitching 139 may extend through at least one of the channels 105. Stitching 139 in the channels 105 may contribute to provision of a hinge line, fold line, or other bending interface that may facilitate flexing or bending of the plate 101 about axes 107 (FIG. 1 ) in use, for example.
Stitching 139 may extend through a suitable combination of layers. In some embodiments, the stitching 139 may extend at least through the molded panel 117 and the cap layer 131. In some embodiments, the stitching 139 may be visible from an exterior of the plate. For example, the stitching 139 may extend through the backing layer 133 and/or the skin layer 135 (e.g., so as to be visible from an exterior of the plate 101, such as in in FIG. 5 and FIG. 7 ). In some embodiments, the stitching 139 is not visible or is obscured from view from at least one side of the plate 101. For example, the backing layer 133 and/or the skin layer 135 may be applied after stitching 139 is applied to the molded panel 117 and the cap layer 131 (e.g., such that the backing layer 133 and/or the skin layer 135 may obscure the stitching 139 from view from at least one side of the plate 101, such as in FIG. 1 or FIG. 6 ).
Stitching 139 is not limited to the depicted arrangements. For example, arrangements of the plate 101 depicted without stitching 139 may have stitching 139 added. Furthermore, arrangements of the plate 101 depicted with stitching may be provided with different stitching 139 or without stitching. Stitching 139 may be provided in differing patterns than depicted, such as to accomplish functional and/or aesthetic purposes.
Other techniques and/or components additionally or alternatively may be utilized for holding or securing parts of the plate 101 together. In some examples, adhesive may be used to hold the skin layer 135 along the molded panel 117 and/or among other parts described herein. Other forms of chemical and/or mechanical bonding may also be utilized.
The plate 101 may be prepared to provide different options of weight configurations and/or overall weight. In some embodiments, different form factors of the plate 101 may be utilized to facilitate different weight options. As one example that may be appreciated by way of example with respect to FIG. 3 , one plate 101 may be provided with projections 127 extending a first distance 141 in the depth direction 115, while another plate 101 may be provided with projections 127 extending a second distance 143 that may be larger than the first distance 141 in the depth direction 115, e.g., to afford larger weight inserts 129 and thus an overall larger aggregate weight for the plate 101. As an illustrative example, approximately 12 millimeters for the first distance 141 may facilitate a plate 101 having an overall weight of 5.75 pounds, while 16 millimeters for the second distance 143 may facilitate a plate 101 having an overall weight of 8.75 pounds, although different sizes and/or weight options may be utilized.
In some embodiments, the weight of the plate 101 may be adjustable according to contents introduced or not introduced into the recesses 125 of the compartments 103. Various examples are represented relative to a bottom recess 125 depicted as empty in FIG. 3 , e.g., which may be subject to introduction of different options of contents, such as depicted by arrow 145.
Preparation of the plate 101 may include inserting weighted inserts 129 into less than all of the recesses 125. For example, in FIG. 3 , the plate 101 may be finalized with an empty space and/or without any weighted insert 129 in the bottom recess 124 (and/or in one or more others).
Preparation of the plate 101 may include use of spacing inserts 147. Spacing inserts 147 may be similar in volume, shape, and/or other size compared to weighted inserts 129. However, spacing inserts 147 may exhibit lower density than weighted inserts. Thus, some spacing inserts 147 may be used in place of some weighted inserts 129 to allow for fine control of aggregate weight of the plate 101. In some examples, spacing inserts may be formed of material that may five times (or ten times or more) less dense than material of the weighted inserts 129. For example, such ratios may be achieved by forming the spacing inserts 147 from foams described for the molded panel or cap layer 131 or other suitable materials.
Preparation of the plate 101 may include slices 149. The slices 149 may include slices 149A of weighted inserts 129 and/or slices 149B of spacing inserts 147. Each slice 149 may individually occupy less than a full depth of a recess 125 and may be combined with other slices 149 to collectively occupy a full depth of a recess 125. Preparation of the plate 101 may thus include inserting a selected number of slices 149 into one of the recesses 125 in accordance with a target weight for the plate 101. For example, a group of all slices 149A of weighted inserts 129 (e.g., as shown second from top at left in FIG. 3 ) may be used when a heavier weight is targeted, a group of all slices 149B of spacing inserts 147 (e.g., as shown fourth from top at left in FIG. 3 ) may be utilized when a lower weight is targeted, and/or a combination of slices 149A of weighted inserts 129 and slices 149B of spacing inserts 147 (e.g., as shown third from top at left in FIG. 3 ) may be used when an intermediate weight is targeted.
FIG. 4 illustrates an end view 151A and a lateral side view 151B of an example of a plate in differing flexed states in accordance with various embodiments. In the end view 151A (e.g., which may correspond to a top or bottom view), the plate 101 has been subjected to forces for folding about a vertical axis 107A, which has imparted deflection away from a laterally extending reference plane 153 (e.g., which may be aligned along the width direction 113) by a lateral deflection angle 155 (which may correspond to a rearward or forward deflection, for example). Construction of the plate 101 may enable the plate 101 to readily deflect through a lateral deflection angle 155 of up to 15 or 20 degrees without permanent deformation and return afterward to a baseline configuration in use. However, other degrees of flexure around a vertical axis 107A may be achieved, and increased degrees of flexure may be achieved by increasing a number and/or width of vertical channels 105A.
In the lateral side view 151B (e.g., which may correspond to a left or right view), the plate 101 has been subjected to forces for folding about various horizontal axes 107B, which has imparted deflection away from a vertically extending reference plane 157 (e.g., which may be aligned along the height direction 111) by a vertical deflection angle 159 (which may correspond to a rearward or forward deflection, for example). The vertical deflection angle 159 may include components 159A and 159B that build upon each other as each representing an incremental amount of further deflection beyond deflection permitted or facilitated by a sequentially adjacent horizontal axis 107B. Construction of the plate 101 may enable the plate 101 to readily deflect through an overall vertical deflection angle 159 of up to 35 or 45 degrees without permanent deformation and return afterward to a baseline configuration in use. However, other degrees of flexure around any suitable horizontal axis 107B may be achieved, and adjusted degrees of flexure may be achieved by adjusting a number and/or height of horizontal channels 105B.
Overall, flexure enabled by the plate 101 can be helpful for allowing the plate 101 to be conforming in use. The flexure of the plate 101 may facilitate a more agile and comfortable fit for a wearer during high intensity workouts, such as in environments described further with respect to FIGS. 5 and 6 , for example.
FIG. 5 is a front view illustrating an example in which the plate 101 can be received for use within a carrier 161. The carrier 161 may have a form factor of a vest, for example. The carrier 161 may include a panel pocket 163, which may be held on the front or rear of a body of a wearer by one or more shoulder straps 165 and/or cummerbund portions 167. In use, the plate 101 may be inserted into the panel pocket 163 (e.g., as depicted by arrow 169) and allowed to conform against the torso of the wearer, such as while the wearer is twisting or bending during exercise.
FIG. 6 is a perspective view illustrating examples of components that may be utilized to facilitate wearing of the plate 101. The plate 101 may be accompanied by straps 171 that may be utilized to attach the plate 101 with another instance of the plate 101 and/or for disposing the plate 101 along a body of a wearer for use. The straps 171 may facilitate use of the plate 101 as a stand-alone piece of equipment during exercise without a separate carrier 161, for example.
Fasteners 173 may be implemented to provide suitable structure for connecting with and/or securing the straps 171. The fasteners 173 are depicted as rings 175 borne by tabs 177 in FIG. 6 , although buckles, hooks, loops, snaps, or other forms of connector or fastener may be utilized. The tab 177 may extend from the plate 101 and support the fastener 173 to permit some degree of freedom of movement of the fastener 173 to facilitate manipulation for engaging the fastener 173 with the strap 171 (such as by passing the strap 171 through the ring 175). The tab 177 may secure the fastener 173 to the plate 101 while allowing the fastener 173 to be positioned alongside a projection 127 of a compartment 103 or at another suitable location for engagement with the strap 171, for example.
FIG. 6A is a detail view showing an example of a construction for securing the tab 177. The tab 177 include a portion captured underneath the edge binding 137. Additionally or alternatively, the tab 177 may be secured by stitching 139. The stitching is shown extending through the edge binding 137, the tab 177, the molded panel 117, and the cap layer 131, although the stitching 139 may extend through any suitable combination of these and/or other layers described herein.
FIG. 7 depicts the plate 101 held by straps 171 in a position of being worn along a body of a wearer. The fasteners 173 may be provided in a set arranged for receiving straps 171 to form the weighted plate 101 into a vest or other form factor for disposing along a body of a wearer for use. The straps 171 may be secured by the fasteners 173 so that some of the straps 171 extend over shoulders similar to shoulder straps 165 of the carrier 161 and/or along sides of the wearer similar to cummerbund portions 167 of the carrier 161.
Based on the disclosure and teachings provided herein, a person of ordinary skill in the art will appreciate other ways and/or methods to implement the various embodiments. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. It will, however, be evident that various modifications and changes may be made thereunto without departing from the broader spirit and scope of the disclosure as set forth in the claims.
Other variations are within the spirit of the present disclosure. Thus, while the disclosed techniques are susceptible to various modifications and alternative constructions, certain illustrated embodiments thereof are shown in the drawings and have been described above in detail. It should be understood, however, that there is no intention to limit the disclosure to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the disclosure, as defined in the appended claims.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the disclosed embodiments (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The term “connected” is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure.
Disjunctive language such as the phrase “at least one of X, Y, or Z,” unless specifically stated otherwise, is intended to be understood within the context as used in general to present that an item, term, etc., may be either X, Y, or Z, or any combination thereof (e.g., X, Y, and/or Z). Thus, such disjunctive language is not generally intended to, and should not, imply that certain embodiments require at least one of X, at least one of Y, or at least one of Z to each be present.
Preferred embodiments of this disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate and the inventors intend for the disclosure to be practiced otherwise than as specifically described herein. Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.
All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

Claims

What is claimed is:

1. A weighted plate assembly, comprising:

a set of metal weighted inserts;

a molded foam panel extending in a height direction, a width direction, and a depth direction, the molded foam panel defining a main body extending in the depth direction between a first reference face and a second reference face, the molded foam panel further defining an array of compartments each including a recess extending inwardly from the first reference face and each at least partially bounded by a projection extending outwardly from the second reference face, wherein the set of metal weighted inserts are received within the array of compartments, wherein the projections are separated by flexure channels, wherein the flexure channels include at least one vertical flexure channel having a longest dimension extending along the height direction so as to facilitate flexure of the molded foam panel about the height direction, wherein the flexure channels include at least one horizontal flexure channel having a longest dimension along the width direction so as to facilitate flexure of the molded foam panel about the width direction; and

a cap layer coupled with the molded foam panel and arranged so as to enclose the set of metal weighted inserts within the compartments of the molded foam panel.

2. The weighted plate assembly of claim 1, further comprising a fabric skin layer form-fitted over the projections and into the flexure channels.

3. The weighted plate assembly of claim 1, wherein the cap layer includes or is covered by a fabric backing layer.

4. The weighted plate assembly of claim 1, wherein the cap layer comprises a foam board sandwiched between the molded foam panel and a fabric backing layer.

5. The weighted plate assembly of claim 1, further comprising an edge binding included along boundaries of the molded foam panel and the cap layer.

6. The weighted plate assembly of claim 1, wherein the array of compartments comprises compartments having differing peripheral shapes from one another and the set of metal weighted inserts are shaped to match the differing peripheral shapes.

7. The weighted plate assembly of claim 1, wherein the at least one vertical flexure channel comprises a central vertical flexure channel and the array of compartments is symmetric from one side of the central vertical flexure channel to an opposite side of the central vertical flexure channel.

8. The weighted plate assembly of claim 1, wherein the at least one horizontal flexure channel comprises a middle horizontal flexure channel and the array of compartments is asymmetric from one side of the middle horizontal flexure channel to an opposite side of the middle horizontal flexure channel.

9. The weighted plate assembly of claim 1, further comprising stitching extending through at least some of the flexure channels so as to secure the molded foam panel with the cap layer.

10. The weighted plate assembly of claim 9, further comprising a fabric skin layer arranged over the molded foam panel so as to obscure the stitching from view.

11. A weighted plate system, comprising:

a molded panel including an array of compartments defining recesses on a first side of the molded panel and projections on a second side of the molded panel, wherein the projections are separated by channels that include at least a first channel and a second channel having longest dimensions extending non-parallel to one another;

a set of weighted inserts sized for receipt in the recesses of the compartments; and

a cap layer sized to overlay the molded panel and enclose the set of weighted inserts within the compartments.

12. The weighted plate system of claim 11, wherein the weighted inserts are formed from a material having a higher density than the molded panel.

13. The weighted plate system of claim 11, wherein the recesses extend inward from a reference face of the molded panel, and wherein an overall depth of the molded panel relative to the reference face is greater along the projections than along the channels.

14. The weighted plate system of claim 11, further comprising a set of fasteners arranged for receiving straps to form the weighted plate system into a vest or other form factor for disposing along a body of a wearer for use.

15. The weighted plate system of claim 11, wherein at least one of:

the molded panel comprises a foam material;

the set of weighted inserts comprises a metal material; or

the cap layer comprises at least one of a foam material or a fabric material.

16. A method of preparing a weighted plate assembly, the method comprising:

accessing a molded panel including an array of compartments defining recesses on a first side of the molded panel and projections on a second side of the molded panel, wherein the projections are separated by channels that include at least a first channel and a second channel having longest dimensions extending non-parallel to one another;

inserting a set of weighted inserts into the recesses of the compartments; and

securing a cap layer to the molded panel in a position enclosing the set of weighted inserts within the compartments.

17. The method of claim 16, wherein the securing comprising stitching the cap layer to the molded panel with stitching in at least one of the channels.

18. The method of claim 16, wherein inserting the set of weighted inserts comprises inserting weights into less than all of the recesses.

19. The method of claim 16, wherein inserting the set of weighted inserts comprises inserting a selected number of slices into one of the recesses in accordance with a target weight for the weighted plate assembly.

20. The method of claim 16, wherein at least one spacing insert having a density at least five times less than one of the weighted inserts is inserted into at least one of the recesses.