PICKLEBALL PADDLE

Description

BACKGROUND

Pickleball is the fastest growing racquet sport. There is a continuing need to provide a pickleball paddle that improves a player's performance and/or confidence.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view illustrating portions of an example pickleball paddle.

FIG. 2 is a sectional view of the pickleball paddle of FIG. 1 taken along line 2-2.

FIG. 3 is a sectional view of an example implementation of the pickleball paddle of FIG. 1 taken along line 2-2.

FIG. 4 is a sectional view of an example implementation of the pickleball paddle of FIG. 1 taken along line 2-2.

FIG. 5 is a sectional view of an example implementation of the pickleball paddle of FIG. 1 taken along line 2-2.

FIG. 6 is a sectional view of an example implementation of the pickleball paddle of FIG. 1 taken along line 2-2.

FIG. 7 is a front view illustrating portions of an example pickleball paddle.

FIG. 8 is a front view illustrating portions of an example pickleball paddle.

FIG. 9 is a front view illustrating portions of an example pickleball paddle.

FIG. 10 is a sectional view of the pickleball paddle of FIG. 9.

FIG. 11 is a front view illustrating portions of the example pickleball paddle of FIG. 9.

FIG. 12 is a sectional view of the pickleball paddle FIG. 11 along line 12-12.

FIG. 13 is an end view of the pickleball paddle of FIG. 11.

FIG. 14 is a sectional view of the pickleball paddle of FIG. 11 taken along line 14-14.

FIG. 15 is a perspective view of a layup or arrangement of layers of fiber composite material.

FIG. 16 is a top perspective view of the layup of layers of fiber composite material of FIG. 15.

FIG. 17 is a perspective view of the leg up of layers of fiber composite material of FIG. 15 wrapped about a bladder and a mandrel.

FIG. 18 is a perspective view of the leg up of layers of fiber composite deposit material with Amanda removed in the lap of layers curve to approximate the shape of a pickleball paddle and a yoke fiber composite layup.

FIG. 19 is a perspective view of the leg up the layers of fiber composite material of FIG. 18 prior to being placed into the pickleball paddle frame forming mold.

FIG. 20 is an exploded perspective view of the layup of layers being placed into the pickleball paddle outer frame forming mold.

Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements. The figures are not necessarily to scale, and the size of some parts may be exaggerated to more clearly illustrate the example shown. Moreover, the drawings provide examples and/or implementations consistent with the description; however, the description is not limited to the examples and/or implementations provided in the drawings.

DETAILED DESCRIPTION OF EXAMPLES

Disclosed are example pickleball paddles that may enhance a player's performance. The example pickleball paddles have an internal construction that assists in isolating the primary sweet spot and impact regions of the paddle from the handle portions of the paddle. In some implementations, the internal construction dampens vibration and other forces resulting from impact with the pickleball, inhibiting such forces from being transmitted to the handle portion of the pickleball paddle. In some implementations, the internal construction facilitates enhanced responsiveness of the impact portion of the pickleball by facilitating a degree of floating or movement of the impact region (sometimes referred to as the core) relative to the handle portion.

Unless otherwise indicated, the example pickleball paddles satisfy the requirements or standards for pickleball paddles used in officially sanctioned events or competitive play. Unless otherwise indicated, the example pickleball paddles satisfy the requirements set forth in the November 2023 USA Pickleball Equipment Standards Manual. Unless otherwise indicated, the example pickleball paddles each have a combined maximum length and maximum width less than or equal to 24 inches. Unless otherwise indicated, the example bucket ball paddles have opposite pickleball impacting faces that have a maximum kinetic coefficient of friction less than or equal to 0.1875 when tested pursuant to protocol IAW ASTM D1894-14. As should be appreciated, particular characteristics of the example pickleball paddles may be modified such that the pickleball paddles no longer satisfy the requirements or standards for pickleball paddles used in officially sanctioned events or competitive play, but where such modified pickleball paddles still incorporate the performance enhancement features disclosed with respect to the example pickleball paddles.

Disclosed are example pickleball paddles that comprise a handle portion and a head portion. The head portion is coupled to the handle portion.

The head portion may comprise an outer frame extending about an opening, a pickleball impacting region or “core” within the opening, and a core flexor extending between the core and the handle portion within the opening. In some implementations, the frame may be a tube with an interior. In some implementations, the tube may include external grooves, indentations or channels along the top and/or sides of the head portion, such grooves potentially improving the strength and rigidity of the outer frame.

In some implementations, the interior of the tube may be filled with another material, such as a foam. In some implementations, the interior of the tube may be void of any material or may contain a bladder or other volume which is void of any solid material, but where the interior of the bladder or other volume contains a gas, such as air. In some implementations, the interior of the tube may be pressurized with a gas, such as air, during molding and shaping of the tube to form the outer frame. In some implementations from a fiber composite material or materials which are formed about a bladder initially supported by a mandrel, wherein the mandrel is removed, and the bladder is inflated during molding of the tube (and curing or hardening of the fiber composite material). In other implementations, the tube may be formed from other materials and may be formed in other manners. In some implementations, the tube may be formed and hardened with an inflated bladder, wherein the inflated bladder is subsequently deflated and removed upon hardening and shaping of the tube.

In some implementations, the tube may additionally form portions of the handle portion. For example, in some implementations, the tube may be shaped in a loop so as to form the head portion, wherein end portions of the tube extend substantially parallel to one another and form an internal core of the handle portion. In some implementations, an additional yoke piece may be secured across spaced portions of the loop, opposite the handle portion, wherein an opening is provided in the pickleball paddle, between the yoke and the handle portion.

Disclosed are examples of the above pickleball paddles where the core is perforated. In some implementations, the core may comprise a layer or layers having a honeycomb configuration or honeycomb core. In some implementations the core may comprise a layer or layers having a lattice. For example, core may comprise a lattice formed by additive manufacturing, such as 3D printing. The perforate nature of the core provides stiffness while reducing weight of the pickleball paddle. In yet other implementations, the core may be imperforate. In some implementations, the core has a compressive stiffness of at least 200 psi (Pounds per square inch) and no greater than 300 psi (as measured pursuant to ASTM C365).

Disclosed are examples of the above pickleball paddles where the core flexor partially extends about or partially encircles the core. For example, the core may have a semicircular or U-shaped configuration around the lower perimeter of the core between the core and the handle portion. In some implementations, the core flexor may completely wrap about or extend about a perimeter of the core without interruption, in a continuous manner. In some implementations, the core flexor may extend on all sides of the core, along a top and bottom of the car and along both sides of the core, but wherein the core flexor comprise multiple distinct spaced sections or segments along and about the core. In some implementations, core flexor may have a uniform width along its extent. In yet other implementations, the core flexor may have a varying width along its extent, such as where the core flexor has an increased thickness in those regions closer to the handle portion and a reduced thickness in those regions farther from the handle portion. In some implementations, the core flexor has a width of at least 5 mm in at least regions between the core and the handle portion. In some implementations, the core flexor has a width of at least 10 mm in at least regions between the core and the handle portion. The increased width may offer a greater coefficient of restitution and enhanced flexing of the core.

The core flexor has a stiffness or rigidity less than that of the core. The core flexor may have a greater degree of compressibility as compared to the compressibility of the core. In some implementations, the core flexor comprises a foam material forming a foamed layer. In one example implementation, the core flexor comprises a foamed polymer. In some implementations, the core flexor comprises an ethylene-vinyl acetate (EVA) foam having a density of 2 to 6 pounds. In some examples, the core flexor has a Shore 00 hardness of 40 to 60.

In some implementations, the core flexor is formed from other polymeric foam materials such as urethane foams or polyurethan foams. In other implementations, the core flexor may comprise a flexible compressible sleeve, tube or film having a hollow interior or an interior that is filled with a material having a degree of flexibility and/or compressibility that is greater than that of the material forming the core. In yet other implementations, core flexor may have other configurations or may be formed from other materials.

For purposes of this disclosure, the term “coupled” shall mean the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members, or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature. The term “fluidly coupled” shall mean that two or more fluid transmitting volumes are connected directly to one another or are connected to one another by intermediate volumes or spaces such that fluid may flow from one volume into the other volume.

For purposes of this disclosure, the phrase “configured to” denotes an actual state of configuration that fundamentally ties the stated function/use to the physical characteristics of the feature proceeding the phrase “configured to”.

For purposes of this disclosure, the term “releasably” or “removably” with respect to an attachment or coupling of two structures means that the two structures may be repeatedly connected and disconnected to and from one another without material damage to either of the two structures or their functioning.

FIGS. 1 and 2 illustrate portions of an example pickleball paddle 20. Pickleball paddle 20 has a construction that may enhance a player's performance. FIG. 2 is a sectional view of paddle 20 taken along line 2-2 of FIG. 1. Pickleball 20 has an internal construction that assists in isolating the primary sweet spot or central point and impact regions of the paddle from the handle portions of the paddle. The internal construction dampens vibration and other forces resulting from impact with the pickleball, inhibiting such forces from being transmitted to the handle portion of the pickleball paddle. The internal construction of pickleball paddle 20 facilitates enhanced responsiveness of the impact portion of the pickleball by facilitating a degree of floating or movement of the impact region (sometimes referred to as the core) relative to the handle portion.

Pickleball paddle 20 satisfies the requirements or standards for pickleball paddles used in officially sanctioned events or competitive play. Unless otherwise indicated, each of the example pickleball paddles satisfies the requirements set forth in the November 2023 USA Pickleball Equipment Standards Manual. Pickleball paddle 20 has a combined maximum length and maximum width less than or equal to 24 inches. Pickleball paddle 20 has opposite pickleball impacting faces that have a maximum kinetic coefficient of friction less than or equal to 0.1875 when tested pursuant to protocol IAW ASTM D1894-14.

Pickleball paddle 20 comprises a handle portion 24 and a head portion 28. The head portion 28 is coupled to the handle portion 24 and comprises an outer frame 32 extending about an opening 34, core 36, core flexor 40 and faceplates 44-1 and 44-2 (collectively referred to as faceplates 44). Handle portion 24 is dimensioned so as to be gripped by a player's hand. In some implementations, handle portion 24 may have a round or oval cross-sections. In other implementations, handle portion 24 may have a polygonal cross-section. Handle portion 24 may include an outer wrap such as a polymer, rubber or leather material. In some implementations, handle portion 24 has an internal core provided by an extending portion of outer frame 32. In other implementations, handle portion 24 may be joined or affixed to outer frame 32.

Head portion 28 provides the hitting surface for paddle 20. Outer frame 32 forms an outer rim extending about opening 34 and forming a perimeter of head portion 28. In some implementations, bumpers, cushions, weights or wraps of protective material may be provided on exterior portions of outer frame 32. Outer frame 32 and handle portion 24 define the maximum width and together, define the maximum length of pickleball paddle 20. Outer frame 32 and handle portion 24 satisfy the requirements set forth in the November 2023 USA Pickleball Equipment Standards Manual. The entire length of paddle 20, extending from the butt of handle portion 24 to the top of head portion 28 form the maximum length of paddle 20. The maximum width of head portion 28 (measured perpendicular to the central axis of handle portion 24) forms a maximum width of paddle 20. The sum of the maximum length and the maximum width of paddle 20 is less than or equal to 24 inches.

Outer frame 32 may be a shaped band or tube of material that forms a loop defining the opening 34. As indicated above, in some implementations, portions of the band or tube may further extend in a parallel fashion to form a core of handle portion 24. In some implementations, the band or tube or tube forming outer frame 32 may be solid, omitting any internal voids, lumens or internal cavities. Where the band or tube has an interior void, the void may be filled with another material, such as a foam. In some implementations, the band or tube forming outer frame 32 may have a hollow interior, void of any solid material or filler. For example, the hollow band or tube may have an interior containing a gas, such as air.

Core 36 extends across and fills a majority of the area of the opening 34 defined by outer frame 32. In the example illustrated, core 36 is perforate, having openings, channels or voids that extend completely through core 36, from a first face to a second opposite face. In some implementations, core 36 may have a honeycomb configuration. For example, the core 36 can be formed of a polymeric material, such as polyethylene. In other implementations, the core 36 can be formed of other materials, such as other polymers or plastics. In other implementations, core 36 may have a lattice configuration. For example, core 36 may comprise any of the lattice configurations described in co-pending U.S. patent application Ser. No. 17/177,899 filed on Feb. 17, 2021, by Thurman et al. and entitled Pickleball Paddle, the full disclosure of which is hereby incorporated by reference. In yet other implementations, core 36 may be imperforate. For example, core 36 may be formed by the solid wood, polymer or foamed material having a greater stiffness and lesser degree of compressibility as compared to core flexor 40. In some implementations, core 36 may be formed from a non-foamed polymer layer or layers having perforations, a foam layer having perforations, a cellulose (wood) or paperboard-based material with perforations or the like, wherein core 36 has a greater stiffness and/or lesser degree of compressibility as compared to core flexor 40. In some implementations, the core 36 has a compressive stiffness of at least 200 psi (pounds per square inch) and no greater than 300 psi (as measured pursuant to American Society for Testing Materials (ASTM) C365). In other implementations, the core 36 can have other compressive stiffness values outside of 200 to 300 psi.

Core flexor 40 (schematically illustrated in FIG. 2) comprises a structure extending between handle portion 24 and core 36, wherein the structure has a greater degree of compressibility and/or a lesser degree of stiffness or rigidity as compared to core 36. In the example illustrated, the core flexor 40 may completely wrap about or extend about a perimeter of the core 36 without interruption, in a continuous manner. In the example illustrated, the core flexor 40 has a width W of at least 5 mm in regions between the core 36 and the handle portion 24. In some implementations, the core flexor 40 has a width W within the range of 5 mm to 25 mm and, in some implementations a width W of at least 10 mm.

The core flexor 40 has a stiffness or rigidity less than that of the core. The core flexor 40 may have a greater degree of compressibility as compared to the compressibility of the core. In some implementations, the core flexor 40 comprises a foam material. In one example implementation, the core flexor 40 an ethylene-vinyl acetate (EVA) foam having a density of 2 to 6 pounds. In some examples, the core flexor has a Shore 00 hardness of 40 to 60. In some implementations, the core flexor is formed from other polymeric foam materials such as urethane foams or polyurethan foams.

In other implementations, the core flexor 40 may comprise a flexible compressible sleeve, tube or film having a hollow interior or an interior that is filled with a material having a degree of flexibility and/or compressibility that is greater than that of the material forming the core. In yet other implementations, core flexor 40 may have other configurations or may be formed from other materials. In some implementations, the core flexor 40 may be glued, welded, fastened or mechanically interlocked to one or both of outer frame 32 and core 36.

In some implementations, the core 36 is inset within the core flexor 40 without being directly bonded or fixed to core flexor 40. As result, the core 36 may be compressed in a direction perpendicular to or normal to the face of the paddle (such as during impact with a pickle ball), being compressed relative to core flexor 40. In some implementations, the core 36 is supported in a fashion similar to that of a trampoline by the flexor 40 which serves as a support similar to the springs in a trampoline. In such implementations, the coefficient of restitution of core 36 may be enhanced. In some implementations, core 36, at least partially supported by core flexor 40, is provided with a coefficient of restitution of at least 0.40, and in some implementations, at least 0.46. In such implementations, the opposite faces of the core 36 and the core flexor 40 may be directly bonded to the interior faces of faceplates 44.

Core flexor 40 assists in isolating the primary sweet spot or center point and impact regions of the paddle 20 from the handle portions 24 of the paddle 20. Core flexor 40 may dampen vibration and other forces resulting from impact with the pickleball, inhibiting such forces from being transmitted to the handle portion 24 of the pickleball paddle 20. Core flexor 40 may enhance responsiveness of the impact portion of the pickleball by facilitating a degree of floating or movement of the impact region (sometimes referred to as the core) relative to the handle portion 24. In some implementations, core flexor 40 may reduce the noise produced during pickleball impact. The core flexor 40 is positioned between the core 36 and the handle portion 24 such that the core 36 does not directly contact the handle portion 24. In some implementations, the core flexor 40 can enable the core 36 to move independently from the handle portion 24 during impact with a pickleball.

Faceplates 44 extend on opposite faces of head portion 28 and provide the surfaces against which the pickleball impacts. Faceplates 44 extend over, cover and span both core 36 and core flexor 40. In some implementations, faceplates 44 completely cover front and rear faces of outer frame 32. In other implementations, faceplates 44 partially extend over and partially cover the front and rear faces of outer frame 32. Faceplates 44 are generally smooth and may be formed from a polymer, cellulose material or other materials or combinations of materials. In the example illustrated, faceplates 44 satisfy the requirements set forth in the November 2023 USA Pickleball Equipment Standards Manual. Each of faceplates 44 has a maximum kinetic coefficient of friction less than or equal to 0.1875 when tested pursuant to protocol IAW ASTM D1894-14.

FIG. 3-6 are sectional views of various particular examples of paddle 20 taken along line 2-2 of FIG. 1. FIG. 3 illustrates pickleball paddle 120. Pickleball paddle 120 is similar to pickleball paddle 20 described above except that paddle 120 comprises outer frame 132 and core flexor 140, particular examples of outer frame 32 and core flexor 40 described above. Those remaining components of paddle 120 which correspond to components of paddle 20 are numbered similarly and/or are shown and described with respect to FIG. 1.

Outer frame 132 comprises a tube 148 shaped into the loop shown in FIG. 1. As noted above, in some implementations, tube 148 may have end portions extending substantially parallel to one another to form an internal core portion of handle portion 24. The tube 148 has a hollow interior 149 which omits or is void of any solid material. In the example illustrated, tube 148 has an internal bladder 150 containing a gas, such as air. In some implementations, bladder 150 is pressurized with air to maintain the shape of tube 148 as it cures or takes on a permanent shape. In some implementations, tube 148 may be formed from one or more plies of a fiber composite material, wherein bladder 150 is formed from a flexible polymer, rubber or synthetic rubber material. In other implementations, bladder 150 may be omitted, such as where tube 148 is extruded and shaped into the loop shown in FIG. 1. After molding and curing of the tube 148, the bladder 150 can be removed from within the tube. In some implementations, the film or one or more layers are molded or wrapped about a sacrificial mandrel or core, wherein the mandrel or core is removed, leaving the hollow tube 148. Although tube 148 is illustrated as having a generally rectangular or square cross-section, in other implementations, tube 148 may have external or internal grooves, an oval cross-section, a round cross-section or a polygon cross-section.

Core flexor 140 comprises one or more layers of foam material sandwiched between plies 44-1 and 44-2 between core 36 and handle portion 24. In the example illustrated, core flexor 140 comprise one or more layers of foam material that completely encircle core 36 in a continuous uninterrupted manner. In other words, core flexor 140 comprise a continuous unbroken ring about core 36.

Core flexor 140 has a width W (shown in FIG. 1) between handle portion 24 and core 36. In some implementations, the width W is at least 5 mm and no greater than 25 mm. In some implementations, the width W is uniform along the entire length of core flexor 40 about 436. In other implementations, the width W may vary as it extends about core 36. In some implementations, core flexor 40 comprises a foam material. In one example implementation, the core flexor 40 comprises an ethylene-vinyl acetate (EVA) foam having a density of 2 to 6 pounds. In some examples, the core flexor 40 has a Shore 00 hardness of 40 to 60. In some implementations, the core flexor 40 is formed from other polymeric foam materials such as urethane foams or polyurethan foams.

In some implementations, the material forming core flexor 40 is preformed and cut or molded to the desired size and shape prior to being inserted into the opening 34 formed by outer frame 32. The preformed core flexor 40 may be positioned within the opening 34 prior to the insertion of core 36 or after the insertion of core 36 in opening 34. In some implementations, no adhesives or other fasteners are used between the core flexor 40 and the core 36. In some implementations, the core flexor 40 may be formed by depositing a fluid foam or foaming material into opening 34 about core 36 (or about a temporary removable piece in the shape of core 36), between core 36 and outer frame 32. In some implementations, the fluid foam or foaming material may be injected into the space or volume defined on its sides by to 148 and core 36 and defined on its top and/or bottom by plate 44-1 and/or plate 44-2.

FIG. 4 illustrates pickleball paddle 220. Pickleball paddle 220 is similar to pickleball paddle 120 described above except that paddle 220 comprises outer frame 232, a particular example of outer frame 32 described above. Those remaining components of paddle 220 which correspond to components of paddle 20 and/or paddle 120 are numbered similarly and/or are shown and described with respect to FIGS. 1 and 3.

Outer frame 232 is similar to outer frame 132 described above except that tube 148 omits the internal bladder 158 and that the to 148 surrounds an internal solid frame core 252. In some implementations, the frame core 252 comprises a foam or foaming material. In some implementations, frame core 252 comprise a foam such as EVA foam, urethane foam or polyurethan foam. The foam may be injected or otherwise provided into the interior of tube 148 during the shaping and molding of tube 148 to assist in maintaining the structural integrity and shape of tube 148 during the molding and shaping of tube 148 into the loop of outer frame 32. In other implementations, the foam material forming frame core 252 may be injected into the interior of tube 148 after tube 148 has been shaped. In still other implementations, one or more layers may be molded about frame core 252 or wrapped about frame core 252, prior to being shaped and solidified or cured or after being shaped, solidified or cured, to form the tube 148 about core 252; the combined tube 148 and core 252 forming the outer frame 232.

FIG. 5 illustrates pickleball paddle 320. Pickleball paddle 320 is similar to pickleball paddle 220 described above except that paddle 320 comprises core 336 and core flexor 340, particular examples of core 36 and core flexor 40. Those remaining components of paddle 320 which correspond to components of paddle 20 and/or paddle 220 are numbered similarly and/or are shown and described with respect to FIGS. 1 and 4.

Core 336 may comprise a perforate core, a particular example of core 36. In some implementations, core 336 may have a reduced thickness along its perimeter. In some implementations, core 336 may have a honeycomb configuration or a lattice configuration. Core 336 may extend outwards into abutment or near abutment with outer frame 32 or may terminate prior to reaching the interior sides of opening 34 defined by outer frame 32. As with core 36, core 336 may be formed from a non-foamed polymer layer or layers having perforations, a foam layer having perforations, a cellulose (wood) or paperboard-based material with perforations or the like. In some implementations, core 336 is formed from a polymer such as polyethylene, nylon, polyurethane, or the like.

Core flexor 340 comprises one or more layers of material or materials extending between portions of core 336 and outer frame 232. In the example illustrated, the one or more layers of material or materials encapsulate and/or impregnate the perforations, hollow portions of the honeycomb or voids in the lattice) to mechanically interlock flexor 340 and core 336. In some implementations, core flexor 340 is injected as a fluid into the perforations of core 336 along the perimeter of core 336, along the interior sides of opening 34 and outer frame 232, wherein the fluid is allowed to cure or solidify forming the final core flexor 340. In some implementations, the fluid material is a foam or foaming material. In some implementations the injection of the fluid material to form core flexor 340 occurs while core 336 is positioned within the opening defined by outer frame 232. In other implementations, the injection of the fluid material to form core flexor 340 may occur prior to positioning of core 336 into opening 34, wherein the interlocked core 336 and core flexor 340, (solidified) are subsequently inserted into opening 34 and otherwise secured, such as by adhesive, fusing, melting the like, to outer frame 232.

FIG. 6 illustrates pickleball paddle 420. Pickleball paddle 420 is similar to pickleball paddle 320 described above except that paddle 420 comprises frame 132, described above, in place of outer frame 232. Those remaining components of paddle 420 which correspond to components of paddle 20 and/or paddle 320 are numbered similarly and/or are shown and described with respect to FIGS. 1 and 5.

FIG. 7 illustrates an example pickleball paddle 520. Pickleball paddle 520 is similar to pickleball paddle 20 except that paddle 520 comprises core flexor 540 in place of core flexor 40 and spacers 560-1, 560-2, and 560-3 (collectively referred to as spacers 560). Those remaining components of pickleball paddle 520 which correspond to components of pickleball paddle 20 are numbered similarly and/are our described above with respect to FIG. 1.

Core flexor 540 is similar to core flexor 40 except that core flexor 540 does not comprise a continuous uninterrupted ring or does not continuously extend around core 36 in an uninterrupted fashion. In contrast, core flexor 540 is interrupted by spacers 560. As with pickleball paddle 20, pickleball paddle 520 may have any of the particular example configurations shown and described above with respect to FIG. 3-6, but with the addition of spacers 560 at particular locations about core 36. For example, outer frame 32 may be in the particular form of outer frame 132 or outer frame 232. Core 36 may be in the form of core 36 or core 336. Core flexor 540 may have a composition and cross-sectional architecture of flexor 140 or flexor 340.

Spacers 560 interrupt the otherwise continuous nature of core flexor 540. In some implementations, spacers 560 are formed from a material or materials that are more rigid and less flexible as compared to flexor 540. In some implementations, spacers 560 may be formed from polymers or metals. In some implementations, spacers 560 are fastened, welded, fused, bonded or otherwise secured to outer frame 32. In some implementations, spacers 560 are alternatively secured to core. In some implementations, spacers 560 may be integrally formed as part of a single unitary body with core 36, comprising outwardly protruding portions of core 36. For example, core 36 may have a general oval shape shown, but with protruding tabs or protuberances forming spacers 560. In such implementations, spacers 560 may be perforate. In some implementations, spacers 560 and core 36 may have a honeycomb configuration, and the spacers 560 can be extensions of the core 36. In some implementations, the spacers 560 may have a reduced thickness, wherein the core flexor 540 fills or impregnates the perforations to mechanically interlock core flexor 540 with the protruding portions of core 36 as described above with respect to paddle 320 or paddle 420.

Spacers 560 may limit or control any relative movement of core flexor 540 with respect to outer frame 32. In the example illustrated, spacers 560-1, 560-2 and 560-3 are provided at the 3 o'clock, 9 o'clock and 12 o'clock positions, respectively, as shown in FIG. 7. In other implementations, such spacers 560 may be provided at other locations. In other implementations, a greater or fewer number of spacers may be employed and the relative size of each of spacers 560 may be adjusted.

FIG. 8 illustrates an example pickleball paddle 620. Pickleball paddle 620 is similar to pickleball paddle 20 except that paddle 520 comprises core flexor 640 in place of core flexor 40 and upper wrap 660. Those remaining components of pickleball paddle 620 which correspond to components of pickleball paddle 20 are numbered similarly and/are our described above with respect to FIG. 1.

Core flexor 640 is similar to core flexor 40 except that core flexor 640 does not comprise a continuous uninterrupted ring or does not continuously extend around core 36 in an uninterrupted fashion. In contrast, core flexor 640 extends along a lower portion of core 36 between core 36 and handle portion 24, terminating at upper wrap 660. In the example illustrated, core flexor 640 has a semicircular, semioval or U-shape. As with pickleball paddle 20, pickleball paddle 620 may have any of the particular example configurations shown and described above with respect to FIG. 3-6 but terminating at wrap 660. For example, outer frame 32 may be in the particular form of outer frame 132 or outer frame 232. Core 36 may be in the form of core 36 or core 336. Core flexor 640 may have a composition and cross-sectional architecture of flexor 140 or flexor 340.

Core wrap 660 extends along the distal end of paddle 620, the end of paddle 620 most distant from handle portion 24. In the example illustrated, wrap 660 is illustrated as extending about a majority of core 36, at least 180° about the center of core 36. In other implementations, wrap 660 may extend to a greater degree or to a lesser degree about core 36. Wrap 660 provides different feel or different pickleball impact properties towards a distant end of paddle 620 as compared to those portions more proximate to handle portion 24.

In some implementations, wrap 660 is formed from a more rigid, less flexible material than that of core flexor 640, such as a more rigid or more incompressible polymer or metal. In some implementations, wrap 660 is fastened, welded, fused, bonded otherwise secured to outer frame 32. In some implementations, wrap 660 is alternatively secured to core 36. In some implementations, wrap 660 may be integrally formed as part of a single unitary body with core 36, comprising outwardly protruding portions of core 36. In some implementations, wrap 660 and core 36 may be molded as a single body Core 36 may have a general oval shape as shown, but additionally with extending portions forming core wrap 660. In such implementations, wrap 660 may be perforate.

FIGS. 9 and 10 illustrate an example pickleball paddle 720. FIG. 10 is a sectional view of paddle 720. Paddle 720 comprises handle portion 724 and head portion 728. The head portion 728 is coupled to the handle portion 724 and comprises an outer frame 732 extending about an opening 734, core 736, core flexor 740 and faceplates 744 (one of which is shown). Handle portion 724 is dimensioned so as to be gripped by a player's hand. In some implementations, handle portion 724 may be round or oval. In other implementations, handle portion 24 may have a polygon cross-section.

As shown by FIG. 10, hollow tube 748 forms a portion of both outer frame 732 and handle portion 724. The hollow tube 748 has end portions 749 that are shaped so as to extend substantially parallel to one another to form a handle core 770. Handle portion 724 further comprises a pallet 772 and an outer wrap 774. Pallet 772 extends about the end portion 749 of tube 748 to form a uniform outer surface for handle portion 724. The pallet 772 can form an outer polygonal shape. In other implementations, the pallet 772 may for other outer shapes. In some implementations, pallet 772 may be formed from a wood, such as balsa wood, a foam material or other materials.

Outer wrap 774 wraps about end portion 749 and pallet 772. Outer wrap 774 provides a gripping surface and texture for handle portion 724. Outer wrap 774 may comprise a sleeve or a wrapped band. Outer wrap 774 may be formed from a polymer, rubber or leather material. In other implementations, handle portion 724 may not be partially formed from the outer tube 748, wherein handle portion 724 may be separately performed and coupled to head portion 728.

Head portion 728 provides the hitting surface for paddle 720. Outer frame 732 forms an outer rim extending about opening 734 and forms a perimeter of head portion 728. In some implementations, bumpers, cushions, weights or wraps of protective material may be provided on exterior portions of outer frame 732. In other implementation, the outer tube 748 of the outer frame 732 can form the outer edge of the head portion 728. Outer frame 732 and handle portion 724 define the maximum width and together, define the maximum length of pickleball paddle 720. Outer frame 732 and handle portion 724 satisfy the requirements set forth in the November 2023 USA Pickleball Equipment Standards Manual. The entire length of paddle 720, extending from the butt of handle portion 724 to the top of head portion 728 form the maximum length of paddle 720. The maximum width of head portion 728 (measured perpendicular to the central axis of handle portion 724) forms a maximum width of paddle 720. The sum of the maximum length and the maximum width of paddle 720 is less than or equal to 24 inches.

Outer frame 732 is formed by the shaped tube 748 and yoke 776. Tube 748 forms a loop which has a lower end closed by yoke 776 to define opening 734. As indicated above, in the example illustrated, portions of the tube may further extend in a parallel fashion to form a core of handle portion 724. In the example illustrated, the tube 748 forming outer frame 732 is hollow, having a hollow interior 778, void of any solid material or filler. For example, the hollow band or tube may have an interior containing a gas, such as air. In some implementations, a bladder may be 748, the bladder the air or other gas. In other implementations tube 748 may be solid, omitting any internal voids, lumens or internal cavities, such as where tube has an interior void filled with another material, such as a foam.

Yoke 776 comprises a band or tube bridging between opposite portions of tube 748 at the top of a paddle 720, opposite to handle portion 724.

Yoke 776 forms a portion of the outer frame 732 just above handle portion 724. Tube 748 continues to extend below yoke 776 to form the throat 780 of paddle 720 which extends between handle portion 724 and head portion 728. The throat 778 has an opening 782, defined by tube 748 and yoke 776, between yoke 776 and handle portion 724.

In the example illustrated, yoke 776 comprises a tube 784 having end portions that are fused, bonded otherwise integrated with tube 748. In the example illustrate, tube 784 is filled with a filler 785, such as a foam. In other implementations, tube 784 may be hollow, omitting any filling or may have other configurations. In other implementations, yoke 776 may be omitted, such as where and portions 749 of tube 748 are brought together at a 90 degree angle so as to omit any opening, such as opening 782.

Core 736 extends across and fills a majority of the area of the opening 734 defined by outer frame 732. In the example illustrated, core 736 is perforate, having openings, channels or voids that extend completely through core 736, from a first face to a second opposite face. In the example illustrated, core 736 has a honeycomb configuration. In other implementations core 736 may alternatively comprise a lattice configuration. For example, core 736 may comprise any of the lattice configurations described in co-pending U.S. patent application Ser. No. 17/177,899 filed on Feb. 17, 2021, by Thurman et al. and entitled Pickleball Paddle, the full disclosure of which is hereby incorporated by reference. In yet other implementations, core 736 may be imperforate. For example, core 736 may be formed by polyethylene, solid wood, one or more other polymers or foamed material having a greater stiffness and lesser degree of compressibility as compared to core flexor 740. In some implementations, core 736 may be formed from a non-foamed polymer layer or layers having perforations, a foam layer having perforations, a cellulose (wood) or paperboard-based material with perforations or the like, wherein core 736 has a greater stiffness and/or lesser degree of compressibility as compared to core flexor 740. In the example illustrated, core 736 is formed from polypropylene and has a thickness within the range of 6 to 32 mm. In some implementations, the core 736 has a thickness within the range of 12 to 18 mm.

Core flexor 740 comprises a structure extending between handle portion 724 and core 736, wherein the structure has a greater degree of compressibility and/or a lesser degree of stiffness or rigidity as compared to core 736. In the example illustrated, the core flexor 740 completely wraps about or extends about a perimeter of the core 736 without interruption, in a continuous manner. In the example illustrated, the core flexor 740 has a width of at least 5 mm in at least in regions between the core 736 and the handle portion 724, and in some implementations, at least 10 mm. In other implementations, core flexor 740 may not extend completely about core 736, such as where core flexor 740 has a configuration similar to core flexor 540 (with spacers 560) or similar to core flexor 640 (with wrap 660).

The core flexor 740 has a stiffness or rigidity less than that of the core. The core flexor 740 may have a greater degree of compressibility as compared to the compressibility of the core. In some implementations, the core flexor 740 comprises a foam material. In one example implementation, the core flexor 740 comprises a foam material. In one example implementation, the core flexor 740 comprises an ethylene-vinyl acetate (EVA) foam having a density of 2 to 6 pounds. In some examples, the core flexor 740 has a Shore 00 hardness of 40 to 60. In some implementations, the core flexor 740 is formed from other polymeric foam materials such as urethane foams or polyurethan foams. In some implementations, the core flexor 740 can be positioned between the core 740 and the frame 732 without the use of an adhesive or other fasteners on the surfaces between the core flexor 740 and the core 740, and between the core flexor 740 and the frame 732.

In other implementations, the core flexor 740 may comprise a flexible compressible sleeve, tube or film having a hollow interior or an interior that is filled with a material having a degree of flexibility and/or compressibility that is greater than that of the material forming the core. In yet other implementations, core flexor 740 may have other configurations or may be formed from other materials. In some implementations, the core flexor 740 may be glued, welded, fastened or mechanically interlocked to one or both of outer frame 732 and core 736.

In other implementations, the core flexor 740 may comprise a flexible compressible sleeve, tube or film having a hollow interior or an interior that is filled with a material having a degree of flexibility and/or compressibility that is greater than that of the material forming the core 736. In yet other implementations, core flexor 740 may have other configurations or may be formed from other materials. In the example illustrated, the core flexor 740 may be glued, welded, fastened or mechanically interlocked to one or both of outer frame 732 and core 736.

In the illustrated example, the core 736 is inset within the core flexor 740 without being directly bonded or fixed to core flexor 740. As result, the core 736 may be compressed in a direction perpendicular to or normal to the face of the paddle (such as during impact with a pickle ball), being compressed relative to core flexor 740. In some implementations, the core 736 is supported in a fashion similar to that of a trampoline by the flexor 740 which serves as a support similar to the springs in a trampoline. In such implementations, the coefficient of restitution of core 736 may be enhanced. In some implementations, core 736, at least partially supported by flexor 740, is provided with a coefficient of restitution of at least 0.40, and in some implementations, at least 0.46. In such implementations, the opposite faces of the core 736 and the core flexor 740 may be directly bonded to the interior faces of faceplates 744.

Core flexor 740 assists in isolating the primary sweet spot and impact regions of the paddle 720 from the handle portion 724 of the paddle 720. Core flexor 740 may dampen vibration and other forces resulting from impact with the pickleball, inhibiting such forces from being transmitted to the handle portion 724 of the pickleball paddle 720. Core flexor 740 may enhance responsiveness of the impact portion of the pickleball by facilitating a degree of floating or movement of the impact region (sometimes referred to as the core) relative to the handle portion 724.

Similar to faceplates 44, faceplates 744 extend on opposite faces of head portion 728 and provide the surfaces against which the pickleball impacts. Faceplates 744 extend over and cover both core 736 and core flexor 740. In some implementations, faceplates 744 completely cover front and rear faces of outer frame 732. In other implementations, faceplates 744 partially extend over and partially cover the front and rear faces of outer frame 732. Faceplates 744 are generally smooth and may be formed from a polymer, cellulose material or other materials or combinations of materials. In the example illustrated, faceplates 744 satisfy the requirements set forth in the November 2023 USA Pickleball Equipment Standards Manual. Each of faceplates 744 has a maximum kinetic coefficient of friction less than or equal to 0.1875 when tested pursuant to protocol IAW ASTM D1894-14.

Although pickleball paddle 720 is illustrated as having the hollow interior, void of any internal filling, and as having core flexor 740, in other implementations, pickleball paddle 720 may have any of the particular example configurations shown and described above with respect to FIGS. 3-6. For example, outer frame7 32 may be in the particular form of outer frame 132 or outer frame 232. Core 736 may be in the form of core 36 or core 336. Core flexor 740 may have a composition and cross-sectional architecture of flexor 140 or flexor 340.

FIGS. 11-14 illustrate pickleball paddle 720 without core 736, core flexor 740 or handle wrap 774. FIGS. 11-14 illustrate tube 748 and the remaining components that form handle portion 724. FIG. 11 is a front view of the depicted portion of paddle 720. FIG. 12 is a sectional view of the depicted portion of paddle 720 taken along line 12-12 of FIG. 11. FIG. 13 is a top view of the depicted portion of paddle 720. FIG. 14 is a sectional view of paddle 720 taken along line 14-14 of FIG. 11.

As noted above, outer frame 732 and handle portion 724 define the maximum length L of paddle 720. Outer frame 732 further defines the maximum paddle width PW. Outer frame 732 and handle portion 724 satisfy the requirements set forth in the November 2023 USA Pickleball Equipment Standards Manual. The sum of the maximum length L and the maximum paddle width PW of paddle 720 is less than or equal to 24 inches.

As further shown by FIGS. 11-14, the outer frame 732 has an outer perimeter comprising grooves or channels. As shown by FIGS. 12 and 13, the top 786 of outer frame 732 has an indentation or groove 788 projecting inwards into the tube 748. The groove 788 has ends and terminates prior to reaching the sides 790 of outer frame 732. As shown by FIG. 14, the sides 790 of outer frame 732 have indentation the grooves 792 projecting inwards into tube 748. The grooves 788 and 792 do not impair the structural integrity of tube 748, merely comprise outer perimeter surfaces of tube 748 that are bent inwardly deformed. Such grooves may assist in increasing the stiffness or rigidity of outer frame 732. Although such grooves 788 and 792 are illustrated having a V-shape, for aesthetics, it should be appreciated such grooves may have other cross-sectional shapes, such as U-shaped, semi-circular, semi-ovular and other curved or irregular shapes, and may have other relative sizes and depths. In some implementations, grooves 788 and 792 may replace with a single continuous groove or channel that continuously extends around and along the top 786 and the sides 790. In some implementations, the grooves 788 and 792 are molded during the shaping of tube 748. In one implementation the top 786 can be formed without groove 788 and sides 790 can include grooves 792. In another implementation, the top 786 can be formed with groove 788 while the sides 792 can be formed without groove 792.

FIGS. 15-20 illustrate one example method forming outer frame 732 of pickleball paddle 720. With the example method shown in FIGS. 15-20, tube 748 and, in some implementations, yoke 776 is formed from a fiber composite material. As used herein, the term “fiber composite material” or “composite material” refers to a plurality of fibers within and permeated throughout a resin. The fibers can be co-axially aligned in sheets, layers or plies, or braided or weaved in sheets or layers, and/or chopped and randomly dispersed in one or more layers. A single ply typically includes hundreds or thousands of fiber bundles that are initially arranged to extend coaxially and parallel with each other through the resin that is initially uncured. Each of the fiber bundles includes a plurality of fibers. The fibers are formed of a high tensile strength material such as carbon. Alternatively, the fibers can be formed of other materials such as, for example, glass, graphite, boron, basalt, carrot, Kevlar, Spectra, poly-para-phenylene-2,6-benzobisoxazole (PBO), hemp, flax, other natural fibers and combinations thereof. In one set of preferred implementations, the resin is preferably a thermosetting resin such as an epoxy or a polyester resin. In other sets of preferred implementations, the resin can be a thermoplastic resin. The composite material is typically wrapped about a mandrel and/or a comparable structure and cured under heat and/or pressure. While curing, the resin is configured to flow and fully disperse and extend throughout the matrix of fibers. In multiple layer or ply constructions, the fibers can be aligned in different directions with respect to the longitudinal axis, and/or in braids or weaves from layer to layer.

Referring to FIG. 15, a portion of a layer 860 of fiber composite material is illustrated. The layer 60 is formed by one or two plies 862 (862a and 862b) of fiber composite material. A ply 862 of fiber composite material refers to an arrangement of fibers 864 and fiber bundles 866 in a resin 868, wherein the fibers 864 and the fiber bundles 866 are arranged and aligned such that the fibers 864 and the fiber bundles 866 generally extend coaxially with respect to each other and are generally parallel to one another. The fibers 864 or fiber bundles 866 are preferably formed such that they extend along the ply 862 and form generally the same angle with respect to an axis, such as a composite axis 870. The plies 862 are typically identified, at least in part, by the size and polarity of the angle defined by the fibers 864 or fiber bundles 866 with respect to the axis 870. As shown in FIG. 15, the ply 62a has fibers 64 and fiber bundles 866 aligned at a positive 45 degree angle ply, and the ply 62b has fibers 864 and fiber bundles 866 aligned at a negative 45 degree angle ply. In other implementations, the plies 862 can include fibers 864 or fiber bundles 866 defining a positive 30 degree angle ply, a negative 30 degree angle ply, a positive 45 degree angle ply, a negative 45 degree angle ply, a positive 40 degree angle ply, a negative 40 degree angle ply, a positive 35 degree angle ply, a negative 35 degree angle ply, a 90 degree angle ply (extending perpendicular to the axis), and a 0 degree angle ply (or extending parallel to the axis). Other positive or negative angles for plies can also be used. Accordingly, in the present application, a single ply 862 refers to a single layer of fiber composite material in which the fiber bundles 866 extend in substantially the same direction with respect to a longitudinal axis along the single layer, such as plus or positive 45 degrees or minus or negative 30 degrees. A layer 860 formed of a pair of plies 862 having fibers 864 of generally the same angle but arranged with opposite polarities is also referred to a ply arrangement. This pattern typically extends throughout a fiber composite material. The alternating angular arrangement of the fiber bundles 866 and fibers 864 is important to achieving and maintaining the structural integrity of the component or structure being formed of the fiber composite material. The overlapped region of the two plies 862a and 862b can be essential for ensuring that, once cured, the fiber composite material has the desired strength, durability, toughness and/or reliability.

During heating/molding and curing, the resin 868 can flow between plies 862 and within the fiber bundles 866. The plies 862 preferably typically have a thickness within the range of 0.002 to 0.015 inch. In other implementations, other thickness ranges can also be used.

As shown by FIG. 16, in other implementations, one or more of the layers 860 can include a plurality of braided fibers 862c. The braided fibers 862c can extend at angles with respect to the lay-up axis 870 of at least 35 degrees with positive and negative polarities. In other implementations, the braided fibers 862c can extend at angles with respect to the lay-up axis 70 of at least 40 degrees (with positive and negative polarities).

FIGS. 17-20 illustrate one example process or method by which tube 748 may be shaped and fused to form the head portion 728, the throat portion 780 and portions of the handle portion 724. Referring to FIG. 17, when the layers 860 are wrapped or laid up around the bladder 876 and the mandrel 874, the plies 862 are no longer arranged in a flat sheet, and therefore, the fiber bundles 866 and fibers 864 no longer follow or define generally parallel lines. Rather, the fiber bundles 866 and fibers 864 are adjacent to one another, and are curved or otherwise formed so that they follow substantially the same adjacent paths. For example, when the ply 862 is wrapped about the bladder 876 and the mandrel 874, the ply 862 can take a generally cylindrical or tubular shape and the fiber bundles 866 and fibers 864 can follow the same cylindrical path or define a helical path (depending upon their angle within the ply 862). The fibers 864 remain adjacent to one another, are aligned with each other and follow substantially similar paths that are essentially parallel (or even co-axial) for example, when viewed in a sectional view in a single plane or other small finite segment of the ply 862.

In one implementation, the mandrel 874 may include a pull tab 882 for facilitating the pulling or removal of the mandrel 74 from the plurality of layers 860 wrapped about the bladder 876 and the mandrel 874. The lay-up 880 of FIG. 17 is uncured. In one implementation, the mandrel 874 using the pull tab 882 can be drawn, pulled or otherwise removed from the bladder and the lay-up 880.

Referring to FIGS. 18 and 19, once the mandrel 874 is removed from the bladder 876 and the lay-up 880, the uncured lay-up 880 can be gently positioned into the shape of a racquet frame. An uncured yoke lay-up 884 of fiber composite material can be prepared for positioning next to the curved lay-up 880. As shown in FIG. 19, the lay-up can be shaped to resemble portions of the outer frame 732, and the yoke lay-up 884 can be attached to the lay-up 880. In one implementation, additional relatively short ties or tying plies can be applied over the connection points of the yoke lay-up 884 to the lay-up 880. In other implementations, the yoke lay-up may be replaced with a preformed yoke structure that is added attached to the lay-up 880 prior to molding.

Referring to FIG. 20, the uncured lay-up 880 and the uncured yoke lay-up 884 is positioned within a mold cavity 888 of a racquet forming mold 90. A supply line 886 can be attached to the bladder 876 for supplying air or other gas to the bladder, and the pieces of the racquet forming mold 890 can be positioned around the lay-up 880 and the yoke lay-up 884. The bladder 876 can be pneumatically pressurized by air or other gas to a predetermined pressure (such as with a pressure valve 886 connected to bladder 876), and the racquet forming mold 890 can then be heated in an oven or furnace, or where the mold is heated, to a predetermined temperature. Once subjected to heat and pressure, the viscosity of the resin 868 in the lay-up 880 and the yoke lay-up 884 drops and the resin 868 flows through out the plies 862 of the lay-up 880 and yoke lay-up 884 in the mold cavity 888 creating a more uniform structure and the fibers 864 are positioned into the shape of the mold cavity. After a first predetermined amount of time, the racquet forming mold 890 is removed from the heat and the lay-up 880 and yoke lay-up 884 are allowed to cool. After a second pre-determined amount of time, the racquet forming mold 890 is opened and outer frame 732 is removed from the mold 890. Thereafter, the bladder 876 is removed from the tube to further reduce weight of the paddle 720 and to avoid any noise that may occur as a result of bladder 876 being left in the tube.

The above-described method of making a frame of the paddle 720 formed of a fiber composite material using bladder molding is significantly better than forming a tubular fiber composite object using activating foam as the internal pressure source during molding. The incorporation of a bladder into the molding of the frame 732 of the pickleball paddle 720 allows for a predetermined internal pressure to be applied to tube during molding and curing which helps prevent the undesirable formation of air bubbles, wrinkles, creases and non-uniform wall thicknesses. All of the above conditions can negatively affect the consistency, durability and playability of the frame 732 and the paddle 720. Further, fiber composite pickleball frames formed using activating foam necessarily have the foam within the fiber composite tube. The foam adds weight and can negatively affect the playability of the paddle. The present method of forming a pickleball paddle using bladder molding is the first of its kind.

Although the present disclosure has been described with reference to example implementations, workers skilled in the art will recognize that changes may be made in form and detail without departing from the scope of the claimed subject matter. For example, although different example implementations may have been described as including features providing benefits, it is contemplated that the described features may be interchanged with one another or alternatively be combined with one another in the described example implementations or in other alternative implementations. Because the technology of the present disclosure is relatively complex, not all changes in the technology are foreseeable. The present disclosure described with reference to the example implementations and set forth in the following claims is manifestly intended to be as broad as possible. For example, unless specifically otherwise noted, the claims reciting a single particular element also encompass a plurality of such particular elements. The terms “first”, “second”, “third” and so on in the claims merely distinguish different elements and, unless otherwise stated, are not to be specifically associated with a particular order or particular numbering of elements in the disclosure.