Composite Exercise Weight Structure for Accurate Mass Calibration
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Solution Overview
Problem
Current exercise weight structures made from low-grade cast iron face issues with weight accuracy, high energy consumption, environmental concerns, and high transportation costs, along with the need for a cleaner and more energy-efficient manufacturing process.
Innovation Solution
The production of exercise weight structures using particulate material mixed with a binder, molded into shape, and forming an outer skin to encapsulate an inner weight section, potentially from recycled materials, to achieve improved weight accuracy and reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If low-grade cast iron is used for weight bodies, then manufacturing cost is reduced, but weight accuracy deteriorates
Solution Approach 1:
The patent uses a composite structure consisting of an inner cast iron weight core surrounded by an outer rubber or polyurethane skin. This composite design allows the use of low-grade cast iron (reducing cost) while the outer skin provides protection and enables precise weight calibration during assembly, thereby achieving both cost reduction and weight accuracy.
2Ease of manufacture
If cast iron processing is used, then weight structures can be manufactured economically, but energy consumption increases
Solution Approach 1:
The manufacturing process is segmented into distinct stages: casting the inner iron core, separately manufacturing the outer rubber/polyurethane skin, and then assembling them together. This segmentation allows each component to be optimized independently and assembled with precise weight calibration, reducing overall energy consumption while maintaining manufacturing economy.
3Ease of manufacture
If cast iron processing is used, then weight structures can be manufactured, but environmental pollution increases
Solution Approach 1:
The patent converts the typically harmful sand-based molding process into a beneficial by utilizing the sand molds only for casting the inner iron core, which is then enclosed by the outer rubber or polyurethane skin. This enclosure encapsulates any residual pollution from the casting process, while the outer material provides a clean, non-polluting finish that is safe for gym and home environments.
4Ease of operation
If rubber coating is applied to cast iron weights, then user friendliness is improved, but energy consumption and pollution increase
Solution Approach 1:
The outer rubber or polyurethane skin is pre-formed as a separate component with the exact shape and weight requirements before assembly. This preliminary formation allows for precise weight calibration and eliminates the need for energy-intensive post-casting coating processes, while still providing the user-friendly tactile properties and protection against damage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method provides exercise weight structures with enhanced weight accuracy, reduced energy usage, and lower production costs, allowing for local manufacturing closer to the end user while maintaining a clean and efficient process.
Implementation Method 1
particulate material mixed with a binder material and molded to the appropriate shape
Implementation Method 2
the outer skin forming a mold into which an inner weight section or body is molded or cast
Data Source
AI summary
A method of producing an exercise weight structure comprises mixing a particulate material with a binder material and molding the resulting mixture to an appropriate shape. An outer skin for the exercise weight structure is firstly formed of a resilient material, and forms a mold into which an inner weight section or body is molded or cast. The inner weight section and the outer skin are both formed of recycled material and include a common binder material.