Cable Connection Assembly

This application is a nonprovisional of, and claims priority to, U.S. Provisional Application No. 63/641,230, filed May 1, 2024, which prior application is incorporated by reference herein in its entirety.

This disclosure relates to a connection assembly for providing a connection at an end of a cable, and more specifically to a connection assembly for providing a connection at an end of a cable system for a weightlifting machine that uses one or more cables.

Weightlifting machines using cables to connect a user input point to a weight source are known in the art, as well as weight rack assemblies having such weightlifting machines mounted thereon. Weightlifting machines of this type often require connection assemblies at the end of the cable for various purposes, including connection of attachments to the cable. It is advantageous for such a connection assembly to be easily assembled and disassembled, because routing the cable through various pulleys and openings in the weightlifting machine may not be possible with a large connection at the end of the cable. Existing cable connection assemblies do not provide an adequate combination of achieving a strong connection, durable structure, avoiding damage to the cable, and ease of assembly and disassembly.

The present disclosure is provided to address this need and other needs in existing cable connection assemblies. A full discussion of the features and advantages of the present invention is deferred to the following detailed description, which proceeds with reference to the accompanying drawings.

Aspects of the disclosure relate to a connection assembly for connection to a cable having an enlarged end piece. The assembly includes a base having a connector at a first end configured for connection to an attachment and a cavity extending inward from a second end opposite the first end, a holder received within the cavity of the base, and a shell having a side wall and an end wall defining a chamber receiving the base and the holder therein, such that at least the first end of the base extends out of the chamber. The cavity has a threaded inner surface, and the holder has a threaded outer surface that is threadably engaged with the threaded inner surface of the cavity to removably fix the holder within the cavity. The base also has and a base fastener hole extending through the base to the cavity, and the shell has a shell fastener hole extending through the side wall and into the chamber. A fastener extends through the shell fastener hole and is received in the base fastener hole to removably fix the base within the chamber of the shell. The holder also has a receiver and a passage extending to the receiver, where the passage is configured to receive the cable therethrough, and the receiver is configured to receive and engage the enlarged end piece of the cable to retain the cable within the passage. The end wall of the shell has an aperture configured for receiving the cable therethrough to engage the holder within the chamber.

According to one aspect, the assembly also includes a ring comprising a resilient material and positioned within the chamber and between the holder and the end wall of the shell, the ring having a ring passage configured to receive the cable therethrough such that the ring extends around the cable. In one configuration, the holder further includes a first end having the receiver therein, a second end opposite the first end and adjacent to the end wall of the shell, and a recess in the second end, and the ring is received within the recess.

According to another aspect, the holder further includes a first end having the receiver therein, a second end opposite the first end and adjacent to the end wall of the shell, and beveled surfaces at the second end configured to assist a user in rotating the holder to thread the holder into the cavity. In one configuration, the base fastener hole extends from the outer surface of the base into the cavity, and the fastener extends through the base fastener hole to engage the holder and further removably fix the holder within the cavity.

According to a further aspect, the holder also includes a slot extending from an outer surface or side surface of the holder to the passage and to the receiver, where the slot is configured to permit the cable to be inserted laterally into the passage and the receiver.

Additional aspects of the disclosure relate to a connection assembly for connection to a cable having an enlarged end piece. The assembly includes a base having a connector at a first end configured for connection to an attachment and a cavity extending inward from a second end opposite the first end, a holder received within the cavity of the base and removably fixed within the cavity, and a shell having a side wall and an end wall defining a chamber receiving the base and the holder therein, such that the base is removably fixed within the chamber and at least the first end of the base extends out of the chamber. The holder has a passage configured to receive the cable therethrough, and the holder is configured to engage the enlarged end piece of the cable to retain the cable within the passage. The end wall of the shell has an aperture configured for receiving the cable therethrough to engage the holder within the chamber. The connector may be or include a clevis connector in one example.

According to one aspect, the assembly also includes a ring comprising a resilient material and positioned within the chamber and between the holder and the end wall of the shell, and the ring has a ring passage configured to receive the cable therethrough such that the ring extends around the cable. In one configuration, the holder further includes a first end, a second end opposite the first end and adjacent to the end wall of the shell, and a recess in the second end, and the ring is received within the recess.

According to another aspect, the cavity of the base has a threaded inner surface, and the holder has a threaded outer surface that is complementary to the threaded inner surface of the base, such that the holder is removably fixed within the cavity by threaded engagement between the threaded inner surface of the base and the threaded outer surface of the holder. In one configuration, the holder may have a first end, a second end opposite the first end and adjacent to the end wall of the shell, and beveled surfaces at the second end configured to assist a user in rotating the holder to thread the holder into the cavity. In another configuration, the base may have a base fastener hole extending from the outer surface of the base into the cavity, and a fastener extends through the base fastener hole to engage the holder and further removably fix the holder within the cavity.

According to a further aspect, the base has a base fastener hole in an outer surface thereof, and the shell has a shell fastener hole extending through the side wall and into the chamber. The connection assembly further includes a fastener extending through the shell fastener hole and engaged with the base fastener hole to removably fix the base within the chamber of the shell.

According to yet another aspect, the holder has a first end, a second end opposite the first end and adjacent to the end wall of the shell, and a receiver in the first end, such that the passage extends through the holder to the receiver. The holder is configured to engage the cable such that the cable extends through the passage to the receiver. The passage has a width that is configured to be smaller than the enlarged end piece of the cable to resist passage of the enlarged end piece through the passage, and the receiver has a width that is enlarged with respect to the width of the passage, such that the receiver is configured to receive and retain the enlarged end piece. In one configuration, the holder may have a slot extending from an outer surface of the holder to the passage and to the receiver, such that the slot is configured to permit the cable to be inserted laterally into the passage and the receiver.

Further aspects of the disclosure relate to a cable system for use with a weightlifting machine, including a cable having an input end with an enlarged end piece, and a connection assembly according to any aspects disclosed herein connected to the input end of the cable. For example, the connection assembly may include a base having a connector at a first end configured for connection to an attachment and a cavity extending inward from a second end opposite the first end, a holder received within the cavity of the base and removably fixed within the cavity, and a shell having a side wall and an end wall defining a chamber receiving the base and the holder therein, where the base is removably fixed within the chamber. The holder has a passage receiving the cable therethrough, where the holder engages the enlarged end piece of the cable to retain the cable within the passage, and the end wall of the shell has an aperture through which the cable extends to engage the holder within the chamber.

According to one aspect, the connection assembly further includes a ring comprising a resilient material and positioned within the chamber and between the holder and the end wall of the shell, the ring having a ring passage receiving the cable therethrough such that the ring extends around the cable.

According to another aspect, the cavity of the base has a threaded inner surface, and the holder has a threaded outer surface that is complementary to the threaded inner surface of the base, such that the holder is removably fixed within the cavity by threaded engagement between the threaded inner surface of the base and the threaded outer surface of the holder.

According to a further aspect, the base has a base fastener hole in an outer surface thereof, and the shell has a shell fastener hole extending through the side wall and into the chamber. A fastener extends through the shell fastener hole and engages with the base fastener hole to removably fix the base within the chamber of the shell.

According to yet another aspect, the holder has a first end, a second end opposite the first end and adjacent to the end wall of the shell, and a receiver in the first end, such that the passage extends through the holder to the receiver, and the cable extends through the passage to the receiver. The passage has a width that is smaller than the enlarged end piece of the cable to resist passage of the enlarged end piece through the passage, and the receiver has a width that is enlarged with respect to the width of the passage, such that the receiver is configured to receive and retain the enlarged end piece.

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

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

General aspects of the disclosure relate to a connection assemblyfor providing a connection at an end of a cable system for a weightlifting machine that uses one or more cables. Referring to the drawings, and initially to, there is shown an example of a weight rack assemblythat includes a frameand one or more weightlifting structures connected to and/or supported by the frame, including one or more shelves, barbell racks, and body weight exercise supports (e.g., bars, handles, and other structures for use in body weight exercises such as chin-ups, climbing, and others), and weightlifting accessories and mechanisms. Two weightlifting machinesare also supported by the framefor use in weightlifting exercises.

The framemay include an arrangement of frame members, including a plurality of vertical frame membersthat are connected together with a plurality of lateral frame membersextending between the plurality of vertical frame membersA. For example, the framein the embodiment ofis primarily formed by a plurality of structural support members or frame membersin the form of metal bars, which may be arranged and connected to each other as vertical beams, horizontal or lateral crossbeams, and angular beams to support the various structures of the rack assembly. The framemay also include connectors in the form of brackets or other connecting structures for connecting the frame memberstogether to form the frame. The vertical and lateral frame membersas shown inmay be formed as rectangular metal tubes having four side surfaces defining a hollow interior. As known to one skilled in the art, a rectangular tube may have either a square cross-sectional shape where each side surface has the same width or rectangular cross-sectional shape where a first side surface may have a different width than its adjacent side surface.

At least one of the side surfaces of each frame membermay include a plurality of openings or fastener holesarranged along the lengths of frame member. Additionally, the plurality of holesmay be identical in shape and size as well as evenly spaced apart from one another along at least a portion of a length of each frame member. In some configurations, the holeson each surface may be the same shape, such as circular openings, while in other configurations, the holesmay not be the same shape on each surface. The fastener holesmay have different shapes, such as circular holes, elongated (i.e., “keyhole” shaped) holes, etc. A single surface of a frame membermay include a mixture of different types of holesin one embodiment. For example, as shown in, the vertical frame membershave circular holeson some surfaces and a combination of circular holes and elongated holesspaced along a second surface that is adjacent to the first surface. It is understood that opposing holes(i.e., located directly across from each other) may be axially aligned along the length of the frame memberand have the same shapes.

Alternatively, in some embodiments, the frame membersmay include an L-shape or U-shaped structure with a plurality of holesarranged along the length of each surface. This arrangement of fastener holespermits fasteners (not shown) to extend into or through each frame memberin two transverse directions for connection of various components to any side of each frame member, including weightlifting structures, other frame members, and other structures. Suitable fasteners include pins (including cotter pins or other locking pins), bolts and other threaded connectors, clamps, and other types of fasteners. The rack assemblyand framestructured in the manner illustrated inand described herein permits construction in a modular manner to provide a wide variety of configurations as desired, including customizable sizes, layouts, and supported weightlifting structures. It is understood that various weight rack assembliesand framesofmay have a smaller and/or simpler form or a larger and/or more complex form, with multiple weightlifting structures connected thereto.

The weight rack assemblyinincludes two weightlifting machineseach configured for use with a weight sourceto provide resistance for a weightlifting exercise. The weight sourcemay include a weight stack, a free weight such as a weight plate, a resistance band, a machine or constrained weight, a moveable carriage for engagement of different weighted articles (e.g., weight plates and/or resistance bands), and/or a combination of weight sources or other similar arranged element, and such a weight sourcemay be configured to be adjustable in weight and/or to permit interchanging of weighted articles. The weightlifting machinesineach include a weight stack as the weight source, to provide adjustable resistance, as known in the art. Both weightlifting machinesinare configured for use in a tricep pull exercise, where the user pulls substantially downward with both hands. However, the weightlifting machinesmay be configured for use with different exercises, such as by interchanging grip attachments, changing the cable length (e.g., through adding or removing cable extensions), re-routing the cables, etc.

The weightlifting machinegenerally includes a weight sourcethat may be mounted on or supported by the framein some embodiments, a cable systemhaving an input endformed as a distal end of the cable systemand configured for connection to an attachment(such as a grip attachment) and engaged with the weight source, and a pulley systemrouting the cable systemfrom the input endto the weight source. In each of the weightlifting machinesof, the cable systemhas a weight endcoupled to the weight sourcesuch that the weight endand the input endform opposite ends of the cable system. In another embodiment, the cable systemmay be engaged with a pulley coupled to the weight source, such that the cable runs through the pulley and has an end located elsewhere, e.g., fixed to a different point on the frameor configured as a second input end. Various different embodiments of weightlifting machinesmay incorporate the connection assemblydisclosed herein. Examples of weightlifting machines that may be designed to incorporate various embodiments of the connection assemblydisclosed herein are shown in U.S. Pat. No. 11,260,261 B2, filed on Oct. 14, 2019, and granted on Mar. 1, 2022, and U.S. Application Publication No. 2022/0072361 A1, filed on Oct. 20, 2021, and published on Mar. 10, 2022, both of which are incorporated by reference herein in their entireties.

Each cable systeminincludes a single cableconnected at the weight endto the weight sourceand at the input endto a grip attachment. The cable systemmay include multiple cablesin another embodiment, which may create a single input endor multiple input endsthat may have the same or different mechanical advantages. Additionally, the cable systemmay include stops (not shown) to limit movement of the cable(s), such as a rubber ball. The cable systemsmay be configured so that the cable(s)passes through one or more of the frame members, such as through one or more fastener holesand/or through the central passage of the frame member(s). Each of the cablesinpasses through one of the frame memberstransversely to the frame member(i.e., passing vertically through a passagein the horizontal frame member) by entering one of the fastener holes, through the hollow interior of the horizontal frame member, and exiting through another fastener holeon the opposite side of the lateral frame member. The relevant fastener hole(s)may be outfitted with a grommet or other protector to avoid damage to the cable.

The pulley systemmay include one or more pulleysconfigured to guide and, in some cases, redirect the cable(s)of the cable system. For example, each pulley systemin the embodiment ofincludes two pulleysmounted to the frameat different locations spaced from each other, redirecting the cablefrom vertical to horizontal and back to vertical. The pulley systemalso includes one or more mountsconfigured for mounting the pulley(s)to the frame. One of the weightlifting machinesinhas a single pulley mountmounting both pulleys, and the other weightlifting machinehas two pulley mountseach mounting one of the pulleys. In another embodiment, the pulley systemmay also be configured to create a mechanical advantage in a weightlifting exercise, such as through incorporation of travelling pulleys and additional cables.

An example embodiment of a connection assemblyfor use with a weightlifting machinesuch as shown inis illustrated in. While the weightlifting machinesinare not depicted as using the connection assembly, it is understood that the input endsof each of the cable systemsmay be outfitted with the connection assembly. In other embodiments, one or more ends of a cable systemmay be outfitted with the connection assembly, including one or more input ends, weight ends, or ends that are fixed to the weight rack frame. The connection assemblyis configured to permit simple connection of an attachment, such as a grip attachment, a cable extension, or other article, via a connection assembly such as a carabiner, a clevis or shackle, or other connection, which may use a removable connecting structure. The connection assemblyis configured for use with a cablethat has an enlarged end pieceat the terminal end thereof, which is in the form of a rigid ball (e.g., formed of metal) in the embodiment of. The enlarged end pieceis larger in width than the cableitself in at least one plane or direction. The rigid ball enlarged end piecein the embodiment ofhas a larger width than the cablein all planes and directions measured perpendicular to the axis of the cable. It is understood that other shapes of the enlarged end piecemay be used in other embodiments.

The connection assemblyincludes a basehaving a connectorat a first endand a cavityextending inward from an opposed second end, a holderreceived within the cavityof the baseand having a receiverfor receiving the enlarged end pieceof the cable, a ringpositioned around the cable, and a shellhaving a chamberreceiving the base, the holder, and the ringtherein. In one embodiment, the holderis removably fixed within the cavityof the base, and the holderand the baseare removably fixed within the chamberof the shell. The connectorin the embodiment ofis in the form of a loop or clevis structure, but other connectorsmay be used in other embodiments, including releasable connectors. It is understood that the connectoris configured for connection to an attachmentas described herein and shown in.

The basein the embodiment ofis formed as a single-piece structure with the connector, such as by casting and/or machining, and may be formed of a high-strength material such as stainless steel or other metal. The basemay have a generally cylindrical structure, with the cavityextending inward from the second endthereof. The cavitymay be formed by drilling a blind hole in one embodiment. The cavityinis defined by a cylindrical inner surfacethat is threaded. The baseincludes at least one fastener hole(also referred to as a “base fastener hole”) extending from the outer surface into the cavity, and the embodiment ofhas two fastener holesextend inward from opposite sides of the base.

The holderis a generally cylindrical body that has a generally cylindrical outer surfacethat is threaded with complementary threading to the inner surfaceof the cavityof the base. The receiverextends inward from a first endof the holdermore proximate to the connector, and a passageextends through a bottom wallof the receiverto permit the cable to pass through the second endof the holderwhen the enlarged endis received in the receiver. The width or diameter of the passageis smaller than the width/diameter of the enlarged endto prevent the enlarged endfrom passing through the passage, such that the bottom wallof the receiverengages the enlarged endto hold the enlarged endin place when tension is exerted on the cable. The holderinalso has a slotextending from the outer surfaceto the receiverand the passage, to permit insertion of the cablethrough the passageand into the receiver. The slotalso has a smaller width than the width/diameter of the enlarged end, so the enlarged endcannot pass laterally out of the receiverthrough the slot. In this configuration, the enlarged endcan only pass into or out of the receiveraxially through the first endof the holder. A cable end(such as an input end) is connected to the holderby inserting the cableinto the slotlaterally (see) and pulling the cableaxially until the enlarged endpasses into the receiverfrom the first endof the holder. It is understood that the slotextends inwardly from the outer surfaceto the passageand the receiverin the lateral direction of insertion of the cableinto the slot, and that this lateral direction is perpendicular to the axial direction of the passage. Thus, the outer surfacemay be considered a side surface between the ends,of the holder. The second endof the holder(distal from the connectorand adjacent to the end wallof the shell) has a portion that is not threaded and has two beveled surfaceson opposite sides of the holder, as well as a recesslocated between the beveled surfaces. The beveled surfacesprovide a grip and space from the inner surfaceof the cavityof the base, to assist the user in rotating the holderto thread the holderinto the cavityby engagement of the threading on the inner surfaceof the cavityand the outer surfaceof the holder. Once the cableis connected to the holdersuch that the enlarged endis received in the receiver, and the holderis threaded into the base, the enlarged endis retained within the receiver. The recessis centrally located and is separated from the receiverby the bottom wall, such that the passageand the slotextend into the recess.

The ringextends around the cableto hold the cablein place and resist side-to-side movement of the cable, further securing the connection between the cableand the connection assemblyand protecting the cablefrom wear. The ringis an annular structure made of a rubber or other resilient material in the embodiment of FIGS.-. The ringhas a passagethat receives the cabletherethrough. The ringmay be positioned between the holderand the end wallof the shell. The ringin the embodiment ofis received in the recessin the second endof the holderand may engage the shell. The width/diameter of the ringis approximately equal to the width/diameter of the recess, to resist movement of the ringwithin the recess. In other embodiments, the ringmay not be a completely annular structure (e.g., a split ring) and/or may have a completely or partially non-circular outer periphery.

The shellis a cup-shaped member having an end walland a side wallextending from the end wallto define a chamber, with an apertureextending through the end wallto the chamber. The chamberis open at the end of the shellopposite the end wall, defining an end openingin the end of the shell. The shellmay be made from a strong and durable material in one embodiment, such as a high-strength plastic or fiber-reinforced plastic (FRP). In the embodiment of, the shellreceives at least a portion of the base, as well as the holder, the ring, and the endof the cable, including the enlarged end piece, within the chamber. The shellhas a circular shape in this embodiment when viewed axially, with the side wallhaving a partially cylindrical shape. The side wallalso has one or more fastener holes(also referred to as “shell fastener holes”) extending therethrough, and when the connection assemblyis assembled, the fastener holesof the shellare aligned with the fastener hole(s)of the base. The shellinhas two fastener holesto match the two fastener holesof the base, and it is understood that different numbers of fastener holes,may be used in other embodiments. The fastener holesof the basemay be threaded, but the fastener holesof the shellmay or may not be threaded, and the fastener holesin the embodiment ofare not threaded. In this configuration, fastenersare received through the fastener holesof the shelland are threaded into the fastener holesof the baseto connect the shellto the baseand secure the components of the connection assembly. The fastenersmay further engage the holderwithin the cavityof the baseto resist rotation of the holderthat may disrupt the threaded connection between the baseand the holder.

Assembly of the connection assemblyofis illustrated in. The connection assemblyis assembled by first passing the cable endthrough the apertureof the shelland the passageof the ring, and then engaging the cable endwith the holdersuch that the enlarged end portionis received in the receiveras disclosed herein. The holderis then threaded into the cavityof the baseby rotating the holder, thereby securing the cable endwithin the receiver. Once secured, the ringis pushed into the recess, and the ring, the holder, and the baseare inserted into the chamberof the shell. Finally, fastenersare inserted through the fastener holesin the shelland are threaded into the fastener holesin the baseuntil the ends of the fastenersengage the holder. Disassembly of the connection assemblyis accomplished by reversing these steps. Once assembled, the connection assemblymay be connected to an attachmentas discussed herein, such as a grip attachment or a cable extension.

In assembling a weightlifting machineand/or a weight rack assemblyincluding such a machine, the cable systemis routed as desired through the pulley system. Once the cable systemis fully routed, a cable stop (e.g., a ball stop) may be connected to the cablenear the cable endif desired. The connection assemblyis then assembled and connected to the cable endas disclosed herein. If the cable systemis desired to be re-routed, the connection assemblyis first disassembled and disconnected from the cable endas disclosed herein, and any cable stop can be removed. The cable systemis then re-routed, and the cable stop (if any) and the connection assemblycan then be reconnected to the cable end.

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

The connection assembly disclosed herein provides benefits and advantages over existing cable connections and similar devices. For example, the connection assembly provides a strong and secure structure for connection to a cable end that may offer greater connection security than existing devices. As another example, the connection assembly is easy to assemble and disassemble without specialized tools, and assembly and disassembly can be quickly accomplished as necessary. This facilitates routing and re-routing cables in a weightlifting machine as desired. Still other benefits and advantages are recognized by those skilled in the art upon reading this disclosure.

Several alternative embodiments and examples have been described and illustrated herein. A person of ordinary skill in the art would appreciate the features of the individual embodiments, and the possible combinations and variations of the components. A person of ordinary skill in the art would further appreciate that any of the embodiments could be provided in any combination with the other embodiments disclosed herein. It is understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein. Terms such as “top,” “bottom,” “front,” “back,” “side,” “rear,” “proximal,” “distal,” and the like, as used herein, are intended for illustrative purposes only and do not limit the embodiments in any way. Nothing in this specification should be construed as requiring a specific three dimensional orientation of structures in order to fall within the scope of this invention, unless explicitly specified by the claims. When used in description of a method or process, the term “providing” (or variations thereof) as used herein means generally making an article available for further actions, and does not imply that the entity “providing” the article manufactured, assembled, or otherwise produced the article. The term “approximately” as used herein implies a variation of up to% of the nominal value or property modified by such term, or up to% of a midpoint value of a range modified by such term. Additionally, the term “plurality,” as used herein, indicates any number greater than one, either disjunctively or conjunctively, as necessary, up to an infinite number. Accordingly, while the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention and the scope of protection is only limited by the scope of the accompanying claims.