GB2602062A

GB2602062A - Improvements in or relating to fitness equipment assemblies

Info

Publication number: GB2602062A
Application number: GB2019961.8A
Authority: GB
Inventors: Heinich Kieran
Original assignee: Bulldog Gear Ltd
Current assignee: Bulldog Gear Ltd
Priority date: 2020-12-17
Filing date: 2020-12-17
Publication date: 2022-06-22
Anticipated expiration: 2040-12-17
Also published as: GB2602062B; EP4263004A1; GB202019961D0; WO2022129884A1

Abstract

A fitness equipment assembly comprises a frame for supporting one or more pieces of fitness equipment and/or a user of the equipment in use. The frame is made from a plurality of elongate frame members 16, wherein each of the frame members 16 includes a mating portion 18 in the form of a cut out 20 formed partially through a width (W) of the frame member 16. The mating portions 18 are formed to permit the mating portion 18 of one frame member 16 to locate with the mating portion 18 of another frame member 16 to join the frame members 16 in place relative to one another to form the frame. The joints make the frame easy and quick to assemble. The frame members may be formed from extruded box sections which may be bolted together. The fitness equipment may form a squat, power or weights rack.

Description

IMPROVEMENTS IN OR RELATING TO FITNESS EQUIPMENT ASSEMBLIES

This invention relates to a fitness equipment assembly which is easy and quick to assemble while providing adequate structural rigidity.

Fitness equipment assemblies come in many different forms and typically include some form of frame which supports one or more pieces of fitness equipment and/or a user who is working out. An example of a fitness equipment assembly is a fitness/weights bench which typically has a frame that supports a seat or bench for a user to sit or lie on to allow them to perform certain exercises. Another example is a fitness, squat or power rack which typically has a tall frame with uprights that can support various fitness equipment such as pull-up/chin-up bars, barbells, overhead ladders and/or a weights rack.

Such known fitness equipment assemblies are made from steel extrusions that are typically welded together to form the desired frame shape. In other known fitness equipment assemblies, the steel extrusions may be joined by using additional support plates (often triangular in shape) which are bolted onto adjacent extrusions to hold them in place. Other known assemblies may use a combination of these two joining zo methods.

Joining the frame using welding and/or additional support plates is extremely labour intensive. For welding, jigging and work-holding is required and the labour time and cost (especially in western countries) is very high. Using additional support plates also requires labour intensive work as normally several bolts are required to form a single join in the frame. Moreover, additional material and parts are required (i.e. the additional support plates and many bolts), which increases material cost and weight (and therefore shipping) of the assemblies.

There is, therefore, a need for a fitness equipment assembly which can be manufactured and assembled with minimal labour and cost.

According to a first aspect of the invention there is provided a fitness equipment assembly, comprising a frame for supporting one or more pieces of fitness equipment and/or a user of the equipment in use, the frame being made from a plurality of elongate frame members, wherein each of the frame members includes a mating portion in the form of a cut out formed partially through a width of the frame member, the mating portions being formed to permit the mating portion of one frame member to locate with the mating portion of another frame member to position the frame members in place relative to one another to form the frame.

As discussed above, the frame of the fitness equipment assembly can take many forms depending on the desired use of the assembly. For example, the frame may support a bench or other fitness equipment.

Each of the frame members having a mating portion in the form of a cut out formed partially through the width of the frame member means that the frame members themselves have a mating portion that permits locating of two frame members together. Thus, the frame members can be slotted into place at the corresponding mating portions to hold them in a desired position to form the frame without the need for any work-holding, welding or additional support brackets. Such ease of locating the frame members to one another not only significantly reduces the assembly time of is the fitness equipment assembly, but also minimises the need for additional materials and parts (such as additional support brackets).

Moreover, the frame members are easy to package and ship, thus reducing shipping costs, because their uniform shape and lack of additional support brackets means they can be packed tightly together.

The fitness equipment assembly may further include a fastener secured through two frame members at the located mating portions to secure the frame members in place. Preferably, a single fastener is used at a given mating portion location.

Using a fastener through the frame members at the located mating portions provides a reliable means of securing adjacent frame members together to therefore lock them in position. Moreover, being able to use only a single fastener at a given mating portion location (i.e. where two frame members are located at their respective mating portions) significantly reduces the number of fasteners required to assemble the frame, thus reducing the number of parts and time for assembly. The inventors found that the cutout nature of the mating portions provides sufficient support to the adjacently located frame members such that a single fastener is all that is required to provide adequate rigidity in the assembly.

Preferably, the mating portions are positioned in-board from the edge of the frame member.

The mating portions being located in-board from the edge of the frame member means that the cut out is formed inwards from the edge, rather than at the edge. This results in the cut out having two opposing cut out sides (whereas if the cut out is formed right at the edge of the frame member, one side would be missing), which provides further support to the mating portions when located with one another.

Optionally, the frame members are box section extrusions.

Box section extrusions (e.g. hollow extrusions with a square or rectangular profile) lend themselves to frame construction and to forming of the mating portions. They are easy to manufacture and package for shipping.

Preferably, the mating portions are box cut outs which form a C-shaped profile.

The mating portions being box cut outs which form a C-shaped profile provides sturdy and reliable mating portions. The C-shape profile, especially formed in a box section frame member, means that the cut out itself provides reliable support around the mating portion of an adjacently located frame member. Moreover, such box cut outs are straightforward to manufacture.

The mating portions may be positioned on the frame members to orient adjacently located frame members perpendicularly to one another.

Such perpendicular orienting of the adjacently located frame members lends itself for forming a frame with good structural integrity.

In one embodiment, the frame includes an upright foot frame portion made up of a horizontal frame member that locates with an upright frame member at corresponding mating portions.

Inclusion of such an upright foot frame portion provides a support for other parts of the frame or fitness equipment to be joined onto. The foot support can be positioned on the floor to provide a good grounding support for the rest of the assembly. As outlined, the foot frame portion is assembled using the cut out mating portions of the frame members.

It will be understood that the terms "horizontal support frame member" and "upright support frame member" in the context of this application means the orientation of the frame member when the fitness equipment assembly is assembled. In particular, the upright support frame member would stand substantially vertical (i.e. erect) when the frame is assembled (e.g. upstanding from the floor, if the assembly is one which is supported on the floor). Whereas, the horizontal support frame member would be flat or parallel to the floor compared to the upright support frame member when the frame is assembled. In other words, the horizontal and upright support frame members are perpendicular to one another and are out of plane from one another.

In such an embodiment, two foot frame portions may be provided, and a horizontal support frame member, the horizontal support frame member being located with the upright frame member of each foot frame portion at corresponding mating portions positioned at either end of the horizontal support frame member, the horizontal support frame member being configured to support a bench seat in use.

The horizontal support frame provides support to a bench seat in use so that the fitness equipment assembly can be used as a fitness bench. The horizontal support frame member is assembled to the two upright foot frame portions using the cut out mating portions of the corresponding frame members. Thus, the frame for the weights bench can be assembled efficiently and without any welding or additional support plates.

In another embodiment, the frame includes a wall frame portion made up of one or more horizontal frame members that locate with two upright frame members at corresponding mating portions to form a rectangular shaped wall.

As such, a frame wall (i.e. a wall forming a single plane) made up of various frame members is formed using the cut out mating portions. The horizontal frame members space the upright frame members apart from one another by a desired width and also provide structural support. The wall frame portion can be used in many different ways to form different configurations of a fitness equipment assembly.

In this embodiment, the frame may include more than one wall frame portion positioned parallel to one another and joined to one another by a horizontal frame member that locates with each wall frame portion at corresponding mating portions.

Positioning two wall frame portions parallel to one another and joining them by a horizontal frame member forms a type of "box" assembly onto which various types of fitness equipment can be attached (e.g. it can be used as a fitness, squat or power rack). For example, a chin-up/pull-up bar can be secured across the two wall frame portions and barbell supports can be secured to adjacent upright frame members.

The horizontal frame member spaces the two wall frame portions by a desired width and also provides structural support to the assembly. Since the horizontal frame member is located with each wall frame portion using the cut out mating portions (and, as above, the wall frame portions are also assembled using the mating portions), the frame for the fitness/squat/power rack can be assembled efficiently and without any welding or additional support plates.

Any number of parallel facing wall frame portions can be joined to one another to form different sized fitness equipment assemblies. Moreover, additional wall frame portions could be positioned perpendicular to the two parallel facing wall frame portions.

In a further embodiment, the frame includes a horizontal foot frame portion made up of horizontal frame members located with one another at corresponding mating portions.

Such a horizontal foot frame portion does not include any upright frame members and therefore the frame members all lie in a single plane. For example, the frame members when assembled into the horizontal foot frame portion could all sit flat on the floor.

The horizontal foot frame portion provides a sturdy base frame for fitness equipment to be joined onto to form a fitness equipment assembly, wherein such a base frame can be assembled efficiently and without any welding or additional support plates.

Preferably, the frame members are laser cut to form the mating portions.

Laser cutting the mating portions is a quick and reliable means of forming the cut outs.

According to another aspect of the invention, there is provided a method of assembling a frame for a fitness equipment assembly comprising: forming the frame by locating a plurality of elongate frame members with one another at mutual mating portions so as to position the frame members in place relative to one another, wherein the mating portion in each frame member is in the form of a cut out formed partially through a width of the frame member.

According to a further aspect of the invention there is provided a kit of parts for assembling a frame of a fitness equipment assembly, the kit of parts comprising a plurality of elongate frame members, each frame member including a mating portion in the form of a cut out formed partially through a width of the frame member, the mating portions being formed to permit the mating portion of one frame member to locate with the mating portion of another frame member to position the frame members in place relative to one another to form a frame.

According to a further aspect of the invention there is provided a fitness rack assembly, comprising two upright supports that are free to move relative to one another, each upright support including a horizontal foot frame assembly and an upright support member being supported in the upright position by the horizontal foot frame assembly, each horizontal foot frame assembly including a plurality of elongate frame members wherein each of the frame members includes a mating portion in the form of a cut out formed partially through the width of the frame member, the mating portions being formed to permit the mating portion of one frame member to locate with the mating portion of another frame member to position the frame members in place relative to one another to form the horizontal foot frame assembly.

Such a configuration provides a reliable and sturdy attachment of the upright support.

Since in this embodiment the upright support is not attached to anything else, it is important that its attachment to the horizontal foot frame assembly provides enough support to the upright support. Although in this embodiment the upright support is not joined to the horizontal foot assembly by mating portions (since doing so would not provide enough structural rigidity to the upright support nevertheless, the horizontal foot assembly being joined by the mating portions still significantly reduces the overall assembly time and costs for the weights rack compared to conventional similar (free moving) racks.

Such an assembly means that the two upright supports are free to move around since they are not joined to one another by any horizontal supports/frame members. This makes the upright supports easy to store and they can be positioned relative to one another by a user as they see fit (i.e. the user is not tied to a particular spacing apart of the upright supports).

Moreover, the horizontal foot frame assembly is made up of frame members that are joined by corresponding mating portions. Such a horizontal foot frame assembly provides a sturdy base for the upright supports, wherein such a base can be assembled efficiently and without any welding or additional support plates.

The upright support member may be attached to the horizontal foot frame assembly via a fastener, either directly or via a support plate.

The frame members of the horizontal foot frame assembly may have any of the same features outlined above in relation to the frame members of the fitness equipment assembly.

Preferred embodiments of the invention will now be described, by way of non-limiting examples, with reference to the accompanying drawings in which: Figure 1 shows an exemplary frame member that forms part of the fitness equipment assembly of the invention; Figures 2a to 2e show a step-by-step assembly of a fitness equipment assembly according to a first embodiment of the invention; Figures 3a to 3d show a step-by-step assembly of a fitness equipment assembly according to a second embodiment of the invention; Figures 4a to 4d show a step-by-step assembly of a fitness equipment assembly according to a third embodiment of the invention; Figures 5a to 5e show a step-by-step assembly of a fitness equipment assembly according to a fourth embodiment of the invention; and Figures 6a and 6b illustrate a stress test analysis of the fitness equipment assembly according to the second embodiment.

Several embodiments of fitness equipment assemblies 10', 10", 10", 10" are shown in Figures 2a to 5e. Each of the assemblies 10', 10", 10", 10-includes a frame 12', 12", 12", 12" that is made up of a plurality of elongate frame members 16.

An exemplary frame member 16 is shown in Figure 1 and is described below. The features described apply to the frame members 16a, 16b, 16c shown in Figures 2a to 4d.

The frame member 16 includes a mating portion 18 in the form of a cut out 20. The cut out 20 is formed partially through a width W of the frame member 16.

In the embodiments shown, the frame member 16 is a square box section extrusion. In other embodiments, the frame member 16 may be a rectangular box section extrusion or may take another suitable form (e.g. cylindrical extrusions). The frame member 16 is made from steel but may instead be made from any suitable material.

The cut out 20 is a box cut out which forms a C-shaped profile 22. In other embodiments the cut outs may take a different shape and profile.

Moreover, the cut out 20 is positioned in-board from the terminal edge 24 of the frame member 16. In the example frame member 16 shown in Figure 1, the frame member 16 has two cut outs 20, each of which is positioned near the terminal edge 24 of the frame member 16 (i.e. towards either end of the frame member 16). As will be seen in the embodiments of Figures 2a to 4d, the frame member 16 may have a single cut out 20 positioned near or at the centre of the length of the frame member 16. Moreover, the frame member 16 may have any number of cut outs 20 positioned along its length.

In each case, the cut out 20 creates a pair of opposing mating support sides 26. The mating support sides 26 are formed by walls of the frame member 16 itself which are created by the cut out 20.

zo The dimensions of the cut outs 20 match one another. The cut outs 20 are cut (preferably laser cut) with a +/-1 mm tolerance between the frame members 16. This helps to account for things like a coating which may be added to the frame members 16 after the cut outs 20 have been formed.

As can be seen in Figure 1, the frame member 16 has cut outs 20 positioned on different faces of the frame member 16. In this example, the cut outs 20 are formed on adjacent faces of the frame member 16 so that the cut outs 20 face in a perpendicular direction to one another. In other embodiments (as will be seen from Figures 2a to 4d), the cut outs 20 may be formed on the same face of the frame member 16 so that they face in the same direction. Further (as will be seen from Figures 2a to 4d), the cut outs 20 may be formed on opposing faces of the frame member 16 so that the cut outs 20 face in an opposing parallel direction to one another.

The cut outs 20 are so formed so that another frame member 16 can be located at mutual mating portions 18 with one another to position the two frame members 16 in a desired orientation.

In the embodiments shown, all of the cut outs 20 orient adjacently located frame members 16 perpendicularly to one another. In other embodiments, this may not be the case, e.g. they cut outs may be formed to angle the frame members 16 relative to one another.

The frame member 16 further includes a fastener receiving portion 28 positioned at each cut out 20. In the embodiments shown, the fastener receiving portion 28 is an aperture formed through the remaining wall of the frame member 16 where the cut out 20 is created.

A fitness equipment assembly in the form of a fitness (or weights) bench 10' is shown in Figures 2a to 2e.

The fitness bench 10' includes a frame 12' which, in this embodiment, supports a bench seat 40 (see Figures 2d and 2e). The frame 12' is made up of a plurality of elongate frame members 16a, 16b with the features described hereinabove.

Starting with Figure 2a, the frame 12' of the fitness bench 10' includes an upright frame member 16a which has two cut outs 20 positioned towards either end of the upright frame member 16a. The cut outs 20 are located on adjacent sides of the box section frame member 16a such that the cut outs 20 face in perpendicular directions to one another.

The frame 12' also includes a horizontal frame member 16b which has a single cut out 20 positioned in the centre of the horizontal frame member 16b.

The cut outs 20 in this example are 50x50 mm (with a 1 mm tolerance), but the dimensions may be any suitable size.

so The cut out 20 of the horizontal frame member 16b is located with one of the cut outs of the upright frame member 16a, as shown by the arrow in Figure 2a. This creates an upright foot frame portion 30 (see Figures 2b to 2e). In the upright foot frame portion 30, the horizontal frame member 16b positions the upright frame member 16a in the upright (vertical) position such that the two frame members 16a, 16b are orientated perpendicularly to one another and out of plane to one another.

As shown, there are two upright foot frame portions 30 in the frame 12' of the fitness bench 10'.

Moving onto Figure 2b, the upright and horizontal frame members 16a, 16b are secured to one another by a single fastener 32 which is fastened at the fastener receiving portion 28, i.e. which is positioned at the mating cut outs 20 of the two frame members 16a, 16b. In this embodiment, the fastener is a bolt 33 and nut 34 (with appropriate washers 36).

Turning to Figure 2c, the frame 12' of the fitness bench 10' further includes a horizontal support frame member 16c. The horizontal support frame member 16c includes two Cut outs 20 positioned towards either end of the horizontal support frame member 16c.

This time, the cut outs 20 are positioned on opposing sides of the box section frame member 16c such that the cut outs 20 face in opposite but parallel directions to one another.

As indicated by the arrows in Figure 2c, the cut outs 20 of the horizontal support frame member 16c locate with the exposed cut outs 20 of the upright frame members 16a. Thus, locating the horizontal support frame member 16c with the two upright feet frame portions 30.

As shown in Figure 2d, the horizontal support frame member 16c is secured to the upright feet frame portions 30 by a single fastener 32 at each fastener receiving portion 28.

As described, the frame 12' of the fitness bench 10' is formed by locating and fastening the different frame members 16a, 16b, 16c without any need for welding or additional support brackets.

The horizontal support frame member 16c in this embodiment includes three support brackets 38 (although fewer or more may be included) positioned along the length of 30 the frame member 16c.

The horizontal support frame member 16c is tabbed and slotted along its length to allow for accurate location of the support brackets 38 onto the horizontal support frame member 16c. Once located, the support brackets 38 are welded onto the horizontal support frame member 16c.

The support brackets 38 allow attachment of a bench seat 40, as indicated by the arrows in Figure 2d. The attachment of the bench seat 40 is made by bolting via the support brackets 38.

Figure 2e shows the fully assembled fitness bench 10'. As can be seen, end caps 42 are fitted onto the exposed ends of the horizontal frame members 16b of the feet frame portions 30. The thickness of the end caps 42 is chosen to match the thickness of the cut out 20 under-hang 44 which extends underneath the horizontal frame member 16b. In this way, the end caps 42 prevent the fitness bench 10' from wobbling or being

unstable.

In other embodiments, the fitness bench 12' may include wheels which may be secured to one or both of the foot frame portions 30.

is A fitness equipment assembly in the form of a first fitness (or squat or power) rack 10" is shown in Figures 3a to 3d.

The first fitness rack 10" includes a frame 12" which, in this embodiment, supports various fitness equipment (see Figure 3d, discussed in more detail below). As with the fitness bench 10', the frame 12" is made up of a plurality of elongate frame members 16a, 16b with the features described hereinabove in relation to Figure 1.

The same reference numeral has been used for "horizontal" and "upright" frame members throughout the described embodiments. It will be understood that the principal of these frame members 16a, 16b is the same although the length of frame members 16a, 16b and positioning of the cut outs 20 may differ to suit the assembly in which it is being used.

Starting with Figure 3a, the frame 12" of the first fitness rack 10" includes two upright frame members 16a, each of which includes cut outs 20 located towards either end of the frame member 16a. The two cut outs 20 on each frame member 16a are formed on the same face of the frame member 16a, and so are facing in the same direction as one another. Two horizontal frame members 16b are located at their cut outs (also positioned facing the same direction as one another and towards either end of the frame member 16b) with the upright frame member 16a cut outs 20, as indicated by the arrows shown in Figure 3a.

In this way, the horizontal frame members 16b space the two upright frame members 16a apart from one another but in a parallel manner, so as to form a wall frame portion 44.

In other embodiments, the wall frame portion 44 may include more than two horizontal frame members 16b for extra support, e.g. there may be one the extends between the two horizontal frame member 16b shown in Figure 3a.

The cut outs 20 in this example are 80x80 mm (with a 1 mm tolerance), but the dimensions may be any suitable size.

Turning to Figure 3b, the horizontal and upright frame members 16b, 16a are secured to one another by a single fastener 32 at each fastener receiving portion 28 (i.e. at each mated cut out 20).

The two wall frame portions 44 are assembled and are then stood upright, as indicated by the arrows in Figure 3b.

It is noted that in Figures 3a and 3b, the upright frame members 16a are not in their upright position. This is because, for ease of assembly, they would be assembled flat on the ground at first, as shown in Figures 3a and 3b, and then stood upright, as shown in Figure 3c.

Next, as shown in Figure 3c, a further horizontal frame member 16c is located at its OA outs (which are formed towards either end of the frame member 16c and are facing the same direction) with an exposed cut out 20 on each of the wall frame portions 44. In this regard, the exposed cut out 20 is formed on an upright frame member 16a in each of the wall frame portions 44 and is adjacent to the other cut outs 20 that have already been used with the horizontal frame members 16b to form the wall frame portions 44.

In other embodiments, more than one further horizontal frame member 16c may be used to provide further rigidity to the frame 12".

Again, the further horizontal frame member 16c is secured to the wall frame portions 44 by a single fastener 32 at each mated cut out 20, as indicated in Figure 3d.

Therefore, the frame 12" of the first fitness rack 10" is formed by locating and fastening the different frame members 16a, 16b, 16c as described above without any need for welding or additional support brackets.

In this embodiment, the upright and horizontal frame members 16a, 16b, 16c all include a series of equally spaced holes 46 formed through the frame members 16a, 16b, 16c. This allows attachment of various fitness equipment to any part of the frame 12". In other embodiments, only some of the frame members 16a, 16b, 16c may include the holes 46.

As shown in Figure 3d, various fitness equipment can be attached (e.g. bolted and/or welded) onto the frame 12" of the first fitness rack 10". In this example, a pull-up bar 48 is secured across the top of the frame 12" and two barbell supports 50 are coupled to upright frame members 16a via the holes 46.

Moreover, in this embodiment the first fitness rack 10" includes ground support brackets 51 secured to each bottom corner of the rack 10" (i.e. at the bottom of each upright frame member 16a). These allow the first fitness rack 10" to be secured to the ground for further stability.

The first fitness rack 10" may additionally or instead include wheels at the bottom of the rack 10". Moreover, the first fitness rack 10" may include end caps (as described above in relation to the fitness bench 10') to cover the ends of the exposed frame members 16a, 16b.

A fitness equipment assembly in the form of a second fitness (or squat or power) rack 10" is shown in Figures 4a to 4d.

The second fitness rack 10-includes a frame 12" which, in this embodiment, supports an upright support which in turn supports fitness equipment (see Figure 4d, discussed in more detail below). As with the fitness bench 10' and the first fitness track 10", the frame 12" is made up of a plurality of elongate frame members 16a, 16b as described above in relation to Figure 1.

As shown in Figure 4a and 4b, the frame 12-includes three horizontal frame members 16b (only two shown in Figure 4a to illustrate initial assembly) which are located with one another at corresponding cut outs 20 so as to form a horizontal foot frame portion 52. In this embodiment, the horizontal foot frame portion 52 is a H-shaped frame portion (see Figure 4b). Other configurations are possible.

The horizontal foot frame portion 52 includes a first horizontal frame member 16b that has two cut outs 20 positioned towards either end of the frame member 16b. The cut outs 20 are formed on the same side of the frame member 16b and therefore face the same direction. The horizontal foot frame portion 52 also includes two further horizontal frame members 16b each of which includes a single cut out 20 positioned centrally along the length of the frame member 16b.

In this example, the cut outs 20 are 75x50 mm (with a 1 mm tolerance), but the dimensions may be any suitable size.

As can be seen, the two further horizontal frame members 16b are positioned parallel to one another and perpendicularly to the first horizontal frame member 16b, i.e. to form the H-shape. As can also be seen, the frame members 16b are all in a single plane (i.e. "horizontal plane", with no upright frame members).

As shown in Figure 4b, the horizontal frame members 16b are secured to one another by a single fastener 32 at each fastener receiving portion 28 (i.e. at each cut out location 20).

In this embodiment, the horizontal foot frame portion 52 is the frame 12". Therefore, the frame 12" of the second fitness rack 10" is formed by locating and fastening the different horizontal frame members 16b as described above without any need for welding or additional support brackets.

In another embodiment (not shown), the horizontal foot frame portion may take a different form in that it may be made up of four horizontal frame members 16b that are joined at the ends to one another (via mating cut outs) so as to take a rectangular or square shape.

As shown in Figure 4c, the second fitness rack 10" further includes an attachment plate 54 which is fastened (e.g. via bolts 56, in this embodiment) to opposing sides of the first horizontal frame member 16b. The attachment plate 54 as shown is triangular in shape but may take any other suitable form. Moreover, it may be secured to the horizontal frame member 16b by other means, e.g. welding.

Turning to Figure 4d, the second fitness rack 10" further includes an upright support 58 which is fastened (e.g. via bolts 56, in this embodiment) to the attachment plate 54 so as to secure the upright support 58 in an upright position relative to the horizontal foot frame portion 52. The upright support 58 may be secured to the attachment plate 54 by other means, e.g. welding.

As outlined previously, the upright support 58 is not secured to the horizontal foot frame portion 52 via mating cut outs due to the extra structural rigidity that is required to hold the free-standing upright support 58 in place. Moreover, in this embodiment, the upright support 58 is made from a rectangular box section which would not mate with the square box section of the horizontal foot frame portion 52 if mutual cut outs were used. It may be possible to use mutual cut outs if the upright support 58 was made from the same square box section as the horizontal foot frame portion 52, although additional support may be required for the reason given above.

In other embodiments, the upright support 58 may be secured to the foot frame portion 52 directly without any attachment plates, e.g. it may be bolted, screwed or welded directed to the horizontal frame member 16b.

As can be seen in Figure 4d, two upright support 58 and horizontal foot frame portion 52 assemblies are provided. These can be used to support fitness equipment as desired. In this embodiment, the upright supports 58 include a series of apertures 60 along their lengths which can receive barbell supports 50.

Moreover, one of the horizontal frame members 16b in each of the horizontal foot frame portions 52 includes wheels 62.

In addition, end caps 42 are fitted onto the exposed ends of the horizontal frame members 16b of the horizontal feet frame portions 52. As described above in relation to the fitness bench 10', the thickness of the end caps 42 is chosen to match the thickness of the cut out 20 under-hang 44 which extends underneath the horizontal frame member 16b. In this way, the end caps 42 prevent the second fitness rack 10-from wobbling or being unstable.

The two upright support 58 and horizontal foot frame portion 52 assemblies are free to move around since they are not joined to one another by any horizontal supports/frame members. This makes the second fitness rack 10-easy to store.

Moreover, a user is not tied to a particular width of rack since the user can freely move the assemblies to be closer or wider apart from one another.

A fitness equipment assembly in the form of a third fitness (or power) rack 10" is shown in Figures 5a to 5e.

The third fitness rack 10" is similar to the first fitness rack 10", as described in Figures 3a to 3d, in that it includes a wall frame portion 44 which is made up of upright frame members 16a and horizontal frame members 16b (see Figure 5a).

Moving onto Figure 5b, an additional two horizontal feet frame members 16c are joined to the bottom of the wall frame portion 44 so that they extend in parallel and in the same direction as one another. The additional two horizontal feet frame members 16c are so joined by locating at mutual cut outs 20 in the additional horizontal feet frame members 16c and the bottom of the upright frame members 16a in the wall frame portion 44, and securing the frame members 16a, 16c by a single fastener 32 at each mated cut out 20.

The additional horizontal feet frame members 16c each have a cut out 20 located approximately half-way along the length of the frame member 16c (although could be located anywhere along the length). These cut outs 20 are mated with a cut out of an additional upright frame member 16d and joined by a single fastener 32 at each mated cut out 20, as shown in Figure 5c.

Next, as shown in Figure 5d, two horizontal head frame members 16e are joined to the top end of the wall frame portion 44 and to the top end of the additional upright frame members 16c. This is done by locating the cut out 20 of the horizontal head frame member 16e with the exposed cut out 20 at the top of the wall frame portion 44 (i.e. at the top of the upright frame member 16a in the wall frame portion 44) and the cut out 20 at the top of the additional upright frame member 16d. The horizontal head frame members 16e are joined to the upright frame members 16a, 16d by a single fastener 32 at each mated cut out 20.

As can be seen, the frame 12" of the third fitness rack 10" is formed by locating and fastening the different frame members 16a, 16b, 16c, 16d, 16e as described above without any need for welding or additional support brackets.

In this embodiment, the upright and horizontal frame members 16a, 16b, 16c, 16d, 16e all include a series of holes 46 formed through the frame members 16a, 16b, 16c, 16d, 16e. This allows attachment of various fitness equipment to any part of the frame 12". In other embodiments, only some of the frame members 16a, 16b, 16c, 16d, 16e may include the holes 46.

As shown in Figure Se, various fitness equipment is attached onto the frame 12-of the fitness rack 10-by a mixture of bolting, welding and pegging onto the holes 46. In this example, an overhead ladder 70 is secured across the top of the frame 12", as well as various support pegs 72, support arms 74 and barbell supports 50 on the horizontal and upright support frames.

In addition, the third fitness rack 10" includes ground support brackets 76 located at the bottom four corners of the rack 10". These allow the fitness rack 10" to be secured to the ground for further stability. In this embodiment, the support brackets 76 also extend under the horizontal feet frame members 16c by a thickness that matches the thickness of the cut out 20 under-hang 44 formed by the upright frame members 16a, 16d. In this way, the support brackets 76 prevent the fitness rack 10" from wobbling or being unstable. Also in this embodiment, the support brackets 76 cover the exposed ends of the horizontal feet frame members 16c.

Assembly of each of the fitness assemblies 10', 10", 10", 10" described above is achieved by following the steps shown in the figures. Since additional support plates and/or welding is minimised or completely eliminated, the assembly time is very quick.

The located frame members 16 only requiring a single fastener 32 also helps to greatly reduce assembly time. Moreover, the nature of the mating cut outs 20 makes it easy and intuitive to join the various frame members 16 together.

For example, the inventors found that assembly time was reduce by at least half (and in some instances, by three quarters) when compared to assembly of a conventional gym equipment assembly which uses welded cross members with support brackets and bolting.

Moreover, the inventors have stress tested various fitness assemblies 10', 10", 10", 10" that have frames 12', 12", 12", 12" that are mated together in the manner described above and found that their strength performance is very similar to that of conventional (e.g. welded or part welded) fitness assemblies.

Figures 6a and 6b illustrate a stress and displacement plot of the first fitness rack 10" when tested under a 300kg load on the pull-up bar 48 and a 450kg load on the barbell supports 50. The results are comparable to conventional welded and/or bolt together assemblies.

Claims

CLAIMS: 1. A fitness equipment assembly, comprising: a frame for supporting one or more pieces of fitness equipment and/or a user of the equipment in use, the frame being made from a plurality of elongate frame members, wherein each of the frame members includes a mating portion in the form of a cut out formed partially through a width of the frame member, the mating portions being formed to permit the mating portion of one frame member to locate with the mating portion of another frame member to position the frame members in place lo relative to one another to form the frame.
2. A fitness equipment assembly according to Claim 1 further including a fastener secured through two frame members at the located mating portions to secure the frame members in place.
3. A fitness equipment assembly according to Claim 2 wherein a single fastener is used at a given mating portion location.
4. A fitness equipment assembly according to any of Claims 1 to 3 wherein the mating portions are positioned in-board from the edge of the frame member.
5. A fitness equipment assembly according to any preceding claim wherein the frame members are box section extrusions.
6. A fitness equipment assembly according to any preceding claim wherein the mating portions are box cut outs which form a C-shaped profile.
7. A fitness equipment assembly according to any preceding claim wherein the mating portions are positioned on the frame members to orient adjacently located frame members perpendicularly to one another.
8. A fitness equipment assembly according to any preceding claim wherein the frame includes an upright foot frame portion made up of a horizontal frame member that locates with an upright frame member at corresponding mating portions.
9. A fitness equipment assembly according to Claim 8 including two foot frame portions, and further including a horizontal support frame member, the horizontal support frame member being located with the upright frame member of each foot frame portion at corresponding mating portions positioned at either end of the horizontal support frame member, the horizontal support frame member being configured to support a bench seat in use.
10. A fitness equipment assembly according to any of Claims 1 to 7 wherein the frame includes a wall frame portion made up of one or more horizontal frame members that locate with two upright frame members at corresponding mating portions to form a rectangular shaped wall.
11. A fitness equipment assembly according to Claim 10 wherein the frame includes more than one wall frame portion positioned parallel to one another and joined to one another by a horizontal frame member that locates with each wall frame portion at corresponding mating portions.
12. A fitness equipment assembly according to any of Claims 1 to 7 wherein the frame includes a horizontal foot frame portion made up of horizontal frame members located with one another at corresponding mating portions.
13. A fitness equipment assembly according to any preceding claim wherein the frame members are laser cut to form the mating portions.
14. A method of assembling a frame for a fitness equipment assembly comprising: forming the frame by locating a plurality of elongate frame members with one another at mutual mating portions so as to position the frame members in place relative to one another, wherein the mating portion in each frame member is in the form of a cut out formed partially through a width of the frame member.
15. A kit of parts for assembling a frame of a fitness equipment assembly, the kit of parts comprising a plurality of elongate frame members, each frame member including a mating portion in the form of a cut out formed partially through a width of the frame member, the mating portions being formed to permit the mating portion of one frame member to locate with the mating portion of another frame member to position the frame members in place relative to one another to form a frame.
16. A fitness rack assembly, comprising two upright supports that are free to move relative to one another, each upright support including a horizontal foot frame assembly and an upright support member being supported in the upright position by the horizontal foot frame assembly, each horizontal foot frame assembly including a plurality of elongate frame members wherein each of the frame members includes a mating portion in the form of a cut out formed partially through the width of the frame member, the mating portions being formed to permit the mating portion of one frame member to locate with the mating portion of another frame member to position the frame members in place relative to one another to form the horizontal foot frame assembly.
17. A fitness rack assembly according to Claim 16 wherein the upright support member is attached to the horizontal foot frame assembly via a fastener, either directly or via a support plate.
18. A fitness rack assembly according to Claim 16 or Claim 17 including any of the features recited in Claims 2 to 6.