Fitness machine, handle for fitness machine and method for manufacturing fitness machine and handle

Abstract

A method of manufacturing a fitness machine. The method includes providing a base device with which an operator can perform exercises, and providing handles, each having a non-conductive portion and a conductive portion, the conductive portions being electroplated. The method further includes coupling the handles to the base device for the operator to grasp during exercise, and electrically coupling the conductive portion of each handle to a control system configured to determine cardiac information of the operator, where the conductive portion of each handle receives electrical activity from the operator when the operator grabs, and where the conductive portion of each handle is electrically coupled to the control system. The conductive portions are electrically coupled such that electrical activity is provided to the control system to determine cardiac information of the operator based on the electrical activity.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Patent Application No. 18 / 450,923, filed on August 16, 2023, which claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 399,093, filed on August 18, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure generally relates to an exercise machine, a handle for an exercise machine, and methods of making the exercise machine and the handle. Background Art

[0004] The following is incorporated herein by reference in its entirety.

[0005] U.S. Patent No. 5,365,934 discloses an exercise device for measuring heart rate, the exercise device having a sensor for generating a signal, the signal including a biopotential signal generated by the heart. The signal is filtered, amplified, and digitized. A computer automatically correlates the digitized signal. Then, multiple signal indication routines scan the autocorrelation output to detect the presence of a periodic signal. Each signal indication routine uses a different search or filtering criterion, such as peak and waveform detection, and generates one (and in some cases, several) candidate heart rates. Certain embodiments are particularly suitable for measuring the heart rate of a user while exercising on a stair climber or treadmill.

[0006] US Patent No. 6,783,482 discloses a microprocessor-based sports treadmill control system that includes various functions to enhance user operation.

[0007] Examples of treadmills are described in U.S. Patent Nos. 4,635,928; 4,659,074; 4,664,371; 4,334,676; 4,635,927; 4,643,418; 4,749,181; 4,614,337; 6,095,951; and 6,572,512 and U.S. Patent Application Publication No. 2021 / 0283465. Examples of elliptical trainers are shown in U.S. Patent Nos. 7,101,316; 7,435,202; and 8,021,274. Other examples of exercise equipment are shown in U.S. Patent Nos. 6,203,474; 6,533,709; 7,052,439; 7,267,635; and 9,216,317. Summary of the invention

[0008] This Summary is provided to introduce a selection of concepts that are further described below in the Detailed Description. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to help limit the scope of the underlying subject matter.

[0009] One aspect of the present disclosure generally relates to a method of manufacturing a fitness machine. The method includes providing a base device on which an operator can perform exercises, and providing handles, each handle having a non-conductive portion and a conductive portion, the conductive portion being electroplated. The method also includes coupling the handles to the base device so that they can be gripped by the operator during exercise, and electrically coupling the conductive portion of each of the handles to a control system, the control system being configured to determine cardiac information of the operator, wherein the conductive portion of each of the handles receives electrical activity from the operator when the operator grips, and wherein the conductive portions are electrically coupled so that the electrical activity is provided to the control system to determine cardiac information of the operator based on the electrical activity.

[0010] In some examples, the method further includes forming each of the handles via dual shot injection molding, wherein a first shot in the dual shot injection molding includes a first material that forms the non-conductive portion, and wherein a second shot in the dual shot injection molding includes a second material that defines a shape of the conductive portion, whereby the conductive portion is plated on the second material. In further examples, the first material is incompatible with an electroplating process, while the second material is compatible with an electroplating process, and the method further includes performing an electroplating process on each of the handles to form the conductive portion on the second material of each handle.

[0011] In some examples, the conductive portion includes a first conductive portion and a second conductive portion formed in two non-continuous regions, wherein each of the handles has a first component and a second component, each of the first component and the second component has a non-conductive portion, a first conductive portion, and a second conductive portion, wherein the first region of the two non-continuous regions is formed on the first component and the second region of the two non-continuous regions is formed on the second component, and the method further includes: for each of the handles, coupling the first component to the second component such that the non-conductive portion electrically insulates the first conductive portion and the second conductive portion from each other. In a further example, the method further includes forming the non-conductive portion of the first component and the second component of each handle via bi-shot injection molding, wherein the first shot and the second shot of the bi-shot injection molding include first and second materials that are different from each other, wherein when the first component and the second component are coupled together, the non-conductive portion of each handle has an outer side facing outward and an inner side facing inward, and wherein, for the first component and the second component of each handle, the outer side of the first material is completely covered by the second material.

[0012] In some examples, the conductive portion includes a first conductive portion and a second conductive portion formed in two non-continuous areas, wherein, for each of the handles, each of the two non-continuous areas extends between an outer portion configured to be contacted by an operator in use and an inner portion fixed within one of the handles, and the method further includes: for each of the handles, electrically coupling the control system to the inner portion of the two non-continuous areas via a conductor so that the conductor is protected within the handle. In a further example, the conductor includes a connector for connecting a wire, and the method further includes: electrically coupling the control system to the two non-continuous areas by pulling the connector into contact with the inner portion of the two non-continuous areas via a fastener.

[0013] In some examples, the method also includes forming each of the handles of a first material via injection molding, wherein the first material is compatible with an electroplating process, the method further includes: masking the first material so that each of the handles covers a masked portion of the first material, and performing an electroplating process on each of the handles to form a conductive portion on an unmasked remaining portion of the first material, wherein the masked portion forms a non-conductive portion of the handle.

[0014] In some examples, the method further includes coupling the handles so that the handles are at least partially recessed into the base device. In further examples, each of the handles includes an outer surface configured to be contacted by an operator during use, and the method further includes coupling each of the handles to the base device so that the outer surface is flush with the base device.

[0015] In some examples, the method further includes: for each of the handles, forming a conductive portion having a thickness less than 0.10 mm.

[0016] Another aspect of the present invention generally relates to a handle for an exercise machine produced via an electroplating process. The handle includes a component having a first material compatible with the electroplating process. A masked portion of the component is substantially free of plating from the electroplating process. The plated portion formed via the electroplating process is present in the remainder of the component such that the first material is covered by plating in the plated portion. The masked portion forms a non-conductive portion of the handle, while the plated portion forms a conductive portion of the handle that is configured to conduct electrical activity from an operator of the exercise machine contacting the conductive portion of the handle during use of the exercise machine.

[0017] Another aspect of the present disclosure generally relates to a fitness machine configured to determine cardiac information of an operator. The fitness machine includes a base device on which an operator can perform exercises. Each handle is coupled to the base device and is configured to be gripped by the operator during exercise, wherein each of the handles includes a non-conductive portion and a conductive portion, and wherein, for each of the handles, the conductive portion is electroplated. A control system is electrically coupled to the conductive portion of each of the handles so that the control system receives electrical activity from the operator through the conductive portion, wherein the control system is configured to determine the cardiac information of the operator based on the electrical activity received via the handles.

[0018] In some examples, for each of the handles, the non-conductive portion includes a first material and a second material that are different from each other, the second material covers the first material, and the second material defines a shape of the conductive portion, and the conductive portion is formed on the second material.

[0019] In some examples, each of the handles includes a first material that is compatible with an electroplating process, wherein a surface of the first material includes a masking portion and a remaining portion different from the masking portion, the remaining portion is covered during the electroplating, and the masking portion is substantially free of electroplating, the masking portion forming a non-conductive portion of the handle.

[0020] In some examples, the conductive portion includes a first conductive portion and a second conductive portion formed in two non-continuous areas, wherein each of the handles has a first component and a second component, each of the first component and the second component has a non-conductive portion, a first conductive portion, and a second conductive portion, wherein a first area of ​​the two non-continuous areas is formed on the first component and a second area of ​​the two non-continuous areas is formed on the second component, and wherein, when the first component and the second component are coupled together to form one of the handles, the non-conductive portion electrically insulates the first conductive portion and the second conductive portion from each other.

[0021] In some examples, for each of the handles, the conductive portion extends between an outer portion configured to be contacted by an operator in use and an inner portion located within one of the handles, and wherein, for each of the handles, the control system is electrically coupled to the inner portion of the conductive portion via a conductor such that the conductor is protected within the handle. In further examples, the conductors include wires that electrically couple the control system to the conductive portion of each of the handles, respectively, via a connector that is compression coupled to the conductive portion via a fastener.

[0022] In some examples, the base device includes two arms, and the handle is coupled such that the conductive portion of the handle directly contacts the two arms, respectively.

[0023] In some examples, for each of the handles, the thickness of the conductive portion is less than 0.10 mm.

[0024] It should be recognized that the various aspects described in this disclosure may be combined in different ways, including those explicitly disclosed in the examples provided, while still constituting inventions consistent with the present disclosure.

[0025] Various other features, objects and advantages of the present disclosure will become apparent from the following description taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The present disclosure is described with reference to the following figures.

[0027] Figure 1 is a rear perspective view of an exercise machine according to the present disclosure;

[0028] Figure 2 is an exploded cross-sectional view of the handle of a fitness machine;

[0029] Figure 3 yes Figure 2 A perspective view of the conductive plate shown;

[0030] Figure 4 yes Figure 3 A perspective view of a conductive plate overmolded with a non-conductive body;

[0031] Figure 5 is a flow chart of a method for making a handle according to the present disclosure;

[0032] Figure 6 is a perspective view showing one embodiment of a component of a handle according to the present disclosure;

[0033] Figure 7 is along Figure 6 A cross-sectional view taken along line AA in FIG.

[0034] Figure 8 is a perspective view showing two components that may be combined to form a handle according to the present disclosure;

[0035] Fig. 9 is a perspective view showing another embodiment of a component for a handle according to the present disclosure;

[0036] Fig.10 is a perspective view showing another embodiment of a complete handle according to the present disclosure;

[0037] Fig.11 is a perspective view showing another embodiment of a complete handle according to the present disclosure;

[0038] Fig.12is a perspective view showing another embodiment of a complete handle according to the present disclosure; and

[0039] Fig.13 An exemplary control system for measuring electrical activity through a handle according to the present disclosure is depicted.

[0040] Fig.14 is a flow chart of another method of manufacturing a handle according to the present disclosure;

[0041] Fig.15 is a flow chart of a method for manufacturing an exercise machine according to the present disclosure;

[0042] Fig.16 is a perspective view showing another embodiment of a component of a handle according to the present disclosure; and

[0043] Fig.17 is a perspective cross-sectional view of another embodiment of a component of a handle according to the present disclosure. DETAILED DESCRIPTION

[0044] The present disclosure generally relates to an exercise machine and a handle for an exercise machine and methods of making the exercise machine and the handle. Figure 1 An exercise machine 1 incorporating a handle 2 according to the present disclosure is depicted. The illustrated exercise machine 1 is specifically a treadmill having a belt 4 that continuously loops around a belt roller 6 so that a user (or operator) can run or walk on the belt 4 in a conventional manner. Although the present disclosure is primarily concerned with a treadmill as the exercise machine 1, these teachings are also applicable to other types of exercise equipment known in the art. As non-limiting examples, these equipment may include upright bicycles, recumbent bicycles, cross-trainers or elliptical trainers, rowing machines, and stair climbers.

[0045] Figure 1 The fitness machine 1 is supported by a base 10 and extends between the front 12 and rear 14, the left 16 and right 18, and the top 20 and bottom 22. A vertical member 24 extends upward from the base 10 to support a horizontal member 26 located above the base 10. The horizontal member 26 can be used by an operator to provide support and balance, particularly when getting on and off the fitness machine 1. A pair of arms 28 extend from the horizontal member 26 and provide a structure for mounting the handles 2. The arms 28 position the handles 2 in a comfortable position for the operator to grip while exercising. In some embodiments, the arms 28 include a non-conductive material so that no electrical connection is formed with the handles coupled thereto.

[0046] As discussed further below, the fitness machine 1 includes a control system 300, which is configured to determine the operator's cardiac information (e.g., measure the operator's heart rate in real time) when the operator grasps the handle 2. In particular, two electrodes are provided for each hand in the handle 2, one is a sensing electrode, and the other is a ground electrode. The two electrodes are electrically isolated from each other to prevent short circuits via direct contact with each other and / or through the fitness machine 1 (e.g., through the arm 28). Then, the control system 300 measures the electrical activity from the electrodes of the handle 2 to determine the cardiac information by comparing the signals from the two electrodes of each hand in the two hands. Methods for determining cardiac activity using two or more electrodes are known in the art. Additional information for an example of determining cardiac information is provided in U.S. Patent No. 5,365,934. In short, when the myocardium contracts, the body generates a very low amplitude electrical signal, called a biopotential signal. As is well known, such a biopotential signal can be electronically detected on the surface of a person's skin via electrodes (which sense such electrical activity). As the heart expands and contracts in a regular rhythm, it generates a periodic biopotential signal on the skin that corresponds to the person's heartbeat.

[0047] Typically, voltage fluctuations on a person's skin can be sensed by measuring the voltage potential between two or more electrodes placed in contact with the skin at two different locations on the body. The signal is then amplified and filtered to remove biopotential signals that are not related to the heart rate. The frequency of the residual signal is then determined and displayed as the heart rate (e.g., in beats per minute).

[0048] Although the present disclosure primarily discusses configurations having two electrodes per hand, which provide increased accuracy and reduced signal noise, these teachings are also applicable to configurations in which one or both hands are provided with a single electrode.

[0049] It should be appreciated that the present disclosure contemplates embodiments in which the position of the handle 2 differs from Figure 1 The positions of the exercise machine 1 are shown. These positions may vary depending on the configuration and type of exercise machine, such as, as is conventional, for a recumbent bike, the handles 2 are located at waist height, while for an upright bike, the handles 2 are located in front of the user. In addition, although Figure 1 The exercise machine 1 of FIG. 1 shows only one pair of handles 2 and corresponding arms 28, but the present disclosure contemplates exercise machines 1 in which a different number of handles 2 are provided. Likewise, the handles may be movable or stationary.

[0050] Controller 30 is also supported by horizontal member 26, which may include rollers, buttons, and resistive and / or conductive sensors. A console 32 is also supported by horizontal member 26, which, together with controller 30, allows an operator to control various functions of fitness machine 1 in a conventional manner. These functions may include controlling the speed and / or inclination of belt 4 relative to a horizontal plane (e.g., via height adjustment system 34 in a manner known in the art), resistance levels (e.g., using a bicycle, rowing machine, elliptical trainer, and / or a treadmill where the user rotates the belt), and / or other conventional functions known in the art.

[0051] Figure 2 An example of a handle assembly 38 similar to that currently known in the art is shown. The handle assembly 38 includes a handle 2', which is configured to be mounted to an arm 28' (which arm 28' may be made of, for example, Figure 1 The exercise machine 1 is shown supported by the horizontal member 26 and the base 10. The handle 2' is shown as having two parts 3', 3", each of which includes a conductive plate 40 (also called an electrode) that is partially surrounded by a non-conductive body 42. The body 42 can be a plastic resin overmolded over the conductive plate 40 using conventional methods. The conductive plate 40 can be stamped stainless steel. For simplicity, additional details will be provided for a single part 3', which details can be repeated for the other parts 3".

[0052] Reference Figure 2 and Figure 3Each conductive plate 40 extends along a length between a first end 44 and a second end 46 and along a width between a third end 48 and a fourth end 50, with an inner portion 52 and an outer portion 54 each extending therebetween. A thickness is defined between the inner portion 52 and the outer portion 54. An elongated tab 56 extends away from a body 55 of the conductive plate 40 at approximately a midpoint between the first end 44 and the second end 46. The elongated tab 56 has a first bend 58 of approximately 180 degrees, wherein the first bend extends from the body 55 such that the elongated tab 56 is folded back relative to the inner portion 52. At approximately a midpoint between the third end 48 and the fourth end 50 of the conductive portion, the elongated tab 56 has a second bend 60 of approximately 90 degrees. The second bend 60 causes a free end 62 of the elongated tab 56 to extend generally perpendicularly away from the inner portion 52 of the conductive plate 40, the free end 62 serving as a spade connector 64 for connecting a conductor to the conductive plate 40. In some cases, connector 64 is welded to inner side 52 of conductive plate 40 rather than formed by bending. Conductive plate 40 may have a thickness of about 0.5 mm. An opening 66 is provided through conductive plate 40 so that fastener 68 may extend through opening 66 to couple conductive plate 40 to arm 28' (e.g., to arm 28' via threaded opening 29' in arm 28'). For example, fastener 68 may be a threaded fastener such as a screw or bolt, a press-fit fastener, or a rivet. In other embodiments, rather than each component having its own fastener that threadably engages its own threaded opening in the arm, one or more fasteners extend through one component, through the arm, and then threadably engage an opposing component on the other side of the arm.

[0053] The conductive plate 40 is overmolded by conventional processes to form a body 42 that partially surrounds the conductive plate 40. Figure 2 and Figure 4 , each body 42 extends along a length between a first end 70 and a second end 72 and along a width between a third end 74 and a fourth end 76, with an inner portion 78 and an outer portion 80 each extending therebetween. A thickness is defined between the inner portion 78 and the outer portion 80. A segment 79 extends between the inner portion 78 and the outer portion 80. As with the inner portion 52 of the conductive plate 40, the contour of the inner portion 78 of the body 42 generally corresponds to the shape of the arm 28' to be coupled to the handle (e.g., the outer diameter 113 of the arm 28'). The segments 79 of the body 42 are configured to abut each other when the body 42 is coupled to the arm 28'.

[0054] A collar 83 with an opening 84 is also provided and is configured to align with the connector 64 of the conductive plate 40 so that after overmolding, the connector 64 remains accessible from the inner side 78 of the component 3'. The collar 83 extends upwardly from the inner side 78 by a height 85 and has an opening 84 therein having a diameter 89 sufficient to connect with the connector 64 extending therethrough. The collar 83 also prevents accidental shorting between the connector 64 and the arm 28' or other support structure.

[0055] Continue to refer Figure 4 , a boss or standoff 86 also extends upwardly from the inner side 78 of the body 42 and has a height 88 and an opening 90 therein. Note that for clarity, Figure 2 Certain locations of the support 86 and the corresponding openings in the arm 28' are omitted. The ribs 92 provide stability to the support 86. The fastener 68 ( Figure 2 ) extends through the opening 90 of the support 86 to couple the components 3', 3" to the arm 28'. For embodiments where the handle 2' includes the support 86, such as Figure 4 The body 42 shown, the arm 28' will be designed to accommodate this height 88 (e.g., having a corresponding opening in the arm 28'). The support 86 provides proper alignment and lateral strength for the connection between the handle 2' and the arm 28' or other support element (such as a non-conductive housing), which will be discussed further below. The height 88 of the support 86 of one component 3' is greater than the height of the support 86 of the corresponding component 3". The component 3' can be installed first, allowing the cable to be routed around the support 86 before the component 3" is installed, thereby reducing the risk of the fastener 68 pinching or cutting the wire when extending through the components 3', 3". The fastener 68 is a self-tapping screw that extends entirely through an opening 90 in the support 86 of one component 3' (e.g., those having the lower height 88) and partially extends into the opening 90 of the support 86 of the opposite component 3" (e.g., those having the higher height 88).

[0056] Figure 2 Each conductive plate 40 is shown separated from the corresponding body 42 to show more details of the overall construction of the handle assembly 38 from the overmolding process. The outer side 80 of the body 42 is also defined as having a first surface 100 and a second surface 102 recessed from the first surface 100. The tabs 104 of the first surface 100 extend above the second surface 102 in a cantilevered manner so that cavities 106 are formed between the tabs 104 and the second surface 102. Each cavity 106 extends the length of the conductive plate 40 (i.e., as shown in FIG. 1 ). Figure 3The tab 104 is shown as extending between the first end 44 and the second end 46 and having a width 108 and a depth 110. The depth 110 corresponds to the thickness of the conductive plate 40 between its inner side 52 and outer side 54. The thickness 112 of the tab 104 is approximately 1.0 mm, which must also be thick enough to securely hold the conductive plate 40 within the body 42. Therefore, the outer side 54 of the conductive plate 40 must be recessed from the outer side 80 of the body 42 by at least 1.0 mm. It should be recognized that after the overmolding process, a similar cavity also exists within the body 42 to accommodate the first end 44 and the second end 46 of the conductive plate 40. In this manner, the exposed portion of the conductive plate 40 is necessarily less than its entire surface area. In particular, it should be recognized that the cavity 160 must be of sufficient size to securely capture the conductive plate 40 therein.

[0057] The inventors have recognized that Figures 2 to 4 There are problems with the design of the handle 2' shown. First, the process of manufacturing the conductive and non-conductive portions of the handle necessarily requires at least four components for each handle 2' (not including fasteners): two conductive plates 40, two bodies 42, and then coupling them to a separate arm 28'. In conventional designs known in the art, this number of components is doubled to eight by placing an additional non-conductive housing between the bodies 42. Furthermore, it is important to note that although Figure 2 The handle 2′ in the embodiment is shown as having parts 3′, 3″ that may be identical to each other, but this is generally not the case. In other words, if the handle 2′ has a more complex shape and / or is not formed from symmetrical parts (e.g., left-hand handle vs. right-hand handle, top part vs. bottom part, etc.), the number of unique individual parts will increase further. For cost and inventory reasons, it is advantageous to reduce this parts list, which also reduces the tooling to produce the handle.

[0058] Furthermore, the inventors have recognized that the designs of handles currently known in the art are susceptible to damage. Figure 4 , the conductive plate 40 must be thick enough so that the first bend 58 and the second bend 60 do not cause the elongated tab 56 to fall off the body 55. In addition, the connector 64 is essentially a long lever arm that connects back to the body 55, which poses a risk of damage when wires are subsequently connected or removed from the connector 64. Similarly, through experimentation and development, the inventors have recognized that the press-fit or interference connections currently used for handles known in the art are undesirable because these connections are prone to failure and accidental disconnection over time.

[0059] The inventors have also found that it is often uncomfortable or undesirable for the outer side 54 of the conductive plate 40 to be lower than the outer side 80 of the body 42 surrounding it, as described above, by at least 1.0 mm. Likewise, the exposed surface area of ​​the conductive plate 40 must be less than its total surface area. In other words, there must be a boundary of the body 42 on each side of the conductive plate 40.

[0060] The inventors have discovered another problem with manufacturing the handle 2' using methods currently known in the art. Specifically, when a high temperature liquid resin is molded over an unheated steel electrode, as these different materials cool, they shrink differently. The thermal shrinkage of ABS plastic is approximately 5.5 times that of steel (e.g., 72-108*10 -6 m / (m*℃), while 316SST is 16.0*10 -6 m / (m*℃)). This causes the ABS plastic to shrink around the steel, creating residual stress in the part. This makes the handle's components more susceptible to damage, warping, and stress cracking.

[0061] Additionally, the shape of steel electrodes is limited by the way steel can be formed, and stainless steel also has limited texture, finish, and color options.

[0062] Figure 5 An exemplary method 200 for producing a component of a handle according to the present disclosure is shown. Step 202 describes providing a mold configured to injection mold an article therein, such as performing double shot injection molding in a conventional manner. In step 204, a first shot is injected into the mold. The first shot is particularly a first material that is incompatible with an electroplating process. For clarity, a surface that is incompatible with an electroplating process described herein and / or generally known means that after the component is subjected to an electroplating process, the surface is substantially free of electroplating, while other surfaces of the same component that are compatible with the electroplating process will be electroplated. For example, the first material can be a plastic resin, such as polycarbonate (e.g., unmixed polycarbonate), unmixed polyester, unmixed nylon, unmixed polybutylene terephthalate (Valox) or other materials known in the art. Step 206 injects a second shot into the mold, particularly injecting a second material that is compatible with the electroplating process (e.g., another plastic resin different from the first material). A second shot is injected to form an area supported by the first shot (or in some configurations, formed on the first shot). For example, the second material can be acrylonitrile butadiene styrene (ABS) plastic, Bayblend (a combination of polycarbonate and ABS), polycarbonate, or a polypropylene blend.

[0063] In some examples, the mold is designed to form a U-shaped groove at the intersection between the first material and the second material. The groove prevents accumulation of material after the electroplating process discussed below, which may have an unpolished, discernible feel and / or sharp edges to the user.

[0064] It should be appreciated that the mold into which the first shot and the second shot are injected can constitute two separate parts and / or parts having separate areas for injecting the first shot and the second shot. For example, the first shot can be injected into the first part of the mold, whereby when the first material cools, it is transferred to the second part of the mold via a rotating platen or a robotic arm. Then, depending on the design, the second shot is injected into, through, around and / or on the first material. The first and second materials form a molecular and / or mechanical bond and cool to form a combined object, which is then ejected from the mold.

[0065] Continue to refer Figure 5 Method 200, then in step 208, the article produced by the first shot and the second shot is electroplated using conventional methods (also known as electroplating). In some techniques, the article is immersed in an electroplating material, which can be an aqueous solution of an electrolyte containing a metal to be deposited as an ion (i.e., a dissolved metal salt). An electric field is formed between the anode in the solution and the article as the cathode, which forces the positively charged metal ions to move to the cathode (article). The positively charged metal ions release their charge and are deposited as metal on the electroplating compatible surface of the article. Therefore, the electroplating process forms a conductive material layer on the article only in the area of ​​the second material because the first material is specifically selected to be incompatible with the electroplating process. In some examples, the layer thickness formed via the electroplating process (also known as electroplating, which itself may include many sublayers) is less than 0.10mm.

[0066] The electroplating material and the electroplating process itself can include multiple steps and / or materials. In one example, a base layer is first formed on the second material, which can be copper and can be formed to have a thickness between 15 and 25 microns (0.015 to 0.025 mm). Then a bottom layer is formed on the base layer, which can be nickel and has a thickness between 3 and 7 microns (0.003 to 0.007 mm). The bottom layer can be specifically selected to provide different appearances, such as satin, bright or other desired finishes. Then an additional layer is applied to the bottom layer, which can be chromium applied via electroplating treatment and can have a thickness of 0.05 microns (0.00005 mm). For example, chromium has high hardness and low friction, thereby providing very high wear resistance. Decorative (e.g., satin, bright, etc.), functional (e.g., providing additional hardness) or protective physical vapor deposition (PVD) top layers can be specifically selected to include different pigments, etc., which can be zirconium or titanium. The top layer can be set on a submicron scale. In this way, the conductive portion of the handle can be specifically designed to complement the fitness machine, rather than having a standard stainless steel appearance.

[0067] A further example is now provided in detail for an electroplating metallization process for an acrylonitrile-butadiene-styrene (ABS) surface in a manner known in the art. The ABS material is subjected to an etching process in which butadiene is eluted from the ABS (e.g., via liquid chromium) to form anchor holes on the surface of the ABS. This is followed by a reduction process in which chromium is removed from the surface of the product. This is followed by a first activation process in which a compound of palladium and tin is absorbed into the anchor holes on the implanted surface, followed by a second activation process in which the tin is removed and the palladium is metallized. This is followed by a chemical nickel process in which the nickel and palladium react to form a nickel layer.

[0068] Next comes the copper sulfate plating process, which provides a buffer between the injection and the later nickel plating. Next can be a semi-bright nickel plating process to prevent corrosion of the copper layer, followed by a glossy nickel plating process to increase the gloss of the chrome layer. Then comes the molybdenum nickel plating process to inhibit corrosion, followed by a chrome plating process for aesthetics and wear resistance.

[0069] In one example, the resulting product has the following layers: 1) ABS resin material, 2) an electroless plating layer for increasing conductivity (e.g., ~0.2-0.6 μm), 3) a copper layer for buffering between the metal and the ABS (e.g., ~10.0-20.0 μm), 4) a semi-glossy nickel layer for improving corrosion resistance (e.g., ~12-20 μm), 5) a glossy nickel layer for increasing gloss and corrosion resistance (e.g., ~8-12 μm), 6) a molybdenum-nickel layer for corrosion resistance (e.g., ~0.8-1.2 μm), and 7) a chrome layer for corrosion resistance, wear resistance, and providing gloss (e.g., ~0.25-0.5 μm).

[0070] Once assembled, the handle will have at least one area defined by the second material corresponding to the desired conductive area or electrode for each hand of the user (shown throughout this disclosure as two areas corresponding to two conductive areas or electrodes for each hand). The two conductive areas can be formed in the same component, or can be provided together by coupling two components together, each component having one such area of ​​the second material. The handle and its components are constructed so that when the handle is fully assembled and coupled to the fitness machine, the two or more areas comprising the second material are discontinuous (i.e., are non-contacting so as to be electrically isolated from each other).

[0071] In this way, once the parts are completed and assembled together, each handle has a non-conductive portion where the first material from the first shot is not covered by the second material, and a first conductive portion and a second conductive portion where the two non-continuous areas are formed from the second material and subsequently covered with a galvanic treatment layer.

[0072] Figure 6 and Figure 7 A component 120 of a handle made in accordance with the present disclosure is shown. Component 120 extends along a length between a first end 122 and a second end 124, along a width between a third end 126 and a fourth end 128, and has an inner portion 130 and an outer portion 132 extending therebetween. A thickness is defined between inner portion 130 and outer portion 132. The inner portions 130 of the two components 120 face inwardly toward each other when coupled together to form a handle, while the outer portions 132 face away from each other. The length, width, thickness, and overall shape of component 120 are variable and may be selected to be consistent with the embodiment of the present disclosure. Figure 4 Those of the components 3′ are identical. Figure 6 130, but the dimensions of the support 134 extending away from the inner portion 130 are also the same. This flexibility allows the component 120 to be advantageously retrofitted into existing fitness equipment configured for the component 3'.

[0073] Continue to refer Figure 6and Figure 7 , component 120 includes a non-conductive portion 140 formed of a first material of a first shot, which, as described above, is incompatible with electroplating and therefore remains non-conductive. In contrast, a second material of a second shot (in Figure 7 The electroplating material formed as a layer on the second material by the electroplating process is generally shown as the conductive portion 150. Although Figure 7 Although not shown, the first material may also be present below the second material 141 (e.g., as a core onto which the second material 141 is injected). Figure 7 As shown, the non-conductive portion 140 may be completely encapsulated by the conductive portion 150 on the outer side 132 of the component 120 .

[0074] exist Figure 6 and Figure 7 In the embodiment of the present invention, the non-conductive portion 140 of the inner portion 130 of the component 120 forms two separate regions. Each region forming the non-conductive portion 140 extends along a length between a first end 142 and a second end 144, and extends along a width between a third end 146 and a fourth end 148, the first end 142 and the second end 144, the third end 146 and the fourth end 148 being located inboard of the first end 122, the second end 124, the third end 126 and the fourth end 128 of the component 120 as a whole, respectively. The second end 144 of each region of the non-conductive portion 140 ends at approximately the midpoint between the first end 122 and the second end 124 of the component 120.

[0075] The wall 152 extends vertically upward (along the second end 144 of the non-conductive portion 140) from the non-conductive portion 140. Figure 6 and Figure 7 15). Wall 152 has a base 154 and a top 156 defining a height therebetween. Wall 152 also has an inner surface 158 and an outer surface 161 defining a thickness therebetween, and ends 162 defining a width therebetween. Wall 152 has an approximately semicircular profile between ends 162, such that inner surface 158 is concave and outer surface 161 is convex.

[0076] The walls 152 of the two non-conductive portions 140 together partially surround and thereby protect a boss 170 that extends vertically upward (along the axis of the longitudinal axis) from the conductive portion 150 approximately midway between the first end 122 and the second end 124 of the component 120. Figure 6 and Figure 7170 is a block 170 that is substantially cylindrical in shape. Boss 170 has a base 172 and a top 174 defining a height therebetween that, in this example, is less than the height of wall 152. Boss 170 has an outer surface 176 and an opening 178 extending downwardly from top 174, defining a thickness therebetween. Opening 178 may be threaded, or self-tapping fasteners may be used. Outer surface 176 is shown as forming a circular shape, such that the entire boss 170 is substantially cylindrical. Figure 7 As shown, the top 174 and outer surface 176 of the boss 170 are comprised of the conductive portion 150, while the interior or core of the boss 170 is comprised of the second material 141 onto which the conductive portion 150 is laminated.

[0077] Reference Figure 6 , since the conductive portion 150 is wrapped around the component 120, the boss 170 on the inner portion 130 is electrically connected to the outer portion 132 that the operator contacts during use. The boss 170 is configured so that a conductor 180 (here, a wire with a ring terminal 182) can be coupled to the conductive portion 150 to provide an electrical connection to a control system within the fitness machine, as described below. In particular, a fastener 184, such as a screw or bolt, extends through the ring terminal 182 at the end of the conductor 180 and is screwed into the threaded opening 178 in the boss 170. In this way, the engagement fastener 184 pulls the conductor 180 into contact with the top 156 of the boss 170 to electrically connect the conductor 180 and the conductive portion 150.

[0078] As described above, the wall 152 of the non-conductive portion 140 protects the conductor 180 coupled to the boss 170 from damage during installation. In addition, a gap G is provided between the wall 152 and the boss 170 to provide further cushioning in the event that the wall 152 is bumped. The wall 152 also helps prevent accidental short circuits between the conductor 180 and an arm or other structure to which the handle is mounted.

[0079] The inventors have determined that this design of electrically coupling the conductor 180 to the conductive portion 150 of the handle is particularly advantageous over designs currently known in the art. First, the use of the ring terminal 182 is safer and allows for a better electrical connection than known interference connections, which may be inadvertently disconnected during assembly or use. In addition, because the fastener 184 pulls the conductor 180 into flush contact with the top 156 of the boss 170, there is no wear or abrasion of the electroplated material comprising the conductive portion 150. The inventors have recognized that electroplating cannot be used with spade connectors used in today's handles because the action of connecting and disconnecting the conductors would scrape off a relatively thin layer and destroy its function. Today's handles rely on relatively thick steel plates to not only resist wear from connection and disconnection, but also resist bending and breaking, as described above. In contrast, the present design allows strength to be provided by the width and thickness of the second material 141 within the boss 170, without requiring such strength in the conductive portion itself (e.g., the electroplated material).

[0080] Reference Figure 8 It will be appreciated that the complete handle 2 generally includes two conductive portions 150 in non-contiguous regions of the handle 2 (although, as noted above, a handle having one conductive portion 150 is also contemplated). The two conductive portions 150 may be formed on separate components 120 of the handle, or on the same component of the handle. A separate conductor 180 is coupled to each separate conductive portion 150 for separate connection to a control system in a manner known in the art. The components 120 of a given handle 2 may be identical to one another, may vary in structure (e.g., different mounts 134), may vary in overall shape (e.g., between the first end 122 and the second end 124 and / or between the third end 126 and the fourth end 128), or the shape, size, and / or position of the conductive portion 150 relative to the non-conductive portion 140 may vary. This allows the handle 2 to be designed in a manner that is most comfortable for the operator without being limited by the cost, complexity, and tolerances of a handle that requires stainless steel plate as the conductive portion. For example, the inventors have recognized that an egg-shaped portion of the handle 2 is generally particularly ergonomic for an operator, such as for a cross-trainer or elliptical trainer. However, using steel sheets to make complex shapes (such as Fig.12 The egg-shaped conductive portion 150 (155) would be very challenging and expensive.

[0081] Figure 8The components 120 can be directly coupled to the non-conductive arm (i.e., the arm needs to act as an insulator because the conductive portion 150 of the component 120 wraps around its edge). The arm can have a recessed portion corresponding to the shape of the component 120 so that the conductive portion 150 can be recessed therein, for example, so that the outer portion 132 is flush with the arm. In alternative embodiments, the components 120 can contact each other (e.g., wrap around the arm together) when coupled to the arm, provided that the conductive portions 150 are positioned so as not to contact each other. Figure 8 The component 120 may optionally be provided with an additional non-conductive housing 143 adjacent to any conductive portion 150 (see Fig. 9 ) combination to provide electrical isolation between the conductive portions 150 when assembled into a complete handle.

[0082] Figure 8 The embodiment also shows a configuration in which each component 120 is configured to be coupled to the arm 28 of the exercise machine by press-fitting with a mount 134 and / or an adhesive (see Figure 1 ). This is in contrast to other examples described above where the fastener extends through the component and into the arm or opposing component 120.

[0083] Figures 9 to 12 Additional designs of handle 2 are shown that, while challenging or impossible to manufacture using conventional methods, can be easily manufactured according to the present disclosure. Specifically, these complex designs are made possible by the disclosed process of providing the conductive portion 150 of the handle 2 as layers in two discrete areas rather than using thick steel plates. For example, Fig. 9 , Fig.10 and Fig.12 The contour shape of the conductive portion 150 is very costly and difficult to manufacture. Similarly, Fig.10 A design is shown where an island 186 of non-conductive portion 140 is surrounded by conductive portion 150, which allows for a logo of a different color, gloss, finish, texture, or material to stand out for branding, etc. Under traditional methods, the cutout of the island 186 is costly, presents tolerance challenges, and creates significant risk of ingress, salt bridges (discussed below), and uneven or sharp edges.

[0084] Furthermore, since the conductive portion 150 of the handle 2 according to the present disclosure is directly disposed on the same component 120 as the non-conductive portion 140, there is no need to consider tolerances and thus no need to leave a gap between these parts. For handles currently known in the art, the gap between the conductive and non-conductive portions must be sufficient to allow the non-conductive portion to expand or contract around the conductive portion during production so that internal stresses and strains are not generated. Sufficient gap is also required to provide space for a gripping mechanism that grips the conductive portion 150 on either side during installation on the non-conductive portion 140.

[0085] These gaps can be as large as 1.0 mm, causing dirt and debris to accumulate in conventional exercise machines known in the art, and also causing the ingress of water and sweat which can damage the handles and their components. This also causes an effect known as "salt bridging", where salts from the user's sweat accumulate within the gaps and handles, forming a conductive path to the metal frame within the machine. This electrical short circuit destroys the function of the conductive portion 150 in measuring electrical activity for the user, and can also cause permanent damage to the electrical components. Devices currently known in the art attempt to provide electrical insulation via complex and expensive lips and gaskets between the components of the handle (see Figure 4 The gasket 5 in the handle is used to minimize this ingress and salt bridging, and these lips and gaskets attempt to direct moisture away from the interior of the handle.

[0086] By forming the conductive portion as a layer on the injection molded article via electroplating in the manner of the present disclosure, the need for such gaskets and other features designed to keep the gap between the conductive and non-conductive portions clean is completely eliminated. This saves time and cost in assembly. In addition, the design features of devices currently known in the art are still subject to failure over time, while the design of the present disclosure completely avoids this problem.

[0087] The component 120 can also be advantageously designed so that the conductive portion 150 is recessed or completely flush with the non-conductive portion 140, thereby providing an improved customer experience and overall aesthetics. In particular, the second material is injected to be recessed relative to the first material, and specifically, the height difference between the second material and the first material is equal to the electroplating material that will be formed on top of the second material later. This makes the height of the conductive portion 150 exactly the same as the height of the non-conductive portion 140 when the component 120 is completed.

[0088] In addition, the handle and the method of manufacturing the handle disclosed herein can also be used to eliminate the need for housing components (see Fig. 9 1) and / or a separate arm 28 for connecting the handle 2 to the fitness machine 1 (see Figure 1 ) needs. Fig.11The handle 2 is shown, wherein the non-conductive portion 140 comprises two parts of the handle 2 and a horizontal member 26 to be coupled to the fitness machine 1 (see FIG. Figure 1 ) of the arm 28. This provides electrical isolation between the two conductive portions 150 of the handle 2 while also positioning the handle 2 in the correct position for use. The inventors have recognized that this combination further eliminates inventory, cost, and time and complexity of assembly and / or replacement. This also further reduces tolerance issues because there is no longer a need to accommodate the spacing between the conductive portion and the non-conductive portion of the electrode, the spacing between the non-conductive portion and the non-conductive housing of the electrode, and the spacing between the non-conductive housings of the arms.

[0089] Certain aspects of the present disclosure are described or depicted as functions and / or logic block components or processing steps, which can be performed by any number of hardware, software and / or firmware components configured to perform the specified functions. For example, certain embodiments use integrated circuit components, such as storage elements, digital signal processing elements, logic elements, lookup tables, etc., configured to perform various functions under the control of one or more processors or other control devices. The connections between functions and logic block components are exemplary only, and can be direct or indirect, and can follow alternative paths.

[0090] Reference Fig.13 , the control system 300 communicates with each of one or more components (e.g., handle 2) of the fitness machine 1 via conductor 180 and other communication links CL, which can be any wired or wireless links. The control system 300 is capable of receiving information and / or controlling one or more operating characteristics of the fitness machine 1 and its various subsystems by sending and receiving control signals via the communication link CL (e.g., via commands from the console 32, the controller 30, and the handle 2). In addition, the communication link CL lines are only used to illustrate that the various control elements are able to communicate with each other, and do not represent actual wiring connections between the various elements, nor do they represent the only communication path between the elements. In addition, the fitness machine 1 can be combined with various types of communication devices and systems, so the communication link CL shown can actually represent various different types of wireless and / or wired data communication systems.

[0091] Control system 300 may be a computing system that includes a processing system 310, a storage system 320, and an input / output (I / O) system 330 for communicating with other devices, such as input device 299 and output device 301, any of which may also or alternatively be stored in cloud 302. Processing system 310 loads and executes executable program 322 from storage system 320, accesses data 324 stored within storage system 320, and instructs fitness machine 1 to operate as described in further detail below.

[0092] Processing system 310 may be implemented as a single microprocessor or other circuit, or distributed across multiple processing devices or subsystems that cooperate to execute executable programs 322 from storage system 320. Non-limiting examples of processing systems include general purpose central processing units, special purpose processors, and logic devices.

[0093] The storage system 320 may include any storage medium that can be read by the processing system 310 and is capable of storing executable programs 322 and / or data 324. The storage system 320 may be implemented as a single storage device, or distributed across multiple storage devices or subsystems that cooperate to store computer-readable instructions, data structures, program modules, or other data. The storage system 220 may include volatile and / or non-volatile systems, and may include removable and / or non-removable media implemented in any method or technology for storing information. The storage media may include non-transitory and / or transient storage media, such as random access memory, read-only memory, magnetic disks, optical disks, flash memory, virtual and non-virtual memory, magnetic storage devices, or any other media that can be used to store information and can be accessed by the instruction execution system.

[0094] In this way, the present disclosure improves the process of manufacturing the handles of the fitness machine, enabling more complex geometric designs. As described above, this provides greater comfort for the user, provides an aesthetically pleasing design, and results in a longer-lasting product while reducing production costs and inventory burdens.

[0095] It should be appreciated that while the present disclosure discusses processes where the second material is subsequently layered with an electroplating material, alternative processes where the second material itself is conductive are also contemplated.

[0096] Furthermore, the present disclosure contemplates configurations in which a first material is compatible with an electroplating process and a second material is applied as a mask in masked portions of the first material, whereby the second material is incompatible with the electroplating process. Fig.14 An example method 400 for producing a handle according to the present disclosure using a masking technique is shown. In step 402, a mold configured for injection molding an article therein is provided, and in step 404, a first material compatible with an electroplating process is injected into the mold. For example, the first material may be ABS plastic, and the mold may be filled in a single injection process.

[0097] Then, in step 406, a portion of the first material (also referred to as the masked portion) is masked with a second material that is incompatible with the electroplating process. The second material can provide chemical and / or physical masking of the first material, such that the masked portion is incompatible or no longer compatible with the electroplating process compared to the remaining portion of the first material that is not masked by the second material. For example, the masked portion can be made of a cover and / or plug including a cured silicone material and EPDM rubber, a plating tape including polyester, lead foil, or other materials (e.g., made of The mask may be provided by dipping the component into the second material, spraying or brushing on the second material, or otherwise processing or treating the first material in a manner known in the art. For example, Red Spot Paint & Varnish Co., Inc. of Evansville, Indiana, produces a varnish that may be used as the second material, part number ARC-29718 ("black etch-resistant paint").

[0098] Once masking is complete, step 408 provides for performing an electroplating process on the component, thereby forming a plated portion of the electroplating on the remaining portion of the first material that is not masked (due to compatibility with the electroplating process). The masked portion remains unplated due to incompatibility with the electroplating process. Since electroplating is conductive, the plated portion is the conductive portion of the complete handle, while the masked portion is the non-conductive portion of the handle.

[0099] Fig.15 Another example of a method 500 for manufacturing an exercise machine according to the present disclosure is shown, such as via Fig.14 The handle produced by the method 400 is provided. In step 502, a base device of a fitness machine on which an operator can exercise is provided, which can be the same as or similar to the above-mentioned device. For example, the base device can be a treadmill having an arm configured to couple the handle thereto. The treadmill can also have a control system configured to determine the operator's heart information when exercising when receiving electrical signals from the handle.

[0100] Handles are provided at step 504, wherein each handle has a non-conductive portion and a conductive portion, wherein the conductive portion is plated. Step 506 provides coupling the handles to a base device in a manner described above, further described below, or otherwise known in the art. The handles are coupled to the base device for an operator to grip while exercising (e.g., coupled to the arms of a treadmill, elliptical trainer, or exercise bike).

[0101] Step 508 provides for electrically coupling the conductive portion of the handle to a control system as described above. The control system is configured to determine cardiac information of the operator based on the electrical activity received from the operator through the conductive portion. Once the control system receives the electrical signal, cardiac information can be determined from the electrical signal in a manner well known in the art.

[0102] Additional information is now provided for further embodiments of handles according to the present disclosure. Fig.16 and Fig.17 A component 620 of another handle made in accordance with the present disclosure is shown. Component 620 extends along a length between a first end 622 and a second end 624, along a width between a third end 626 and a fourth end 628, and has an inner portion 630 and an outer portion 632 extending therebetween. A thickness is defined between the inner portion 630 and the outer portion 632. The inner portions 630 of the two components 620 face inwardly toward each other when coupled together to form a handle, while the outer portions 632 face away from each other. The length, width, thickness, and overall shape of component 620 are variable and can be selected to be consistent with the present disclosure. Figure 4 The dimensions of the support 634 extending away from the inner portion 630 are also the same. This flexibility allows the component 620 to be advantageously retrofitted into an existing fitness device configured for the above-mentioned component 3'. It should be recognized that Fig.16 and Fig.17 The component 620 may include although Figure 6 and Figure 7 Features not shown in component 120 but may be combined therewith, and vice versa. Therefore, the present disclosure contemplates different combinations of these features than those shown in a single figure.

[0103] and Figure 6 and Figure 7 Compared to the component 120 shown, the component 620 can be molded by a single shot injection molding and as shown in FIG. Fig.14 The masking process shown and described above is formed. The molding process produces a component made of a first material 639 (such as ABS-PC) that is compatible with the electroplating process. Before performing the electroplating process, a portion of the first material 639 is masked, such as with a polyester tape. This is also referred to as a masking portion 641 of the first material 639 or more generally referred to as a masking portion 641 of the component 620. For simplicity, the masking portion 641 of the same name can be used even if the masking material has been removed. After the electroplating process is completed as described above or in a conventional manner, electroplating 642 (also referred to as a plated portion 643 of the first material 639 or more generally referred to as a plated portion 643 of the component 620) is formed on the remaining portion of the first material 639 that is not masked by the mask. In other words, except for the inside of the masking portion 641, the component 620 can be covered by the electroplating 642.

[0104] The masking portion 641 then acts as the non-conductive portion 640 of the component, while the plated portion 643 acts as the conductive portion 650 of the component. The conductive portion 650 can then be used to receive electrical activity from an operator in the manner described above. It should be appreciated that the masking material can be left in place, or can be removed after the electroplating process is completed. For example, if the first material is non-conductive, the masking material can be removed.

[0105] exist Fig.16 and Fig.17 In the example shown, the masking portion includes an upper portion 652 of a mount 634 for coupling the component 620 to an exercise machine, the upper portion 652 including a top 654, an outer surface 656, and an inner surface 658, the inner surface 658 including an opening 660 for coupling the handle to the exercise machine via fasteners in a conventional manner. In some embodiments, the masking portion is masked via a cover placed over the top of the mount 634 so that the threads in the inner surface 658, the top 654, and the outer surface 656 are all covered during the electroplating process, after which the cover can be removed to expose the masking portion that is substantially free of electroplating.

[0106] Since the upper portion 652 of the component 620 is substantially free of plating, it is non-conductive, thereby allowing the component 620 to be coupled to the exercise machine and another component without creating an electrical path to the component 620. In other words, the upper portion 652 electrically isolates the component 620 from the rest of the exercise machine, even though the rest of the component 620 is covered with plating. It should be appreciated that in other embodiments, the mask (e.g., a cover on the support 634 including the opening 660) can be left in place, particularly where the first material 639 disposed thereunder is conductive, to provide such electrical isolation for the component.

[0107] The conductive portion 650 also includes a boss 670 for electrically coupling the conductive portion of the component 620 to a control system, similar to the above Figure 6 and Figure 7 Boss 170. Figure 6 and Figure 7 The construction of is used to connect a conductor 180 (e.g., a wire) to the component 120 by extending a fastener 184 through the ring terminal 182 of the conductor 180 and into the boss 170. The same fastening technique can also be used for Fig.16 and Fig.17660 of the component 620 (screwing the fastener 184 into the threaded opening 678 in the top 674 of the boss 670). The inventors have determined that the component 620 can alternatively be electrically coupled to the conductor 180 in another manner, including for conductors having other types of connections other than ring terminals (e.g., spade connectors 682 used in some existing fitness machines). In this case, the ring-shovel connector 684 has a ring terminal 686 and a spade 688 extending vertically from one end of the ring terminal 686. By inserting the fastener 184 through the ring terminal 686 and threading it into the opening 660 in the boss 670, the ring-shovel connector 684 is electrically coupled to the conductive portion 650 of the component 620 via compression. The spade connector 682 of the conductor 180 can still be used to electrically couple the conductor 180 to the conductive portion 650 of the component 620, particularly by mating with the spade 688. As described above, this prevents damage to the plating 642 by avoiding the scraping action of the spade connector, but still allows the spade connector to be used. As described above, this is particularly advantageous because many existing fitness machines have conductors with spade connectors. In addition, as Fig.16 and Fig.17 The illustrated component 620 advantageously provides that if the spade 688 becomes damaged, the ring-spade connector 684 may simply be replaced, rather than replacing the entire component 620 or the handle.

[0108] Through experimentation and development, the inventors have recognized further challenges that may arise in certain embodiments of handles produced via an electroplating process. Specifically, because the electroplating 642 may be very thin, any contours on the surface of the underlying component comprising the first material 639 are visible, similar to the contours on the surface of the electroplating 642 (which are visible to the operator for the outer side 632 of the component 620). In this way, any deformation, distortion, warping, etc. produced when producing or processing the first material 639 may detract from the aesthetics and give the operator an unpleasant feeling when holding it in use. The selected color, texture, and finish of the electroplating 642 (as described above) may further exacerbate this problem, whereby the shiny finish may make any defects more visually obvious.

[0109] In view of this, the inventors have designed certain embodiments of the component 620 disclosed herein to prevent surface variations sometimes caused by injection molding the component 620 of the first material 639, such as Fig.16 and Fig.17630 . Specifically, the inventors have recognized that thicker areas of the first material 639 cool at a different rate than thinner areas, thereby causing deformation. Thus, the additional thickness 631 (e.g., between the inner portion 630 and the outer portion 632) necessarily occurs where the standoff 634 and the boss 670 extend upward from the inner portion 630 of the component 620. However, the thickness 690, 692 of the walls 694, 696 forming the standoff 634 and the boss 670 (i.e., between the outer surface 656 and the inner surface 658 and between the outer surface 698 and the inner surface having the threaded opening 678, respectively) also defines how the standoff 634 and the boss 670 cool and thermally expand when they meet the inner portion 630 of the component 620.

[0110] The inventors have recognized that one mechanism to prevent defects while producing the part 620 is by denting the first material 639 . Fig.16 One such example of denting is shown via an annular cutout 712 at the base of boss 670 which provides an over-thickness that does not create a "pinch" in the final part.

[0111] Fig.17 The example of FIG. 6 shows another mechanism for preventing defects when producing component 620. Component 620 is constructed such that support 634 has a lower section 700 and an upper section 702 (upper section 702 includes the masking portion 652 described above), which are separated by a bottom plate 704 that at least partially closes opening 660. Below the bottom plate 704, or in the lower section 700, the thickness 690 of support 634 is reduced compared to in the upper section 702. This design provides less material for cooling near the inner side 630 of component 620, while still having sufficient thickness to make the upper section 702 structurally sound to couple component 620 to another component and fitness machine.

[0112] Further benefits are provided by having an opening 708 in a portion of the outer surface 656 of each support 634, which together with the upper bottom plate 704 is sometimes referred to in the industry as a doghouse 706. The opening 708 of the doghouse 706 allows cooling within the lower section 702 and provides a flow path for the first material 639 along the inner side 630 thereof.

[0113] Benefits may also or alternatively be provided by providing a reduced thickness 631 between the inner portion 630 and the outer portion 632 proximate the thicker region (ie, where the standoff 634 and boss 670 are located). Fig.16 and Fig.17As shown, an annular cutout 712 is provided around the boss 670 to reduce shrinkage issues, as described above. Specifically, the annular cutout 712 has a reduced thickness 631 relative to the thickness of the first material 639. In certain embodiments of the standoff 634 shown here, a lip 714 extends upward from the inner side 630 of the first component 620 into a corresponding hole in the handle plastic to accurately position the components relative to each other. The lip 714 extends upwardly by a height 716.

[0114] The functional block diagrams, operational sequences, and flow charts provided in the accompanying drawings represent exemplary architectures, environments, and methods for performing novel aspects of the present disclosure. Although the methods included herein may be in the form of functional diagrams, operational sequences, or flow charts and may be described as a series of actions for ease of explanation, it should be understood and appreciated that these methods are not limited by the order of actions because, according to these methods, some actions may occur in a different order and / or occur simultaneously with other actions shown and described herein. For example, those skilled in the art will understand and appreciate that a method may alternatively be represented as a series of interrelated states or events, such as in a state diagram. In addition, not all behaviors shown in a method are required for novel implementation.

[0115] This written description uses examples to disclose the invention, including the best mode, and to enable one skilled in the art to make and use the invention. Certain terms are used for brevity, clarity, and understanding. No unnecessary limitations beyond the requirements of the prior art should be inferred from them, as these terms are used for descriptive purposes only and are intended to be broadly interpreted. The patentable scope of the invention is defined by the claims and may include other examples that occur to one skilled in the art. These other examples should be within the scope of the claims if they have features or structural elements that do not differ from the literal language of the claims, or if they include equivalent features or structural elements that do not differ substantially from the literal language of the claims.

Claims

1. A method for manufacturing a fitness machine, the method comprising: Provide basic equipment for operators to exercise; providing handles, each handle having a non-conductive portion and a conductive portion, the conductive portion being plated; coupling the handle to the base device for grasping by the operator during exercise; as well as The conductive portion of each of the handles is electrically connected to a control system, and the control system is configured to determine cardiac information of the operator, wherein the conductive portion of each of the handles receives electrical activity from the operator when the operator grasps it, and wherein the conductive portion is electrically connected so that the electrical activity is provided to the control system to determine the cardiac information of the operator based on the electrical activity.

2. The method of claim 1 , further comprising forming each of the handles via two-shot injection molding, wherein A first shot of the two-shot injection molding comprises a first material forming the non-conductive portion, and wherein a second shot of the two-shot injection molding comprises a second material defining a shape of the conductive portion, whereby the conductive portion is plated on the second material.

3. The method according to claim 2, wherein: The first material is incompatible with an electroplating process, while the second material is compatible with the electroplating process, and the method further includes performing the electroplating process on each handle to form the conductive portion on the second material of each handle.

4. The method according to claim 1, wherein: The conductive portion includes a first conductive portion and a second conductive portion formed in two non-continuous areas, wherein each of the handles has a first component and a second component, and each of the first component and the second component has the non-conductive portion, the first conductive portion, and the second conductive portion, wherein a first area of ​​the two non-continuous areas is formed on the first component, and a second area of ​​the two non-continuous areas is formed on the second component, and the method further includes: for each of the handles, connecting the first component and the second component together so that the non-conductive portion electrically insulates the first conductive portion and the second conductive portion from each other.

5. The method according to claim 4, further comprising: The non-conductive portions of the first component and the second component of each handle are formed via dual-shot injection molding, wherein the first shot and the second shot in the dual-shot injection molding include first and second materials that are different from each other, wherein when the first component is coupled with the second component, the non-conductive portion of each handle has an outer side facing outward and an inner side facing inward, and wherein, for the first component and the second component of each handle, the outer side of the first material is completely covered by the second material.

6. The method according to claim 1, wherein: The conductive portion includes a first conductive portion and a second conductive portion formed in two non-continuous areas, wherein, for each of the handles, each of the two non-continuous areas extends between an outer portion constructed to be contacted by the operator during use and an inner portion positioned inside one of the handles, and the method also includes: for each of the handles, electrically connecting the control system to the inner portions of the two non-continuous areas via a conductor so that the conductor is protected within the handle.

7. The method according to claim 6, wherein: The conductor includes a connector for connecting wires, and the method further includes electrically coupling the control system to the two non-continuous areas by pulling the connector into contact with the inner sides of the two non-continuous areas via a fastener.

8. The method of claim 1, further comprising forming each of the handles of the first material via injection molding, wherein: The first material is compatible with an electroplating process, and the method further comprises: masking the first material so that each of the handles is covered with a masked portion of the first material, and performing the electroplating process on each of the handles to form the conductive portion on the unmasked remaining portion of the first material, wherein the masked portion forms the non-conductive portion of the handle.

9. The method of claim 1, further comprising coupling the handle so that the handle is at least partially recessed within the base device.

10. The method according to claim 9, wherein: Each of the handles includes an outer surface configured to be contacted by the operator in use, the method further comprising coupling each of the handles to the base device such that the outer surface is flush with the base device.

11. The method according to claim 1, further comprising: For each of the handles, the conductive portion is formed to have a thickness of less than 0.10 mm.

12. A handle for a fitness machine produced by an electroplating process, the handle comprising: a component comprising a first material compatible with the electroplating process; a masked portion of the component, the masked portion of the component being substantially free of plating from the electroplating process; as well as a plated portion formed in a remaining portion of the component via the electroplating process such that the first material is covered by electroplating in the plated portion; wherein the masked portion forms a non-conductive portion of the handle, and wherein the plated portion forms a conductive portion of the handle, the conductive portion being configured to conduct electrical activity from an operator of the exercise machine contacting the conductive portion of the handle during use of the exercise machine.

13. A fitness machine, the fitness machine being configured to determine cardiac information of an operator, the fitness machine comprising: a base device with which an operator can perform exercises; handles, each coupled to the base device and configured to be gripped by the operator during exercise, wherein each of the handles includes a non-conductive portion and a conductive portion, wherein, for each of the handles, the conductive portion is plated; and A control system electrically connected to the conductive portion of each of the handles so that the control system receives electrical activity from the operator through the conductive portion, wherein the control system is configured to determine the cardiac information of the operator based on the electrical activity received via the handles.

14. The fitness machine according to claim 13, wherein: For each of the handles, the non-conductive portion includes a first material and a second material that are different from each other, the second material covers the first material, and the second material defines a shape of the conductive portion, the conductive portion being formed on the second material.

15. The fitness machine according to claim 13, wherein: Each of the handles includes a first material compatible with an electroplating process, wherein the first material has a surface including a masking portion and a remaining portion different from the masking portion, the remaining portion being covered during electroplating while the masking portion is substantially free of electroplating, the masking portion forming the non-conductive portion of the handle.

16. The fitness machine according to claim 13, wherein: The conductive portion includes a first conductive portion and a second conductive portion formed in two non-continuous areas, wherein each of the handles has a first component and a second component, and each of the first component and the second component has the non-conductive portion, the first conductive portion, and the second conductive portion, wherein a first area of ​​the two non-continuous areas is formed on the first component, and a second area of ​​the two non-continuous areas is formed on the second component, and wherein when the first component and the second component are coupled together to form one of the handles, the non-conductive portion electrically insulates the first conductive portion and the second conductive portion from each other.

17. The fitness machine according to claim 13, wherein: For each of the handles, the conductive portion extends between an outer portion configured to be contacted by the operator in use and an inner portion positioned inside one of the handles, and wherein, for each of the handles, the control system is electrically connected to the inner portion of the conductive portion via a conductor so that the conductor is protected within the handle.

18. The fitness machine according to claim 17, wherein: The conductors include wires that electrically couple the control system to the conductive portions of each of the handles, respectively, via connectors, and the connectors are press-coupled to the conductive portions via fasteners.

19. The fitness machine according to claim 13, wherein: The base device comprises two arms, and wherein the handle is coupled such that the conductive portion of the handle directly contacts the two arms, respectively.

20. The fitness machine according to claim 13, wherein: For each of the handles, the thickness of the conductive portion is less than 0.10 mm.

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