EXERCISE STEP USING SPIRALLY SHAPED AIR-CUSHIONING LEGS

• US 20120088642A1
• Filed: 09/23/2011
• Published: 04/12/2012
• Est. Priority Date: 10/12/2010
• Status: Active Grant

• Current Assignee: B & R Plastics Incorporated
• Original Assignee: B & R Plastics Incorporated
• Inventors: Kulzer, Darrell A.
• Granted Patent: US 8,944,979 B2
• Time in Patent Office: Days
• US Class Current: 482/142
• CPC Class Codes: A63B 2071/0063 Shock absorbers
• CPC Class Codes: A63B 2225/62 Inflatable
• CPC Class Codes: A63B 23/0458 Step exercisers without moving parts with movable steps A63B22/04
• CPC Class Codes: A63B 26/003 for improving balance or equilibrium balance beams A63B4/00; apparatus for rope dancing A63B7/08; balancing drums, balancing boards or the like A63B22/16
• CPC Class Codes: B29C 45/262 provided with unscrewing drive means unscrewing means outside the mould B29C45/178
• CPC Class Codes: B29C 45/44 for undercut articles
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

Disclosed are embodiments of an exercise step that utilize spirally shaped air-cushioning legs. The direction of the spiral of the air-cushioning legs is alternated around the periphery of the exercise step to eliminate rotational creep. Flow regulators are utilized to control the flow of air from the top of each of the air-cushioning legs into an interior portion of the base of the exercise step. Spokes provide an air flow passage between the air flow regulators and the central air regulator, as well as providing structural support for the base. Rings are also used around the base that inner connect the spokes and provide additional support. Recessed portions of a lower plate of the base are welded to an upper plate during a blow molding process to add additional support to the base of the exercise step.

Claims

1. An exercise step comprising:

a base comprising;

an upper plate having a non-slip top surface;

a lower plate comprising;

a plurality of leg attachments;

flow regulators disposed in said leg attachments;

an air control regulator disposed in said lower plate;

a plurality of rings that provide circumferential support to said lower plate;

a plurality of spokes that inner-connect said plurality of rings to provide lateral support to said lower plate, said spoke providing a plurality of air passages between said air flow regulators and said air control regulator;

a plurality of recessed portions disposed between said plurality of rings and said plurality of spokes that attach said lower plate to said upper plate by creating a weld between said upper plate and said lower plate at said recessed portions;

at least one clockwise air-cushioning leg comprising;

a first sidewall having a clockwise spirally shaped bulge that allows said clockwise air-cushioning leg to compress when a user steps onto said exercise step;

a non-slip cover attached to a bottom portion of said first sidewall that forms an airtight seal with said bottom portion of said first sidewall;

a first attachment plate connected to an upper portion of said first sidewall that forms an airtight seal with said leg attachments on said lower plate so that when said clockwise air-cushioning leg is compressed, air flows from said clockwise air-cushioning leg through said flow regulators and said air control regulator, which control the speed at which said clockwise air-cushioning leg compresses;

at least one counterclockwise air-cushioning leg comprising;

a second sidewall having a counterclockwise spirally shaped bulge that allows said air-cushioning leg to compress when a user steps onto said exercise step;

a second non-slip cover attached to a bottom portion of said second sidewall;

a second attachment plate connected to an upper portion of said second sidewall that forms an airtight seal with said leg attachments on said lower plate so that when said counterclockwise air-cushioning leg is compressed, air flows from said counterclockwise air-cushioning leg through said flow regulators and said air control regulator, which control the speed at which said counterclockwise air-cushioning leg compresses.

2. The exercise step of claim 1 wherein said clockwise air-cushioning leg is attached to said lower plate adjacent to said counterclockwise air-cushioning leg so that said at least one clockwise air-cushioning leg and said at least one counterclockwise air-cushioning leg are alternatively disposed on said lower plate to prevent rotational creep.

3. The exercise step of claim 1 wherein said flow regulators comprise openings having a predetermined size that passes air at a predetermined rate based upon pressure of said air.

4. The exercise step of claim 1 wherein said flow regulators comprise a porous foam disposed in an opening in said lower plate.

5. The exercise step of claim 1 wherein said flow regulators comprise a porous foam disposed in an adjustable opening in said lower plate.

6. The exercise step of claim 3 wherein said air control regulator comprises a porous foam disposed in an opening in said lower plate that controls air flow through said air control regulator and reduces noise.

7. A method of making an exercise step comprising:

forming a plurality of clockwise air-cushioning legs comprising;

forming a first sidewall having a clockwise spirally shaped bulge that allows said clockwise air-cushioning leg to compress when a user steps onto said exercise step;

attaching a first non-slip cover to a bottom portion of said first sidewall to form an airtight seal with said bottom portion of said first sidewall;

forming a first attachment plate that is connected to an upper portion of said first sidewall having latches for attaching said clockwise air-cushioning legs to said exercise stool;

forming a plurality of counterclockwise air-cushioning legs comprising;

forming a second sidewall having a counterclockwise spirally shaped bulge that allows said counterclockwise air-cushioning leg to compress when a user steps onto said exercise step;

attaching a second non-slip cover to a bottom portion of said second sidewall to form an airtight seal with said bottom portion of said second sidewall;

forming a second attachment plate that is connected to an upper portion of said second sidewall having latches for attaching said counterclockwise air-cushioning legs to said exercise step;

forming an upper plate from a parison in a blow molding process;

forming a lower plate from said parison in said flow molding process comprising;

forming a plurality of rings in said lower plate that provide circumferential support to said lower plate;

forming a plurality of spokes in said lower plate that inner-connect said plurality of rings to provide lateral support to said lower plate, said plurality of spokes providing a plurality of air flow passages;

forming leg attachments in said lower plate that allow said latches on said first attachment plate and said second attachment plate to connect said air-cushioning legs to said lower plate with a substantially airtight seal;

forming a first set of openings in said leg attachments that allow air in said clockwise air-cushioning legs and said counterclockwise air-cushioning legs, that is compressed when said user steps onto said exercise step, to flow into said air flow passages;

forming a second opening in said lower plate that is communicatively coupled to said air flow passages;

regulating air flow in said first set of openings and said second opening to control the rate of flow of said compressed air from said clockwise air-cushioning legs and said counterclockwise air-cushioning legs.

8. The method of claim 7 wherein said process of regulating air flow in said first set of openings comprises forming said first set of openings with a size that limits the rate of flow of air from said clockwise air-cushioning legs and said counterclockwise air-cushioning legs into said air passages.

9. The method of claim 7 wherein said process of regulating air flow in said first set of openings comprises providing air flow regulators in said first set of openings.

10. The method of claim 9 wherein said process of providing air flow regulators comprises providing air flow regulators made from a porous material.

11. The method of claim 7 wherein said process of regulating air flow in said second opening comprises forming said second opening that has a size that limits the rate of flow of air from said air passages.

12. The method of claim 7 wherein said process of regulating air flow in said second opening comprises providing an air flow regulator in said second opening.

13. The method of claim 12 wherein said process of providing an air flow regulator comprises providing an air flow regulator made from a porous material.

14. A method of forming a spirally shaped air-cushioning leg comprising:

providing an exterior mold having a spirally shaped leg portion for injection molding of said air-cushioning leg having a spiral shape;

providing an interior mold that has a spiral shape;

injecting a thermoplastic material between said exterior mold and said interior mold in an injection molding device to form an air-cushioning leg molded piece;

unscrewing said interior mold from said air-cushioning leg molded piece formed between said exterior mold and said interior mold after said air-cushioning leg molded piece has cooled sufficiently to allow said interior mold to be removed;

releasing said exterior mold to remove said spirally shaped air-cushioning leg.