BALL WITH NOISE REDUCTION CHARACTERISTICS

Description

CROSS REFERENCE TO RELATED PATENT APPLICATION(S)

This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63/730,614, filed Dec. 11, 2024, the entirety of which is incorporated herein.

TECHNICAL FIELD

The present disclosure relates generally to balls for use in sports. Specifically, the present disclosure relates to systems and methods for balls designed for sports and recreational activities, such as pickleball, including a ball with a surface texture created to facilitate gameplay while minimizing noise generation.

BACKGROUND

Different types of sports are widely embraced by participants for diverse purposes, including enhancing health, leisure, enjoyment, and competitive or professional pursuits, among other purposes. Pickleball is rapidly gaining popularity as a sport. Pickleball is an indoor or outdoor paddle sport wherein two players (singles) or four players (doubles) engage in hitting a perforated, hollow, plastic ball using paddles over a 34-inch-high net until one side is unable to return the ball or commits an infraction.

The perforated, hollow plastic ball utilized in pickleball may comprise a resilient material capable of enduring extended play without succumbing to cracking or breakage. Additionally, unlike other sports such as wiffle ball, which employ perforated balls, a pickleball may feature perforations or apertures distributed across its entire surface. This design characteristic serves to prevent or reduce the possibility of the pickleball rising or curving in flight when struck with a paddle during gameplay.

A pickleball, upon impact with a pickleball paddle or hard surface such as the playing surface, may emit a pronounced popping sound of sufficient volume to constitute a nuisance. This persistent auditory disturbance during gameplay has engendered conflicts between pickleball court proprietors and neighboring property owners, including those of residential properties. The escalating noise, coupled with the rapid surge in the popularity of pickleball, has incited vehement opposition to the sport in communities worldwide. In response, certain municipalities have implemented prohibitions on pickleball activities, citing an inability of residents to engage in conversations within their dwellings, overall disruption within the vicinity, and purportedly deleterious physiological effects stemming from the noise generated by pickleball gameplay.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is set forth below with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The use of the same reference numbers in different figures indicates similar or identical items. The systems depicted in the accompanying figures are not to scale and components within the figures may be depicted not to scale with each other.

FIG. 1 illustrates a front perspective view of a pickleball including two layers of materials and molded apertures, according to an example of the principles described herein.

FIG. 2 illustrates a cross-sectional view of the pickleball along line A depicted in FIG. 1, according to an example of the principles described herein.

FIG. 3 illustrates a front perspective view of a pickleball including two layers of materials and drilled apertures, according to an example of the principles described herein.

FIG. 4 illustrates a cross-sectional view of the pickleball along line B depicted in FIG. 3, according to an example of the principles described herein.

FIG. 5 illustrates a front perspective view of a pickleball including two layers of materials and drilled apertures, according to an example of the principles described herein.

FIG. 6 illustrates a cross-sectional view of the pickleball along line C depicted in FIG. 5, according to an example of the principles described herein.

FIG. 7 illustrates a front perspective view of a pickleball including a dome textured surface, according to an example of the principles described herein.

FIG. 8 illustrates a front perspective view of a pickleball including a hexagon-shaped textured surface, according to an example of the principles described herein.

FIG. 9 illustrates a front perspective view of a pickleball including a fiber-textured surface, according to an example of the principles described herein.

FIG. 10 illustrates a front perspective view of a pickleball including counter-sunk apertures, according to an example of the principles described herein.

FIG. 11 illustrates a cross-sectional view of the pickleball along line D depicted in FIG. 10, according to an example of the principles described herein.

FIG. 12 illustrates a front perspective view of a pickleball including a structural framework, according to an example of the principles described herein.

FIG. 13 illustrates a cross-sectional view of the pickleball along line E depicted in FIG. 12, according to an example of the principles described herein.

FIG. 14 illustrates a front perspective view of a pickleball including a structural framework and apertures, according to an example of the principles described herein.

FIG. 15 illustrates a front perspective view of a pickleball including a structural framework, apertures, and infill faces, according to an example of the principles described herein.

FIG. 16 illustrates a cross-sectional view of the pickleball along line F depicted in FIG. 15, according to an example of the principles described herein.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Overview

This disclosure describes pickleballs with sound-dampening characteristics, architectures, and/or surface treatments that reduce the pronounced popping sound upon impact with a pickleball paddle or hard surface, such as the playing surface. The pickleballs described herein may reduce energy in a sound wave as measured in decibels (dB), the measure of loudness, or intensity of a sound that may be emitted via the striking of the pickleball.

As mentioned above, pickleball is a paddle sport that incorporates elements of tennis, badminton, and ping-pong, and which employs a paddle and a hollow plastic ball with holes or apertures defined therein. Originating in 1965 on Bainbridge Island, Washington, pickleball has swiftly garnered widespread acceptance in recent years. The popularity of pickleball may be attributed to several factors, including its accessibility, low-impact nature suitable for participants of all ages, and the broad appeal of its gameplay across diverse demographics, from children to senior citizens. Moreover, pickleball fosters social interaction within communities, further contributing to its appeal. The surge in popularity of pickleball as a sport reached a milestone when the USA Pickleball Association amassed 10,000 members in 2015, with an estimated 2 million participants nationwide at that time. Notably, the number of individuals engaged in pickleball surged by 159% over three years, reaching 8.9 million in 2022. The pickleball equipment market witnessed substantial growth, achieving a value of $518.98 million in 2022 and is anticipated to reach $1.064 billion by 2030, with a projected compound annual growth rate (CAGR) of 9.52% from 2024 to 2030. Presently, pickleball stands as the fastest-growing sport in North America.

Pickleballs may include between 26 to 40 apertures defined therein, with no existing pickleball models exceeding 40 apertures. These pickleballs may be constructed from durable molded materials including various types of polyethylene (PE). Standard dimensions of a pickleball may be approximately 75 millimeters (mm) in diameter, with a corresponding weight of approximately 25 grams. Manufacturing processes for pickleballs may encompass injection molding, roto-molding, or other suitable techniques. However, a notable drawback of conventional pickleballs is their tendency to generate excessive noise upon contact with pickleball paddles, court surfaces, or other objects. Complaints regarding pickleball noise have led to neighborhood disturbances, disputes, and even prohibition of the sport in designated areas and legal action when violations of noise ordinances are asserted.

In fact, sound levels generated by pickleball activity from a distance of 100 feet may exceed 70 A-weighted decibels (dBA), an indicator of the relative loudness perceived by the human ear. A-weighting is applied to instrument-measured sound levels to account for the varying sensitivity of the human ear to different audio frequencies, serving as the standard for assessing hearing damage and noise pollution. There have been assertions that the persistent, sharp popping sounds associated with pickleball gameplay are distressing to nearby individuals, creating an inescapable nuisance even with closed windows and elevated volumes on audio devices. Such a nuisance has been linked to potential sleep disturbances and heightened anxiety levels.

Consequently, there exists a demand for novel approaches to produce pickleballs that exhibit reduced noise levels while maintaining superior playability. Various methods have been explored to mitigate pickleball noise, including the consideration of foam-based balls. However, these alternatives are characterized as rubbery, bouncy, and lacking in desired performance attributes, rendering them unsuitable for pickleball gameplay by the majority of users. Further, these alternatives may not be approved or approvable by standards set out by official organizations such as the USA Pickleball (USAP) that have established rules and guidelines as to what constitutes conforming pickleballs according to the specifications presented in, for example, the USA Pickleball Equipment Standards Manual (version 2.0, November 2023). These rules and guidelines indicate, among other things, design and manufacturing criteria for pickleballs that may be used in tournament play.

The disclosed example pickleballs may include a ball comprising a spherical shell, along with apertures defined within the structural frame or pickleball material. The ball may contain more than one element, including a structural frame with an additional surface. The structural frame or pickleball material may encompass at least one of the thermoplastic elastomers (TPE), ethylene-vinyl acetate (EVA), polypropylene (PP), polyethylene (PE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), linear low-density polyethylene (LLDPE), polyurethane (PU), thermoplastic polyurethane (TPU), photo-elastomers, other suitable or conforming materials, and combinations thereof.

Examples described herein provide a ball including a spherical shell, apertures defined in the spherical shell, and a surface treatment defined on the spherical shell configured to reduce noise when the ball impacts a surface.

Examples described herein provide a surface treatment that includes a noise-suppressing outer surface mechanically coupled to the spherical shell. The spherical shell may include a structural frame. The noise-suppressing outer surface may extend through the apertures defined in the spherical shell. Further, the noise-suppressing outer surface may further include returns that extend into an interior of the spherical shell and along an interior surface of the spherical shell. The returns may be dimensioned to form an interference fit within the apertures. The structural frame may include a relatively more rigid material as compared to the noise-suppressing outer surface.

Examples described herein also provide a surface treatment that may include a noise-suppressing outer surface mechanically coupled to the spherical shell, a plurality of first apertures defined in the noise-suppressing outer surface, and a plurality of second apertures defined in the spherical shell. A number of the first apertures may be smaller relative to a number of the second apertures.

A total area across a surface of the spherical shell of the second apertures may be greater relative to a total area across a surface of the noise-suppressing outer surface of the first apertures. The spherical shell may include a first injection molded hemisphere, and a second injection molded hemisphere fused to the first injection molded hemisphere. The spherical shell may include a monolithic, rotationally molded sphere. The first apertures or the second apertures may be formed through a subtractive manufacturing process.

The noise-suppressing outer surface may include a first hemisphere of material, and a second hemisphere of material. The first hemisphere and the second hemisphere may be fitted and coupled to the spherical shell through joining or welding of the first hemisphere and the second hemisphere. The first hemisphere and the second hemisphere are fitted and coupled to the spherical shell via adhesive bonding, heat bonding, or mechanical fastening. The material of the spherical shell may exhibit a relatively greater stiffness compared to the noise-suppressing outer surface.

Examples described herein also provide a surface treatment that includes a registration protrusion formed on an exterior surface of the spherical shell, and a noise-suppressing outer surface mechanically coupled to the spherical shell via injection molding to an extent of the registration protrusion. The registration protrusion may include a plurality of registration protrusions formed on the exterior surface of the spherical shell.

The ball may further include a plurality of first apertures defined in the noise-suppressing outer surface, and a plurality of second apertures defined in the spherical shell axially aligning with the plurality of first apertures. The spherical shell may include a first injection molded hemisphere, and a second injection molded hemisphere fused to the first injection molded hemisphere. The spherical shell may include a monolithic, rotationally molded sphere. The first apertures or the second apertures may be formed through a subtractive manufacturing process. A material of the spherical shell may exhibit a relatively greater stiffness compared to the noise-suppressing outer surface.

Examples described herein also provide a surface treatment that includes a textured surface formed on an outer surface of the spherical shell. The textured surface may include a plurality of protuberances. The plurality of protuberances may include a stepped cylinder shape, a dome shape, a tower shape, or a domed cylinder shape. The plurality of protuberances may include a circular or polygonal cross-section.

The textured surface may be molded into the surface of the spherical shell. The textured surface may be coupled to the surface of the spherical shell. The ball may further include a first spacing between the protuberances across at least a first portion of a surface of the ball, and a second spacing between the protuberances across at least a second portion of a surface of the ball. The first spacing may be greater than the second spacing. The first portion and the second portion may border the apertures.

A combination of the first spacing and the second spacing may include at least 15% of a surface area of the ball. A combination of the first spacing and the second spacing may include at least 30% of a surface area of the ball. A combination of the first spacing and the second spacing may include at least 50% of a surface area of the ball. In one example, a combination of the first spacing and the second spacing may be greater than 50% of a surface area of the ball.

The protuberances may include a height between the outer surface of the spherical shell and a distal end of the protuberances. The height between the outer surface of the spherical shell and the distal end of the protuberances may be uniform among the protuberances. The height between the outer surface of the spherical shell and the distal end of the protuberances may be non-uniform among the protuberances. The height between the outer surface of the spherical shell and the distal end of the protuberances may be between less than 0.1 millimeters (mm) to greater than 2.0 mm. The height between the outer surface of the spherical shell and the distal end of the protuberances may be at least 0.1 mm. The height between the outer surface of the spherical shell and the distal end of the protuberances may be at least 0.5 mm. The height between the outer surface of the spherical shell and the distal end of the protuberances may be at least 1.0 mm. The height between the outer surface of the spherical shell and the distal end of the protuberances may be at least 2.0 mm. The height between the outer surface of the spherical shell and the distal end of the protuberances may be at least 3.0 mm.

The textured surface formed on an outer surface of the spherical shell may be molded onto the outer surface along with the molding of the spherical shell or coupled to the outer surface after a molding of the spherical shell. The textured surface formed on an outer surface of the spherical shell may be scratched, carved, cut, or heat branded onto the outer surface.

The number of the protuberances may be at least 200. The number of the protuberances may be at least 500. The number of the protuberances may be at least 1000. In one example, the number of protuberances may be greater than 1000.

The distal ends of the protuberances may be flat. The distal ends of the protuberances curved consistent with the radius of the ball. The protuberances include a radius.

Examples described herein also provide a surface treatment that includes a textured surface formed on an outer surface of the spherical shell. The textured surface may include a plurality of protuberances. The plurality of protuberances may include a hexagonal prism. The plurality of protuberances may be formed along the outer surface of the spherical shell in a geodesic pattern. The geodesic pattern of the protuberances may align with geodesic locations of the apertures defined in the ball.

The apertures may be formed through molding or drilling. Further, in one example, the apertures may be formed to define any shaped void, including round-shaped voids, square-shaped voids, triangular-shaped voids, abstract-shaped voids, or any other shaped void. The number of apertures may include 38 apertures. The number of apertures may include 40 apertures. The number of apertures may include 42 apertures. The number of apertures may include 92 apertures. The number of apertures may be greater than 92 apertures. In one example, the number of apertures may be greater than 500 apertures. Further, in one example, the number of apertures may be greater than 92 apertures. Still further, the number of apertures may be greater than 1,000 apertures. Even still further, the number of apertures may be greater than 5000 apertures. Further, the number of apertures may be greater than 10,000 apertures. However, any number of apertures may be defined in the pickleball as may be required or advantageous.

Examples described herein also provide a surface treatment that includes a textured surface formed on an outer surface of the spherical shell. The textured surface may include fibers bonded to the surface of the spherical shell. The fibers may include one or more of cotton, wool, silk, linen, synthetic fibers, polyester, polymers, nylon, Kevlar®, carbon, or acrylic, or combinations thereof. The fibers may be coupled to the spherical shell via flocking, adhesives, heat bonding, or combinations thereof.

The fibers may include woven fibers to form a woven fiber surface on the spherical shell. The woven fibers may be bonded to the spherical shell via an adhesive, heat bonding, welding, mechanical bonding, hook and loop bonding, elastic fitting, or combinations thereof. The fibers may be subjected to scoring, cutting, fraying, or combinations thereof. Further, in one example, the fibers may be generated directly from the spherical structure via surface fiber extraction, in situ fiber generation, surface fiber sculpting, or other fiber-generation methods or processes.

The fibers may include flashspun fibers to form a web of interconnected fibers on the spherical shell. The flashspun fibers may include a polymer, a high-density polyethylene, or combinations thereof.

Examples described herein also provide a surface treatment that includes counter-sunk edges formed on an outer circumference of the apertures defined in the surface of the spherical shell. The number of apertures may include at least 40 apertures. The apertures may include at least 42 apertures. The number of apertures may include at least 92 apertures. The number of apertures may include at least 120 apertures. In one example, the number of apertures may be between 120 and 250 apertures. Further, in one example, the number of apertures may be between 250 and 1,000 apertures. Still further, in one example, the number of apertures may be greater than 1,000 apertures.

An angle of the counter-sunk edges may be less than 60 degrees with respect to an outer surface of the spherical shell. The angle of the counter-sunk edges may be at least 60 degrees with respect to an outer surface of the spherical shell. The angle of the counter-sunk edges may be at least 80 degrees with respect to an outer surface of the spherical shell. The angle of the counter-sunk edges may be at least 120 degrees with respect to an outer surface of the spherical shell.

The apertures may reduce a surface area of the spherical shell by at least 15%. The apertures may reduce a surface area of the spherical shell by at least 25%. The apertures may reduce a surface area of the spherical shell by at least 40%. The apertures may reduce a surface area of the spherical shell by at least 80%. The apertures may reduce a surface area of the spherical shell by at least 95%.

Additionally, the techniques described in this disclosure may be performed as a method and/or by a system having non-transitory computer-readable media storing computer-executable instructions that, when executed by one or more processors, performs the techniques described above.

Example Embodiments

This disclosure describes pickleballs with sound-dampening characteristics, architectures, and/or surface treatments that reduce the pronounced popping sound upon impact with a pickleball paddle or hard surface, such as the playing surface. Certain implementations and embodiments of the disclosure will now be described more fully below with reference to the accompanying figures, in which various aspects are shown. However, the various aspects may be implemented in many different forms and should not be construed as limited to the implementations set forth herein. The disclosure encompasses variations of the embodiments, as described herein. Like numbers refer to like elements throughout.

FIG. 1 illustrates a front perspective view of a pickleball 100 including two layers of materials and molded apertures, according to an example of the principles described herein. FIG. 2 illustrates a cross-sectional view of the pickleball 100 along line A depicted in FIG. 1, according to an example of the principles described herein. The pickleball 100 may include a spherical shell 202. The spherical shell 202 may include, in this and other examples described herein, any structural frame that supports a noise-suppressing material formed on or coupled to the outer surface of the spherical shell 202.

The pickleball 100 may include at least one aperture 102 defined in the spherical shell 202. In one example, the number of apertures 102 defined in the pickleball 100 may be defined or regulated by organizations such as the USA Pickleball (USAP) that have established rules and guidelines as to what constitutes conforming pickleball according to the specifications presented in, for example, the USA Pickleball Equipment Standards Manual (version 2.0, November 2023). These rules and guidelines indicate, among other things, design and manufacturing criteria for pickleballs that may be used in tournament play. For example, approved pickleballs may include, as to a size, between 2.87 inches (7.29 cm) to 2.97 inches (7.54 cm) in diameter. The weight of the pickleball may also be regulated to be between 0.78 and 0.935 ounces (22.1 and 26.5 grams, respectively). As to the number of apertures 102, the pickleball 100 may be regulated to have a minimum of 26 to a maximum of 40 circular apertures, with spacing of the apertures and overall design of the ball conforming to specific flight characteristics.

The pickleball 100 may include spherical shell 202 with a surface treatment defined on the spherical shell 202 configured to reduce noise when the pickleball 100 impacts a surface, such as a paddle and/or a playing surface. The surface treatment of the example of FIG. 1 may include a noise-suppressing outer surface 104 mechanically coupled to the spherical shell 202. The spherical shell 202 may include a structural frame that supports the noise-suppressing outer surface 104. Further, the noise-suppressing outer surface 104 may extend through the apertures 102 defined in the spherical shell.

For example, the noise-suppressing outer surface 104 may include returns 204 that extend into an interior of the spherical shell and along an interior surface of the spherical shell. The noise-suppressing outer surface 104 may further include an internal rim 106 that bridges the noise-suppressing outer surface 104 with the returns 204. The returns 204 and/or the internal rims 106 may be dimensioned to form an engineering fit within the apertures and other surfaces of the spherical shell 202. As used in the present specification and in the appended claims, the term “engineering fit” is meant to be understood broadly as any engineering fit such as, for example, a clearance fit (e.g., one of a loose running fit, a free running fit, a close running fit, a sliding fit, and a location fit), a transition fit (e.g., one of a similar fit, and a fixed fit), and an interference fit (e.g., one of a press fit, a driving fit, and a forced fit). In this manner, the returns 204 and/or the internal rims 106 may be coupled to the spherical shell 202 via an engineering fit.

In one example, the spherical shell 202 serving as a structural frame may include an/or be made of a relatively more rigid material as compared to the noise-suppressing outer surface 104. This may allow for the material of the noise-suppressing outer surface 104, including the returns 204 and/or the internal rims 106, to move through and past the apertures 102 to mechanically couple the noise-suppressing outer surface 104 to the spherical shell 202.

In one example, the apertures 102 may be molded as the spherical shell 202 is formed. Further, in one example, the apertures 102 may include a chamfer 108 at the edges of the apertures 102. The chamfers 108 may assist in the assembly of the noise-suppressing outer surface 104 with the spherical shell 202 by providing an inclined plane along which portions of the returns 204 and/or the internal rims 106 may slide to engage with the apertures 102. In one example, the spherical shell 202 may include the chamfers 108 defined at the apertures 102, and the noise-suppressing outer surface 104 may include matching chamfers 108 bridging an outer surface of the noise-suppressing outer surface 104 and the internal rims 106.

In one example, the spherical shell 202 serving as a structural frame may be injection molded, including two hemispheres that form the spherical shell 202 when fused or otherwise affixed together to form a single unit. In one example, the spherical shell 202 serving as a structural frame may be roto-molded, resulting in a unified one-piece spherical shell 202 that forms the structural frame of the pickleball.

In one example, the noise-suppressing outer surface 104 may include two hemispheres that are fitted and attached over the structural frame of the spherical shell 202. Apart from or in addition to the engineering fit described above as the mechanical coupling of the noise-suppressing outer surface 104 to the spherical shell 202, various attachment methods may be utilized to secure the noise-suppressing outer surface 104 to the spherical shell 202, including, for example, joining and welding at a seam, adhesive bonding, hermetic sealing, mechanical fastening, other suitable joining methods or processes, and combinations thereof.

In one example, the spherical shell 202 may include apertures 102 with an inside dimension that is relatively larger than an outside diameter of the returns 204 of the noise-suppressing outer surface 104. The returns 204 may snap into the apertures 102 of the spherical shell 202, thereby securing the two layers together.

The noise-suppressing outer surface 104, as well as other surface treatments of the example pickleballs described herein, are configured to reduce noise when the ball impacts a surface such as a paddle, a playing surface or court, or other objects. This reduction in noise greatly increases the enjoyment of play for both those participating in the playing of the sport, who are less distracted by the noise, as well as those who are not involved but who would be within hearing distance of the playing of the sport. This allows for the playing of the sport to be co-located with other areas, including residential and commercial properties. Thus, the spherical shell 202 may include a greater stiffness compared to the noise-suppressing outer surface 104 to provide rigidity to the pickleball, while the noise-suppressing outer surface 104 offers enhanced softening of sound.

FIG. 3 illustrates a front perspective view of a pickleball 300 including two layers of materials and drilled apertures 302, according to an example of the principles described herein. FIG. 4 illustrates a cross-sectional view of the pickleball 300 along line B depicted in FIG. 3, according to an example of the principles described herein. More specifically, the pickleball 300 may include a spherical shell 402. The spherical shell 402 may include the apertures 302 defined therein.

The surface treatment defined on the spherical shell 402 that is configured to reduce noise when the pickleball 300 impacts a surface may include a noise-suppressing outer surface 304 mechanically coupled to the spherical shell 402. A plurality of first apertures 302 may be defined in the noise-suppressing outer surface 304, and a plurality of second apertures 404 may be defined in the spherical shell 402. Together, the first apertures 302 and the second apertures 404 may form a complete via from an outside surface of the noise-suppressing outer surface 304 through to an internal surface of the spherical shell 402.

In one example, the number of first apertures 302 defined in the noise-suppressing outer surface 304 may be smaller or fewer relative to the number of second apertures 404 defined in the spherical shell 402. In this example, as depicted in FIG. 4, one or more of the second apertures 404 may be formed in the spherical shell 402, but a first aperture 302 is not formed in the noise-suppressing outer surface 304 at that location. By closing off one or more of the second apertures 404 defined in the spherical shell 402, the pressures associated with the sound waves may be further dampened as they are produced or enter the interior of the spherical shell 402. Thus, in one example, a total area across a surface of the spherical shell 402 of the second apertures 404 is greater relative to a total area across a surface of the noise-suppressing outer surface 304 of the first apertures 302. Stated another way, the number of second apertures 404 defined in the spherical shell 402 may be greater than the number of first apertures 302 defined in the noise-suppressing outer surface 304. This may result in the surface area of the noise-suppressing outer surface 304 being greater than the surface area of the spherical shell 402 since fewer apertures (e.g., the first apertures 302) are formed or defined in the noise-suppressing outer surface 304. This is depicted in, for example, FIG. 4, in which several instances where the noise-suppressing outer surface 304 is viewable through the second apertures 404 defined in the spherical shell 402.

In one example, the spherical shell 402 may include a first injection molded hemisphere and a second injection molded hemisphere fused to the first injection molded hemisphere. This allows for the manufacture of the spherical shell 402 to be performed via a two-piece method. The fusing of the two separate hemispheres in this example may include, for example, mechanical joining (e.g., via mechanical fasteners), welding, cross-linking adhesive bonding, solvent-based adhesive bonding, hotmelt adhesive bonding, ultrasonic welding, vibration welding, heated tool welding, hot gas welding, hot wedge welding, extrusion welding, hot plate welding, implant induction welding, implant resistance welding, spin welding, electromagnetic welding, radio frequency (RF) welding, infrared welding, laser welding, microwave welding, or combinations thereof.

In one example, the spherical shell 402 may include a monolithic, rotationally molded sphere. In this example, the spherical shell 402 may be formed by injection molding a monolithic or single piece to form the spherical shell 402 unitarily. In one example, the molding process may include molding the second apertures 404 in the instance in which the spherical shell 402 is molded. In other words, the second apertures 404 may be included in the mold used to create the monolithic or single piece of the spherical shell 402. In one example, the spherical shell 402 may be monolithically formed as described above, but without the second apertures 404 defined therein. Thereafter, in this example, the second apertures 404 may be formed in the spherical shell 402 through drilling, melting the spherical shell 402, or other methods. Thus, in the above examples, the first apertures 302 and/or the second apertures 404 may be formed through a subtractive manufacturing process.

The noise-suppressing outer surface 304 may include a first hemisphere of material and a second hemisphere of material. The first hemisphere and the second hemisphere forming the noise-suppressing outer surface 304 may be fitted and coupled to the spherical shell 402 through joining or welding of the first hemisphere and the second hemisphere around the spherical shell 402. In one example, the first hemisphere and the second hemisphere forming the noise-suppressing outer surface 304 may be aligned such that at least one of the first apertures 302 defined in the noise-suppressing outer surface 304 is aligned with at least one of the second apertures 404 defined in the spherical shell 402. In one example, the first hemisphere and the second hemisphere forming the noise-suppressing outer surface 304 may be fitted and coupled to the spherical shell 402 via adhesive bonding, heat bonding, mechanical fastening, other coupling methods and systems, and combinations thereof at a seam between the first hemisphere and the second hemisphere.

In one example, the material of the spherical shell 402 may exhibit a relatively greater stiffness compared to the noise-suppressing outer surface 304. This may provide rigidity to the pickleball 300, while the noise-suppressing material of the noise-suppressing outer surface 304 offers enhanced flexibility and softening of sound.

FIG. 5 illustrates a front perspective view of a pickleball 500 including two layers of materials and drilled apertures, according to an example of the principles described herein. FIG. 6 illustrates a cross-sectional view of the pickleball 500 along line C depicted in FIG. 5, according to an example of the principles described herein. The pickleball 500 of FIGS. 5 and 6 may include a spherical shell 602, a plurality of second apertures 606 defined in the spherical shell 602, and a surface treatment defined on the spherical shell 602 configured to reduce noise when the ball impacts a surface.

The surface treatment may include a noise-suppressing outer surface 504 mechanically coupled to the spherical shell 602. The noise-suppressing outer surface 504 may include features and characteristics of the noise-suppressing outer surface 304 of FIGS. 3 and 4. The noise-suppressing outer surface 504 may include a number of first apertures 502 defined in the noise-suppressing outer surface 504, at least one of which may align with at least one of the second apertures 606 defined in the spherical shell 602.

A plurality of registration protrusions 604-1, 604-2, 604-3, 604-4, 604-5, 604-6, 604-7, 604-8, 604-9, 604-10, 604-11, 604-N (where N is any integer greater than or equal to 1 (collectively referred to herein as registration protrusion(s) 604 unless specifically addressed otherwise)) may be formed on an exterior surface of the spherical shell 602. The noise-suppressing outer surface 504 may be mechanically coupled to the spherical shell 602 and may be applied based on a height of the registration protrusions 604. In one example, the noise-suppressing outer surface 504 may be applied to the exterior surface of the spherical shell 602 at a height or depth at least as high or deep as the registration protrusions 604 extend from the surface of the spherical shell 602. The registration protrusions 604, in this manner, regulate a thickness of the noise-suppressing outer surface 504 by controlling the distance between an exterior or outer diameter of the spherical shell 602 and an internal diameter of a mold used to form the noise-suppressing outer surface 504 on the spherical shell 602. The noise-suppressing outer surface 504 may be introduced into the space between the exterior or outer diameter of the spherical shell 602 and the mold through injection molding or other suitable methods. Thus, the thickness of the noise-suppressing outer surface 504 may be based on the height of the registration protrusions 604.

In one example, the registration protrusions 604 may include a plurality of registration protrusions formed on the exterior surface of the spherical shell 602. The layout or positioning of the registration protrusions 604 may include placement of the registration protrusions 604 in a grid or ordered pattern along the outer surface of the spherical shell 602. In one example, the registration protrusions 604 may be positioned equidistant from any number of second apertures 606 defined in the spherical shell 602. However, the layout or positioning of the registration protrusions 604 may be based on any ordered pattern, any random layout, or any level of order along the outer surface of the spherical shell 602.

In one example, the registration protrusions 604 may be made of the same material as the spherical shell 602. In this example, the registration protrusions 604 may be monolithically formed with the spherical shell 602 during a manufacturing process of the spherical shell 602 or coupled to the spherical shell 602 after manufacturing of the spherical shell 602. In one example, the registration protrusions 604 may be made of the same material as the noise-suppressing outer surface 504. In this example, the registration protrusions 604 may be formed on the spherical shell 602 and may be consumed and coupled to the material of the noise-suppressing outer surface 504 such that the registration protrusions 604 disappear into the material of the noise-suppressing outer surface 504. In one example, the registration protrusions 604 may be made of a material that is different from the spherical shell 602 and the noise-suppressing outer surface 504.

In one example, the pickleball 500 of FIGS. 5 and 6 may be formed by manufacturing the spherical shell 602. As described above, the spherical shell 602, the second apertures 606, and/or the registration protrusions 604 may be formed together in a single mold or separately through subtractive and/or additive manufacturing processes to form the second apertures 606 in the spherical shell 602 and the registration protrusions 604 on the exterior of the spherical shell 602. Once the spherical shell 602 (including the second apertures 606 and the registration protrusions 604) is formed, the spherical shell 602 may be placed in a mold. The mold may hold the spherical shell 602 by coming into contact with the registration protrusions 604 and ensuring that the outer surface of the spherical shell 602 is equidistant from the internal surface of the mold. In this state, the material from which the noise-suppressing outer surface 504 is made may be injected into the mold and caused to fill the space between the outer surface of the spherical shell 602 and the internal surface of the mold.

In an embodiment, at least one of the plurality of first apertures 502 defined in the noise-suppressing outer surface 504 and at least one of the plurality of second apertures 606 defined in the spherical shell 602 may be axially aligned, as described herein in connection with other examples of the pickleball. Further, the spherical shell 602 may include a first injection molded hemisphere and a second injection molded hemisphere fused to the first injection molded hemisphere as described herein. Still further, in one example, the spherical shell 602 may include a monolithic, rotationally molded sphere. The first apertures 502 and/or the second apertures 606 may be formed through a subtractive manufacturing process. As mentioned above, the material of the spherical shell 602 may exhibit a relatively greater stiffness compared to the noise-suppressing outer surface 504.

FIG. 7 illustrates a front perspective view of a pickleball 700 including a dome textured surface, according to an example of the principles described herein. As described herein in other example pickleballs, the pickleball 700 of FIG. 7 may include a spherical shell 702 and apertures 704 defined in the spherical shell 702. The pickleball 700 may further include a surface treatment defined on the spherical shell 702, where the surface treatment is configured to reduce noise when the pickleball 700 impacts a surface.

In the example of FIG. 7, the exterior surface of the pickleball 700 may include an area on which a plurality of protuberances 706 are formed. The protuberances 706 may be laid out along the surface of the spherical shell 702 with a number of different spacings between the protuberances 706, where the different spacings define different levels of densities of the protuberances 706. Thus, the density of the protuberances 706 along the exterior surface of the spherical shell 702 may vary. For example, the protuberances 706 may have a first spacing 708 between the protuberances 706, a second spacing 710 between the protuberances 706, and a third spacing 712 between the protuberances 706. Further, in one example, the first spacing 708, the second spacing 710, and the third spacing 712 may be present in areas along the surface of the spherical shell 702 bordering the apertures 704. The pickleball 700 may include any number of different spacings of the protuberances 706 along any area of the surface of the spherical shell 702. Further, the spacings of the protuberances 706 may be uniform at locations that are not juxtaposition to the apertures 704. In one example, the first spacing 708 may include protuberances 706 that are relatively further spaced out from one another relative to the second spacing 710 of protuberances 706, and the second spacing 710 may include protuberances 706 that are relatively further spaced out from one another relative to the third spacing 712 of protuberances 706.

Prior pickleballs may contain hollow areas on the surface occupying less than 15% of the pickleball surface area and may be available for contact with a paddle. In one example of the pickleball 700 of FIG. 7, the combined first spacing 708, second spacing 710, and third spacing 712 may be greater than 15% of the outermost surface area of the pickleball 700. In one example, the combined first spacing 708, second spacing 710, and third spacing 712 may be greater than 30% of the outermost surface area of the pickleball 700. In one example, the combined first spacing 708, second spacing 710, and third spacing 712 may be greater than 50% of the outermost surface area of the pickleball 700. Further, in one example, the combined first spacing 708, second spacing 710, and third spacing 712 may be greater than 90% of the outermost surface area of the pickleball 700.

The protuberances 706 may be spaced out from one another by any amount. For example, a distance or space between the protuberances 706 may be between less than 0.1 mm to greater than 2.0 millimeters. In one example, the distance or space between the protuberances 706 is greater than 0.1 millimeter. In one example, the distance or space between the protuberances 706 may be greater than 0.5 millimeters. In one example, the distance or space between the protuberances 706 may be greater than 1.0 millimeter. In one example, the distance or space between the protuberances 706 may be greater than 2.0 mm. In one example, the distance or space between the protuberances 706 may be greater than 3.0 mm. In one example, more than one distance or space may exist between the protuberances 706, forming a pickleball with multiple distances or spaces between the protuberances 706. However, any distance or space between the protuberances 706 may be operable to achieve noise suppression.

The protuberances 706 may have any number of configurations, shapes, and/or dimensions. In one example, the individual protuberances 706 may have a stepped cylinder shape, a dome shape, a tower shape, a domed cylinder shape, or other configurations, shapes, and/or dimensions suitable to achieve noise suppression. The head and cross-section of the individual protuberances 706 may exhibit circular, polygonal, or other shapes for effective noise suppression. In one example, more than one type of shape may be applied to the protuberances 706, forming a textured surface with multiple bump shapes.

In one example, the textured surface formed by the protuberances 706 may be molded onto the pickleball surface or along with the molding of the spherical shell 702. In one example, the textured surface formed by the protuberances 706 may be applied post-molding or after a molding of the spherical shell 702. The method in which the protuberances 706 may be formed on the pickleball surface may include scratching, carving, cutting, heat branding, or other methods. In one example, the number of protuberances 706 on the surface of the pickleball 700 may exceed 200 protuberances 706. In one example, the number of protuberances 706 on the surface of the pickleball 700 may exceed 500 protuberances 706. In one example, the number of protuberances 706 on the surface of the pickleball 700 may exceed 1,000 protuberances 706. However, any number of protuberances 706 may be included on the surface of the pickleball 700 to achieve noise suppression.

In one example, the outermost boundary of the protuberances 706 may be flat. In one example, the outermost boundary of the protuberances 706 may have a curved profile consistent with the radius of the pickleball 700. In one example, the edge of the protuberances 706 may have a radius. In one example, the pickleball 700 may include a plurality of layers of protuberances 706 at different distances from the spherical shell 702, whereas the pickleball 700 flexes when striking the distal end to contact successive layers of protuberances 706.

FIG. 8 illustrates a front perspective view of a pickleball 800 including a hexagon-shaped textured surface, according to an example of the principles described herein. In a similar manner as described above in connection with FIG. 7, the pickleball 800 of FIG. 8 may include a spherical shell and a surface treatment defined on the spherical shell configured to reduce noise when the pickleball 800 impacts a surface. In one example, the pickleball 800 may further include a number of apertures defined in the spherical shell in a manner similar to the pickleballs described herein, although apertures are not depicted in the pickleball 800 of FIG. 8.

In the example of FIG. 8, the pickleball 800 may include a textured surface without apertures. In one example, the textured surface of the pickleball 800 may include hexagon-shaped protrusions 802 forming a protrusion arranged along the surface of the spherical shell 804. In one example, the hexagon-shaped protrusions 802 may include a hexagonal prism. In one example, the hexagon-shaped protrusions 802 may be formed along the surface of the spherical shell 804 in a geodesic formation or pattern. The geodesic positioning of the hexagon-shaped protrusions 802 may align with various geodesic locations of apertures defined in the pickleball 800 at a later stage of manufacture to achieve the desired level of noise suppression and performance.

As used in the present specification and in the appended claims, the term “geodesic” is meant to be understood broadly as any shortest path between two points on a surface. A geodesic dome may include any hemispheric structure that is based on a geodesic polyhedron. In the context of the example pickleballs described herein, apertures defined in the surface of the pickleball may be defined at positions along a surface of the pickleball (e.g., a spherical object with an outer surface) at which geodesic lines intersect at vertices.

Examples described herein provide a ball including a spherical shape and apertures defined in the spherical shape. The apertures may be formed in the spherical shape based at least in part on an N-frequency tessellation of the spherical shape, where N is a whole number. In one example, the N-frequency tessellation of the spherical shell may include a 2-frequency (2v) or a 3-frequency (3v) tessellation of the spherical shape of the pickleball 1200. The apertures may include pairs of apertures wherein a first aperture of a first pair of apertures is axially aligned with a second aperture of the first pair of apertures through the center of the pickleball 1200.

In an example where apertures are defined in the pickleball 800, the apertures may be generated through molding, drilling, or any method capable of defining apertures within the spherical shell 804 of the pickleball 800. In one example, the number of apertures may include 38. In one example, the number of apertures may include 40. In one example, the number of apertures may include 42. In one example, the number of apertures may include 92. In one example, the number of apertures may be greater than 92. However, any number of apertures may be included with the hexagon-shaped protrusions 802 of the spherical shell 804 to achieve noise suppression. The pickleball 800 may have a minimum of 26 to a maximum of 40 circular apertures, with spacing of the apertures and overall design of the pickleball 800 conforming to desired or regulated flight characteristics.

In one example, space between the hexagon-shaped protrusions 802 along the surface of the spherical shell 804 may be above 15% of the total exterior surface area of the pickleball 800. The hexagon-shaped protrusions 802 may be spaced out from one another by any amount. For example, a distance or space between the hexagon-shaped protrusions 802 may be between less than 0.1 mm to greater than 2 millimeters. In one example, the distance or space between the hexagon-shaped protrusions 802 is greater than 0.1 millimeter. In one example, the distance or space between the hexagon-shaped protrusions 802 may be greater than 0.5 millimeters. In one example, the distance or space between the hexagon-shaped protrusions 802 may be greater than 1 millimeter. In one example, the distance or space between the hexagon-shaped protrusions 802 may be greater than 2 mm. In one example, the distance or space between the hexagon-shaped protrusions 802 may be greater than 3 mm. In one example, more than one distance or space may exist between the hexagon-shaped protrusions 802, forming a pickleball with multiple distances or spaces between the hexagon-shaped protrusions 802. However, any distance or space between the hexagon-shaped protrusions 802 may be operable to achieve noise suppression.

The hexagon-shaped protrusions 802 may have any number of configurations, shapes, and/or dimensions. In one example, the individual hexagon-shaped protrusions 802 may have different configurations, shapes, and/or dimensions suitable to achieve noise suppression. The head and cross-section of the individual hexagon-shaped protrusions 802 may exhibit polygonal, or other shapes other than the hexagonal cross-section that may provide for effective noise suppression. In one example, more than one type of shape may be applied to the hexagon-shaped protrusions 802, forming a textured surface with multiple protrusions.

In one example, the textured surface formed by the hexagon-shaped protrusions 802 may be molded onto the pickleball surface. In one example, the textured surface formed by the hexagon-shaped protrusions 802 may be applied post-molding. The method in which the hexagon-shaped protrusions 802 may be formed on the pickleball surface may include scratching, carving, cutting, heat branding, or other methods. In one example, the number of hexagon-shaped protrusions 802 on the surface of the pickleball 800 may exceed 200 hexagon-shaped protrusions 802. In one example, the number of hexagon-shaped protrusions 802 on the surface of the pickleball 800 may exceed 500 hexagon-shaped protrusions 802. In one example, the number of hexagon-shaped protrusions 802 on the surface of the pickleball 800 may exceed 1,000 hexagon-shaped protrusions 802. However, any number of hexagon-shaped protrusions 802 may be included on the surface of the pickleball 800 to achieve noise suppression.

In one example, the outermost boundary of the hexagon-shaped protrusions 802 may be flat. In one example, the outermost boundary of the hexagon-shaped protrusions 802 may have a curved profile consistent with the radius of the pickleball 700. In one example, the edge of the hexagon-shaped protrusions 802 may have a radius in a manner similar to the protuberances 706 of the pickleball 700 of FIG. 7. The hexagon-shaped protrusions 802 formed on the spherical shell 804 of the pickleball 800 may be evenly spaced as depicted in FIG. 8. However, the hexagon-shaped protrusions 802 may be arranged along the surface of the spherical shell 804 of the pickleball 800 in any manner.

FIG. 9 illustrates a front perspective view of a pickleball 900 including a fiber-textured surface 904, according to an example of the principles described herein. As in similar examples described herein, the pickleball 900 may include a spherical shell 906 acting as a structural frame and a plurality of apertures 902 defined in the spherical shell 906. A surface treatment may be defined on the spherical shell 906 configured to reduce noise when the ball impacts a surface. The surface treatment may be any noise attenuating surface intended to diminish or lessen the intensity of sound. In one example, the fiber-textured surface 904 may serve as this noise attenuating surface treatment.

In one example, the fiber-textured surface 904 may be composed of fibers bonded to the surface of a spherical shell 906. The fibers may transform a hard surface such as the spherical shell 906 into a sound softening or attenuating surface. The fiber-textured surface 904 with a rigid substrate may be combined to produce a tactile cushioned surface, offering both comfort and noise attenuating properties.

The fiber-textured surface 904 may encompass various forms, including a network of tiny fibers loosely arranged or protruding from the spherical shell 906, a multitude of fine strands, or numerous short fibers protruding from the surface. Types of noise attenuating fibers include cotton, wool, silk, linen, synthetic fibers, polyester, polymers, nylon, Kevlar®, carbon, acrylic, or other fibers.

The fibers of the fiber-textured surface 904 may be bonded to the spherical shell 906 through methods including flocking, adhesives, heat bonding, or other manufacturing methods. In an example in which flocking is utilized, the flock fibers may be electrostatically charged and applied onto an adhesive-coated surface of the spherical shell 906, and adhere to the adhesive in an upright position in order to create a uniform fibrous texture. In one example, the fiber-textured surface 904 absorbs impact energy, resulting in a quieter and more enjoyable playing environment.

In one example, the fiber-textured surface 904 may include a woven surface. The woven surface may entail interlacing threads or fibers in a pattern and creating a fabric where individual threads are tightly integrated into the overall structure. The woven material may be bonded to the spherical shell 906 through methods including but not limited to adhesives, heat bonding, welding, mechanical fasteners, securing via elastic means, hook and loop fasteners where the fabric serves as one of the hook or loop material pairs, or other bonding methods.

Further, the noise attenuating capabilities of the fiber-textured surface 904 may be enhanced by lifting fiber strands from the spherical shell 906 through techniques such as, for example, scoring, cutting, or fraying to create micro-fibers that effectively soften impact noise during gameplay. In one example, the fibers may be generated directly from the spherical structure by surface fiber extraction, in-situ fiber generation, surface fiber sculping, or other fiber generation techniques. Still further, the fiber-textured surface 904 of the pickleball 900 may comprise flashspun fibers. Flashspun fabric may include any nonwoven fabric formed from fine fibrillation of a film by the rapid evaporation of solvent and subsequent bonding during extrusion. The flashspun fabric may be formed by extruding an initial material through fine apertures at high speeds, resulting in a web of interconnected fibers. The flashspun material may include polymers, high-density polyethylene produced through flash spinning, or other types of suitable material.

The fiber-textured surface 904 may include soft textures such as feathery. velvety, fuzzy, smooth, satin, plush, and hairy, or alternatively, textures that are coarse, rough, bristly, or brush-like in appearance or feel. Any texture may be applied as long as noise attenuation is achieved.

FIG. 10 illustrates a front perspective view of a pickleball 1000 including counter-sunk apertures 1002, according to an example of the principles described herein. FIG. 11 illustrates a cross-sectional view of the pickleball 1000 along line D depicted in FIG. 10, according to an example of the principles described herein. As in similar examples described herein, the pickleball 1000 may include a spherical shell 1006 acting as a structural frame and a plurality of the counter-sunk apertures 1002 defined in the spherical shell 1006. A surface treatment may be defined on the spherical shell 1006 configured to reduce noise when the ball impacts a surface. The surface treatment may be any noise attenuating surface intended to diminish or lessen the intensity of sound. In one example, the counter-sunk apertures 1002 may serve as this noise attenuating surface treatment.

In one example, the pickleball 1000 may include 92 counter-sunk apertures 1002. Increasing the number of counter-sunk apertures 1002 may effectively decrease sound emissions. In one example, the number of counter-sunk apertures 1002 may be greater than 40. In one example, the number of counter-sunk apertures 1002 may be 42. In one example, the number of counter-sunk apertures 1002 may be greater than 42. In one example, the number of counter-sunk apertures 1002 is 92. In one example, the number of counter-sunk apertures 1002 may be greater than 92. In one example, the number of counter-sunk apertures 1002 may be greater than 120. In one example, the number of apertures may be greater than 250.

The depth and/or angle of the counter-sunk edges 1004 of the counter-sunk apertures 1002 may attenuate sound waves by redirecting a soundwave path of any noises generated when the pickleball 1000 strikes a hard surface such as a pickleball paddle, a surface of a pickleball court, or other surface or object. The depth and/or angle of the counter-sunk edges 1004 may effectively reduce the overall noise level produced when the pickleball 1000 collides with a pickleball paddle or another surface. Implementing the counter-sunk edges 1004 may offer the advantage of diminishing unwanted noise while minimally impacting the performance of the pickleball 1000.

In one example, the angle of the counter-sunk edges 1004 may be less than 60 degrees. In one example, the angle of the counter-sunk edges 1004 is 60 degrees or greater. In one example, the angle of the counter-sunk edges 1004 is 80 degrees or greater. In one example, the angle of the counter-sunk edges 1004 is 120 degrees or greater. In one example, sound mitigation is achieved by integrating the counter-sunk edges 1004 to the counter-sunk apertures 1002, by reducing the surface area of the material of the spherical shell 1006 of the pickleball 1000 in contact with a hard surface such as a pickleball paddle, a surface of a pickleball court, or other surface or object.

In one example, the surface area of the pickleball 1000 available for contacting a surface is reduced by introducing a hollow space or volume of the pickleball 1000 occupying more than 15% of the surface area. In one example, the hollow space or volume may occupy greater than 25%. In one example, the hollow space or volume may exceed 40%. In one example, the hollow space or volume may exceed 80%. In one example, the hollow space or volume may exceed 90%. Further, in one example, additional textured surfaces as described herein in connection with other examples may be combined with the spherical shell 1006 of the pickleball 1000 of FIGS. 10 and 11.

In the examples described herein, the pickleballs 100, 300, 500, 700, 800, 900, 1000 may have a name or logo of a manufacturer or supplier printed or embossed on the surface of the spherical shell 804. Further, in one example, the “USA Pickleball Approved” seal or text may be similarly presented on the surface of the spherical shell 804 and/or on a case or package of pickleballs 100, 300, 500, 700, 800, 900, 1000 intended for competition. Further, in one example, a “USA Pickleball Approved” seal or text may be similarly presented on the surface of the spherical shell 804 and/or on a case or package of pickleballs 100, 300, 500, 700, 800, 900, 1000 for non-competition applications.

It is noted that any aspect or characteristic of a given example of the pickleballs 100, 300, 500, 700, 800, 900, 1000 may be applied to any other one of the examples of the pickleballs 100, 300, 500, 700, 800, 900, 1000. In this manner, any description associated with a particular example of the pickleballs 100, 300, 500, 700, 800, 900, 1000 provided herein may be similarly described in connection with any other examples of the pickleballs 100, 300, 500, 700, 800, 900, 1000.

FIG. 12 illustrates a front perspective view of a pickleball 1200 including a structural framework, according to an example of the principles described herein. FIG. 13 illustrates a cross-sectional view of the pickleball 1200 along line E depicted in FIG. 12, according to an example of the principles described herein. The pickleball 1200 of FIGS. 12 and 13 may include a geodesic design integrated within the pickleball 1200 that enhances the strength, durability, and noise-dampening properties of the pickleball 1200 through the structural framework. The design of the pickleball 1200 enables the use of softer, sound-dampening materials while maintaining the integrity and performance of the pickleball.

As mentioned herein, a three-dimensional (3D) geodesic structural framework may be integrated into the pickleball 1200. In one example, the structural framework may include interconnected triangular elements that form a geodesic configuration, distributing impact forces efficiently and preventing deformation or collapse of the pickleball 1200. The geodesic structure enhances the performance of the pickleball 1200 by allowing for flexible, sound-reducing materials without compromising strength. In one example, the structural framework may be made of a polymer, an elastomer, other materials, and compounds thereof that provide both flexibility and noise reduction while maintaining structural stability. The internal framework allows the pickleball 1200 to compress upon impact and return to its original shape, enhancing properties such as bounce, durability, and impact resilience.

The geodesic design of the pickleball 1200 has advantages of being lightweight and stable, and minimizes material usage while reinforcing the surface structure of the pickleball 1200. In one example, as described in FIGS. 15 and 16, the pickleball 1200 may include a solid outer surface with infill faces included within the open spaces between the crosspieces 1206 (described below), and/or aperture rings (e.g., 1418 and 1518 of FIGS. 14 and 15) described in more detail below. For example, a surface may have 42 apertures arranged in a two-frequency (2v) geodesic pattern based on a regular icosahedron; a highly symmetrical polyhedron with 20 equilateral triangle faces, 12 vertices (e.g., aperture rings 1418 and 1518 of FIGS. 14 and 15), 80 faces (20 equilateral triangles and 60 isosceles triangles), and 120 edges. In another example, the surface of the pickleball 1200 may include a polyhedron with twenty faces or twenty equilateral triangles or twelve pentagons 1216 and 20 hexagons 1214 with 60 vertices where the edges meet and 90 edges total. However, the pickleball 1200 may include any number of equilateral triangle faces, vertices (e.g., aperture rings 1418 and 1518 of FIGS. 14 and 15), faces, equilateral triangles, isosceles triangles, and edges to create a geodesic pattern along the surface of the pickleball 1200. These example layouts and features may apply to any example pickleball described herein.

In other examples, the pickleball 1200 may include any Archimedean solid, any Goldberg polyhedron, or any solid shape that includes characteristics of both an Archimedean solid and a Goldberg polyhedron. In one example, the pickleball 1200 may be defined by a Magnus Wenninger spherical model, where the polyhedron is given a geodesic notation in the form {3,q+}_{b, c}, where {3,q} is the Schläfli symbol for the regular polyhedron with triangular faces, and q-valence vertices, the “+” symbol indicates the valence of the vertices being increased, and “b, c” represents a subdivision description, with 1,0 representing the base form. With this understanding, the pickleball 1200 may have a {3,5+}_1,0. The Archimedean solid and/or any Goldberg polyhedron serving as the underlying structure of a pickleball 1200 may include a spherical projection (e.g., a projection to the sphere or a homeomorphism from the icosahedron to the sphere) of the icosahedron, for example, including a geometric representation of the edges of the icosahedron being projected onto a sphere, where the sphere and icosahedron share a center using straight lines to create geodesic structures. A spherical polyhedron in this example may include a tiling of a sphere where the surface is divided into spherical polygons by great arcs. The pentagons 1216 formed on the surface of the Archimedean solid and/or a Goldberg polyhedron, making up the pickleball 1200, may be formed by five triangles 1212, and the hexagons 1214 formed on the surface of the Archimedean solid and/or a Goldberg polyhedron, making up the pickleball 1200, may be formed by six triangles 1212.

In one example, the pickleball 1200 may omit the outer solid surface and, instead, utilize only the geodesic space framework that may accommodate various aperture shapes, such as triangles. In one example, the space framework may be modified so that only specific grid, lattice, or matrix elements are exposed for surface contact. The outer surface of the pickleball 1200 may or may not include apertures.

In one example, the structural framework and outer surface may be composed of the same material, allowing for optimized performance in strength, bounce, and noise reduction, and allowing for the pickleball 1200 to be manufactured using simpler or fewer manufacturing processes. In one example, the outer and inner surfaces of the pickleball may be made of different materials. By reinforcing the internal framework, the pickleball retains structural stability even when softer surface materials are used, resulting in a significant reduction in noise generated during play.

In one example, the internal framework structure may be encased in an outer shell. However, in one example, the pickleball may not include a shell, leaving an open geodesic framework. The lightweight geodesic framework may reduce bulk, while the flexibility of the frame material may contribute to enhanced cushioning and bounce characteristics.

In one example, the pickleball 1200 may be fabricated using additive manufacturing or 3D printing processes. Additive manufacturing may employ thermo-polymers, photopolymers, laser processes, or other suitable methods. Alternatively, the 3D-printed lattice or matrix framework structure may be modified for production via injection molding, or similar processes wherein flexible materials allow for molding the pickleball in halves with the internal frame exposed, followed by inverting the halves of the pickleball to encase the frame.

The example of the pickleball 1200 of FIG. 12 may include a three-dimensional (3D) geodesic structural framework that forms an exterior surface 1202 and an interior surface 1204. The exterior surface 1202 may be formed by a plurality of crosspieces 1206 coupled to another at a plurality of exterior hubs to form the geodesic structure of the pickleball 1200. Further, the outer surfaces of the crosspieces 1206 may form the exterior surface of the pickleball 1200 where the crosspieces 1206 lie on a common spherical surface.

In one example, the crosspieces 1206 may be axially straight such that the exterior surface of the pickleball 1200 is defined by the hubs at which the crosspieces 1206 meet and are coupled to one another. However, in one example, the crosspieces 1206 may be curved such that the crosspieces 1206 define the exterior surface of the pickleball 1200 along with the hubs at which the crosspieces 1206 meet and are coupled to one another.

Further, a number of ribs 1208 may be coupled to the crosspieces 1206 and/or the exterior hubs at which the crosspieces 1206 couple to one another. The ribs 1208 may extend into an interior of the pickleball 1200. Further, the ribs 1208 may be coupled to one another at various angles to form internal hubs in a manner similar to the crosspieces 1206 described herein. In one example, the ribs 1208 may extend into an interior of the pickleball 1200 at an angle perpendicular with respect to the outer surface of the pickleball 1200. In one example, the ribs 1208 may extend into an interior of the pickleball 1200 at non-perpendicular angles with respect to the outer surface of the pickleball 1200.

The ribs 1208 may terminate at the interior surface 1204 defined by mutual terminuses of the ribs 1208 at the interior hubs. Further, the interior surfaces of the ribs 1208 may form the interior of the pickleball 1200, where the crosspieces 1206 lie on a common spherical surface. In this manner, the crosspieces 1206 and ribs 1208 form a wall 1302 within the pickleball 1200 such that there exists a void in the center of the pickleball 1200. Further, in one example, the ribs 1208 may be coupled to one another at intersections 1210. In one example, the intersections 1210 form the boundary of the interior surface 1204 or wall 1302 of the pickleball 1200. The wall 1302 formed by the curved features of the crosspieces 1206 of the exterior surface 1202 and the ribs 1208 and intersections 1210 of the interior surface 1204 may have any thickness as defined by these elements. Further, in one example, one or more of the ribs 1208 that meet at the intersections 1210 may be curved such that the thickness of the wall 1302 is generally uniform. However, in the example depicted in FIGS. 12 and 13, one or more of the ribs 1208 may not be curved, resulting in a varying thickness of the wall 1302 along the radius of the pickleball 1200.

In one example, the crosspieces 1206, ribs 1208, and respective hubs and intersections 1210 may form a lattice or matrix of structures to form a 3D geodesic structural framework with a general outer surface defined by the crosspieces 1206 and an inner surface defined by the ribs 1208. In one example, the 3D geodesic structural framework, including the crosspieces 1206 and the ribs 1208, may be formed via an additive manufacturing process such as, for example, 3D printing methods. In one example, the crosspieces 1206 and the ribs 1208 may be individually formed and coupled together after formation via, for example, adhesives, fasteners, welding, and other manufacturing processes. In one example, the crosspieces 1206 and the ribs 1208 may be monolithically formed as a single piece.

Further, in one example, the 3D geodesic structural frame, including the crosspieces 1206 and the ribs 1208, may be made from a polymer, an elastomer, other materials, and compounds thereof that provide both flexibility and noise reduction while maintaining structural stability. The internal frame formed by the ribs 1208 and supported by the crosspieces 1206 allows the pickleball 1200 to compress upon impact and return to its original shape, enhancing properties such as bounce, durability, and impact resilience.

As the 3D structural framework is created, the grid elements created by the crosspieces 1206 at the exterior surface 1202 may be interconnected to form the triangles 1212 in a geodesic configuration. This geodesic pattern produces clusters of the triangles 1212 on the exterior surface 1202 in the form of the hexagons 1214, the pentagons 1216, and/or other shapes such as squares. In one example, the pickleball 1200 may include the structural framework without a solid exterior surface 1202, where the triangles 1212 form apertures. Further, in one example, the interior regions of the triangles 1212 may be filled with a material as described in more detail herein.

The crosspieces 1206 on the exterior surface 1202 of the pickleball 1200 may contact a paddle or other play surfaces during play. In one example, the geodesic layout created by the crosspieces 1206 on the exterior surface 1202 may be curved to match the contour or outer spherical surface of the pickleball 1200 in order to evenly distribute forces, enhance performance, and increase overall strength and stability within the pickleball 1200. In one example, the crosspieces 1206 on the exterior surface 1202 may be straight to improve internal support or curved to influence bounce characteristics.

The thickness of the crosspieces 1206 and ribs 1208 that form the wall 1302 of the pickleball 1200 may vary according to a desired weight and/or performance characteristics. In one example, the crosspieces 1206 and ribs 1208 may have diameters or thicknesses of less than 4 mm, approximately 4 mm, or greater than 4 mm and may be engineered to influence the design of the pickleball 1200. In one example, a pickleball 1200 with a longer total length of crosspieces 1206 and ribs 1208 may include relatively thinner crosspieces 1206 and ribs 1208 compared to a pickleball 1200 of the same weight with a relatively shorter total length of crosspieces 1206 and ribs 1208. The thickness of the crosspieces 1206 and ribs 1208 may be uniform or may be different between the crosspieces 1206 and ribs 1208, as a classification or as individual crosspieces 1206 and ribs 1208. For example, relatively thicker crosspieces 1206 and ribs 1208 may be located on the exterior surface 1202 in order to obtain enhanced durability compared to thinner elements on the interior surface 1204.

The wall 1302 formed by the crosspieces 1206 and ribs 1208 may have a thickness of less than 5 mm, approximately 5 mm, or greater than 5 mm. The stiffness of the pickleball 1200 may be improved by increasing the thickness of the wall formed by the crosspieces 1206 and ribs 1208, with the crosspieces 1206 and ribs 1208 acting as oblique bridge struts perpendicular to the exterior surface 1202 of the pickleball 1200.

FIG. 14 illustrates a front perspective view of a pickleball 1400 including a structural framework and apertures, according to an example of the principles described herein. The pickleball 1400 of FIG. 14 may include any and all characteristics described above in connection with the example pickleball 1200 of FIGS. 12 and 13. Further, the pickleball 1400 of FIG. 14 may include a plurality of aperture rings 1418. More regarding the aperture rings 1418 is described herein.

The pickleball 1400 of FIG. 14 may include a geodesic design integrated within the pickleball 1400 similar to that of the pickleball 1200 of FIGS. 12 and 13, and that has the advantages enumerated herein. As mentioned herein, a 3D geodesic structural framework may be integrated into the pickleball 1400. In one example, the structural framework may include interconnected triangular elements that form a geodesic configuration, distributing impact forces efficiently and preventing deformation or collapse of the pickleball 1400. Further, in the example of FIG. 14, the triangles may be truncated to form irregularly-shaped trapezoidal shapes due to the inclusion of the aperture rings 1418 along the exterior surface 1402 of the pickleball 1400. The geodesic structure enhances the performance of the pickleball 1400 by allowing for flexible, sound-reducing materials without compromising strength. In one example, the structural framework may be made of a polymer, an elastomer, other materials, and compounds thereof that provide both flexibility and noise reduction while maintaining structural stability. The internal framework allows the pickleball 1400 to compress upon impact and return to its original shape, enhancing properties such as bounce, durability, and impact resilience.

The geodesic design of the pickleball 1400 has advantages of being lightweight and stable, and minimizes material usage while reinforcing the surface structure of the pickleball 1400. In one example, as described in FIG. 15, the pickleball 1400 may include a solid outer surface with webbing or surfaces included within the open spaces between the crosspieces 1406 (described below), consistent with conventional pickleballs.

In one example, a surface may have 42 aperture rings 1418 arranged in a two-frequency (2v) geodesic pattern based on an icosahedron (e.g., a polyhedron with twenty faces or twenty equilateral triangles or twelve pentagons 1416 and 20 hexagons 1414 with 60 vertices where the edges meet and 90 edges total). In other examples, the pickleball 1400 may include any Archimedean solid and/or any Goldberg polyhedron. In one example, the pickleball 1400 may be defined by a Magnus Wenninger's spherical model, where the polyhedral is given a geodesic notation in the form {3,q+}_{b, c}, where {3,q} is the Schläfli symbol for the regular polyhedron with triangular faces, and q-valence vertices, the “+” symbol indicates the valence of the vertices being increased, and “b,c” represents a subdivision description, with 1,0 representing the base form. With this understanding, the pickleball 1400 may have a {3,5+}_1,0. The Archimedean solid and/or any Goldberg polyhedron making up the pickleball 1400 may include a spherical projection (e.g., a projection to the sphere or a homeomorphism from the icosahedron to the sphere) of the icosahedron, for example, including a geometric representation of the edges of the icosahedron being projected onto a sphere, where the sphere and icosahedron share a center using straight lines to create geodesic domes. A spherical polyhedron in this example may include a tiling of a sphere where the surface is divided into spherical polygons by great arcs. The pentagons 1416 formed on the surface of the Archimedean solid and/or any Goldberg polyhedron making up the pickleball 1400 may be formed by five trapezoidal shapes 1412, and the hexagons 1414 formed on the surface of the Archimedean solid and/or any Goldberg polyhedron making up the pickleball 1400 may be formed by six trapezoidal shapes 1412.

In one example, the pickleball 1400 may omit the outer solid surface and, instead, utilize only the geodesic space framework that may accommodate various aperture shapes, such as triangles. In one example, the space framework may be modified so that only specific grid, lattice, or matrix elements are exposed for surface contact. The solid outer surface of the pickleball may or may not include apertures.

In one example, the structural framework and outer surface may be composed of the same material, allowing for optimized performance in strength, bounce, and noise reduction, and allowing for the pickleball 1400 to be manufactured using simpler or fewer manufacturing processes. In one example, the outer and inner surfaces of the pickleball may be made of different materials. By reinforcing the internal framework, the pickleball retains structural stability even when softer surface materials are used, resulting in a significant reduction in noise generated during play.

In one example, the internal framework structure may be encased in an outer shell. However, in one example, the pickleball may not include a shell, leaving an open geodesic framework. The lightweight geodesic framework may reduce bulk, while the flexibility of the frame material may contribute to enhanced cushioning and bounce characteristics.

In one example, the pickleball 1400 may be fabricated using additive manufacturing or 3D printing processes. Additive manufacturing may employ thermo-polymers, photopolymers, laser processes, or other suitable methods. Alternatively, the 3D-printed lattice or matrix framework structure may be modified for production via injection molding, or similar processes wherein flexible materials allow for molding the pickleball in halves with the internal frame exposed, followed by inverting the halves of the pickleball to encase the frame.

The example of the pickleball 1400 of FIG. 14 may include a 3D geodesic structural framework as similarly described in connection with the pickleball 1200 of FIGS. 12 and 13 that forms an exterior surface 1402 and an interior surface 1404. The exterior surface 1402 may be formed by a plurality of crosspieces 1406 coupled to another at a plurality of exterior hubs to form the geodesic structure of the pickleball 1400. Further, the outer surfaces of the crosspieces 1406 may form the exterior surface of the pickleball 1400 where the crosspieces 1406 lie on a common spherical surface.

In one example, the crosspieces 1406 may be axially straight such that the exterior surface of the pickleball 1400 is defined by the hubs at which the crosspieces 1406 meet and are coupled to one another. However, in one example, the crosspieces 1406 may be curved such that the crosspieces 1406 define the exterior surface of the pickleball 1400 along with the hubs at which the crosspieces 1406 meet and are coupled to one another.

In the example of FIG. 14, a number of aperture rings 1418 may be formed along the exterior surface 1402 of the pickleball along with the crosspieces 1406. The aperture rings 1418 may be formed to create or define apertures into an interior of the pickleball 1400 as provided in conventional pickleballs. As depicted in FIG. 14, at least some of the crosspieces 1406 may terminate at the aperture rings 1418, creating the irregularly-shaped trapezoidal shapes 1412 from the triangles 1212 depicted in FIG. 12. The aperture rings 1418 may be formed from the same or a different material with respect to the crosspieces 1406. The aperture rings 1418 may be formed to match the curve of the spherical shape of the pickleball 1400.

The aperture rings 1418 formed in the exterior surface 1402 of the pickleball 1400 may have different diameters of openings. Further, as depicted in FIG. 14, the aperture rings 1418 may be located at geodesic-based locations and what would be intersections of the crosspieces 1406.

In one example, the size of the aperture rings 1418 may vary as a whole or between different aperture rings 1418. Further, in one example, the aperture rings 1418 may have any number, size, and pattern (e.g., geodesic or random layouts or patterns). In one example, the pickleball 1400 may include thirty aperture rings 1418 that have an internal diameter of 7.4 mm included in the hexagons 1414. Further, in one example, the pickleball 1400 may include twelve aperture rings 1418 that have an internal diameter of 6.9 mm included in the pentagons 1416.

In one example, the rims of the aperture rings 1418 may be connected to or independent of the ribs 1408 on the interior surface 1404. In one example, the rims of the aperture rings 1418 may be supported by bridge struts 1420 connected to the ribs 1408. The bridge struts 1420 may vary in shape and angle and may be connected to or form continuous supports through the wall (e.g., wall 1302 of FIG. 13), including the crosspieces 1406 and ribs 1408. Further, in one example, the bridge struts 1420 may be coupled to one or more of the ribs 1408.

In one example, the crosspieces 1406 and the aperture rings 1418 may be monolithically formed as a single piece. Still further, in one example, the crosspieces 1406 and the aperture rings 1418 may be individually formed and coupled together after formation via, for example, adhesives, fasteners, welding, and other manufacturing processes.

Further, a number of ribs 1408 may be coupled to the crosspieces 1406, where the crosspieces 1406 directly couple to one another and/or may be coupled to the aperture rings 1418 at which the crosspieces 1406 indirectly couple to one another. The ribs 1408 may extend into an interior of the pickleball 1400. Further, the ribs 1408 may be coupled to one another at various angles to form internal hubs in a manner similar to the crosspieces 1406 described herein. In one example, the ribs 1408 may extend into an interior of the pickleball 1400 at an angle perpendicular with respect to the outer surface of the pickleball 1400. In one example, the ribs 1408 may extend into an interior of the pickleball 1400 at non-perpendicular angles with respect to the outer surface of the pickleball 1400.

The ribs 1408 may terminate at the interior surface 1404 defined by mutual terminuses of the ribs 1408 at the interior hubs. Further, the interior surfaces of the ribs 1408 may form the interior of the pickleball 1400 where the crosspieces 1406 lie on a common spherical surface. In this manner, the crosspieces 1406 and ribs 1408 form a wall (e.g., wall 1302 of FIG. 13) within the pickleball 1400 such that there exists a void in the center of the pickleball 1400. Further, in one example, the ribs 1408 may be coupled to one another at intersections 1410. In one example, the intersections 1410 may form the boundary of the interior surface 1404 or wall (e.g., wall 1302 of FIG. 13) of the pickleball 1400.

In one example, the crosspieces 1406, ribs 1408, bridge struts 1420, and respective intersections 1410 may form a lattice or matrix of structures to form a 3D geodesic structural framework with a general outer surface defined by the crosspieces 1406 and an inner surface defined by the ribs 1408. In one example, the 3D geodesic structural framework including the crosspieces 1406 and the ribs 1408 may be formed via an additive manufacturing process such as, for example, 3D printing methods. In one example, the crosspieces 1406 and the ribs 1408 may be individually formed and coupled together after formation via, for example, adhesives, fasteners, welding, and other manufacturing processes. In one example, the crosspieces 1406 and the ribs 1408 may be monolithically formed as a single piece.

Further, in one example, the 3D geodesic structural frame including the crosspieces 1406 and the ribs 1408 may be made from a polymer, an elastomer, other materials, and compounds thereof that provide both flexibility and noise reduction while maintaining structural stability. The internal frame formed by the ribs 1408 and bridge struts 1420 and supported by the crosspieces 1406 allows the pickleball 1400 to compress upon impact and return to its original shape, enhancing properties such as bounce, durability, and impact resilience.

As the 3D structural framework is created, the grid elements created by the crosspieces 1406 at the exterior surface 1402 may be interconnected to form the trapezoidal shapes 1412 in a geodesic configuration. The trapezoidal shapes 1412 may be considered as analogous to the triangles 1212 of FIG. 12 but with truncated ends due to the inclusion of the aperture rings 1418 along with the crosspieces 1406. This geodesic pattern produces clusters of the trapezoidal shapes 1412 on the exterior surface 1402 in the form of the hexagons 1414, the pentagons 1416, and/or other shapes such as squares. Further, as described herein, in one example, the pickleball 1400 may include the structural framework without a solid exterior surface 1402 where the trapezoidal shapes 1412 form apertures. Further, in one example, the interior regions of the trapezoidal shapes 1412 may be filled with a material as described in more detail herein.

The crosspieces 1406 and the aperture rings 1418 on the exterior surface 1402 of the pickleball 1400 may contact a paddle or other play surfaces during play. In one example, the geodesic layout created by the crosspieces 1406 and the aperture rings 1418 on the exterior surface 1402 may be curved to match the contour or outer spherical surface of the pickleball 1400 in order to evenly distribute forces, enhance performance, and increase overall strength and stability within the pickleball 1400. In one example, the crosspieces 1406 on the exterior surface 1402 may be straight to improve internal support or curved to influence bounce characteristics.

The thickness of the crosspieces 1406, aperture rings 1418, bridge struts 1420, and ribs 1408 that form the wall (e.g., wall 1302 of FIG. 13) of the pickleball 1400 may vary according to a desired weight and/or performance characteristics. In one example, the crosspieces 1406, aperture rings 1418, bridge struts 1420, and ribs 1408 may have diameters or thicknesses of less than 4 mm, approximately 4 mm, or greater than 4 mm and may be engineered to influence the design of the pickleball 1400. In one example, a pickleball 1400 with a longer total length of crosspieces 1406, aperture rings 1418, bridge struts 1420, and ribs 1408 may include relatively thinner crosspieces 1406, aperture rings 1418, bridge struts 1420, and ribs 1408 compared to a pickleball 1400 of the same weight with a relatively shorter total length of crosspieces 1406, aperture rings 1418, bridge struts 1420, and ribs 1408. The thickness of the crosspieces 1406, aperture rings 1418, bridge struts 1420, and ribs 1408 may be uniform or may be different between the crosspieces 1406, aperture rings 1418, bridge struts 1420, and ribs 1408 as a classification or as individual crosspieces 1406, aperture rings 1418, bridge struts 1420, and ribs 1408. For example, relatively thicker crosspieces 1406, aperture rings 1418, bridge struts 1420, and ribs 1408 may be located on the exterior surface 1402 in order to obtain enhanced durability compared to thinner elements on the interior surface 1404.

The wall (e.g., wall 1302 of FIG. 13) formed by the crosspieces 1406, the bridge struts 1420, and the ribs 1408 may have a thickness of less than 5 mm, approximately 5 mm, or greater than 5 mm. The stiffness of the pickleball 1400 may be improved by increasing the thickness of the wall (e.g., wall 1302 of FIG. 13) formed by the crosspieces 1406, the bridge struts 1420, and the ribs 1408, with the crosspieces 1406 and ribs 1408 acting as oblique bridge struts perpendicular to the exterior surface 1402 of the pickleball 1400.

FIG. 15 illustrates a front perspective view of a pickleball 1500 including a structural framework, apertures, and infill faces, according to an example of the principles described herein. FIG. 16 illustrates a cross-sectional view of the pickleball along line F depicted in FIG. 15, according to an example of the principles described herein. FIGS. 15 and 16 illustrate a pickleball 1500 with a 3D geodesic structural frame featuring 42 round apertures in a two-frequency (2v) icosahedral geodesic pattern. Further, as described in more detail below, in one embodiment, the pickleball may include infill faces that finish the exterior of the pickleball 1500. Further, the pickleball 1500 of FIGS. 15 and 16 may include any and all characteristics described above in connection with the example pickleballs 1200 and 1400 of FIGS. 12 through 14.

The pickleball 1500 of FIGS. 15 and 16 may include a geodesic design integrated within the pickleball 1500, similar to that of the pickleballs 1200 and 1400 of FIGS. 12 through 14, and that has the advantages enumerated herein. As mentioned herein, a 3D geodesic structural framework may be integrated into the pickleball 1500. In one example, the structural framework may include interconnected triangular elements that form a geodesic configuration, distributing impact forces efficiently and preventing deformation or collapse of the pickleball 1500. Further, in the example of FIGS. 15 and 16, the triangles may be truncated to form irregularly-shaped trapezoidal shapes due to the inclusion of the aperture rings 1518 along the exterior surface 1502 of the pickleball 1500. The geodesic structure enhances the performance of the pickleball 1500 by allowing for flexible, sound-reducing materials without compromising strength. In one example, the structural framework may be made of a polymer, an elastomer, other materials, and compounds thereof that provide both flexibility and noise reduction while maintaining structural stability. The internal framework allows the pickleball 1500 to compress upon impact and return to its original shape, enhancing properties such as bounce, durability, and impact resilience.

The geodesic design of the pickleball 1500 has advantages of being lightweight and stable, and minimizes material usage while reinforcing the surface structure of the pickleball 1500. In one example, as described in connection with FIGS. 12 through 14, the pickleball 1500 may include a solid outer surface with infill faces included within the open spaces between the crosspieces 1506 (described below), consistent with conventional pickleballs. For example, a surface may have 42 aperture rings 1518 arranged in a two-frequency (2v) geodesic pattern based on an icosahedron (e.g., a polyhedron with twenty faces or twenty equilateral triangles or twelve pentagons 1216 and 20 hexagons 1214 with 60 vertices where the edges meet and 90 edges total).

In other examples, the pickleball 1500 may include any Archimedean solid and/or any Goldberg polyhedron. In one example, the pickleball 1500 may be defined by a Magnus Wenninger's spherical model, where the polyhedral is given a geodesic notation in the form {3,q+}_b,c, where {3,q} is the Schläfli symbol for the regular polyhedron with triangular faces, and q-valence vertices, the “+” symbol indicates the valence of the vertices being increased, and “b,c” represents a subdivision description, with 1,0 representing the base form. With this understanding, the pickleball 1500 may have a {3,5+}_1,0. The Archimedean solid and/or any Goldberg polyhedron making up the pickleball 1500 may include a spherical projection (e.g., a projection to the sphere or a homeomorphism from the icosahedron to the sphere) of the icosahedron, for example, including a geometric representation of the edges of the icosahedron being projected onto a sphere, where the sphere and icosahedron share a center using straight lines to create geodesic domes. A spherical polyhedron in this example may include a tiling of a sphere where the surface is divided into spherical polygons by great arcs. The pentagons 1516 formed on the surface of the Archimedean solid and/or any Goldberg polyhedron making up the pickleball 1500 may be formed by five trapezoidal shapes 1512, and the hexagons 1514 formed on the surface of the Archimedean solid and/or any Goldberg polyhedron making up the pickleball 1500 may be formed by six trapezoidal shapes 1512.

In one example, the pickleball 1500 may omit the outer solid surface and, instead, utilize only the geodesic space framework that may accommodate various aperture shapes, such as triangles. In one example, the space framework may be modified so that only specific grid, lattice, or matrix elements are exposed for surface contact. The solid outer surface of the pickleball may or may not include apertures.

In one example, the structural framework and outer surface may be composed of the same material, allowing for optimized performance in strength, bounce, and noise reduction, and allowing for the pickleball 1500 to be manufactured using simpler or fewer manufacturing processes. In one example, the outer and inner surfaces of the pickleball 1500 may be made of different materials. By reinforcing the internal framework, the pickleball 1500 may retain structural stability even when softer surface materials are used, resulting in a significant reduction in noise generated during play.

In one example, the internal framework structure may be encased in an outer shell. However, in one example, the pickleball 1500 may not include a shell, leaving an open geodesic framework. The lightweight geodesic framework may reduce bulk, while the flexibility of the frame material may contribute to enhanced cushioning and bounce characteristics.

In one example, the pickleball 1500 may be fabricated using additive manufacturing or 3D printing processes. Additive manufacturing may employ thermo-polymers, photopolymers, laser processes, or other suitable methods. Alternatively, the 3D-printed lattice or matrix framework structure may be modified for production via injection molding, or similar processes wherein flexible materials allow for molding the pickleball in halves with the internal frame exposed followed by inverting the halves of the pickleball to encase the frame.

The example of the pickleball 1500 of FIGS. 15 and 16 may include a 3D geodesic structural framework as similarly described in connection with the pickleballs 1200 and 1400 of FIGS. 12 and 14 that forms an exterior surface 1502 and an interior surface 1504. The exterior surface 1502 may be formed by a plurality of crosspieces 1506 coupled to another at a plurality of exterior hubs to form the geodesic structure of the pickleball 1500. Further, the outer surfaces of the crosspieces 1506 may form the exterior surface of the pickleball 1500 where the crosspieces 1506 lie on a common spherical surface.

In one example, the crosspieces 1506 may be axially straight such that the exterior surface of the pickleball 1500 is defined by the hubs at which the crosspieces 1506 meet and are coupled to one another. However, in one example, the crosspieces 1506 may be curved such that the crosspieces 1506 define the exterior surface of the pickleball 1500 along with the hubs at which the crosspieces 1506 meet and are coupled to one another.

In the example of FIGS. 15 and 16, a number of aperture rings 1518 may be formed along the exterior surface 1502 of the pickleball along with the crosspieces 1506. The aperture rings 1518 may be formed to create or define apertures into an interior of the pickleball 1500 as provided in conventional pickleballs. As depicted in FIGS. 15 and 16, at least some of the crosspieces 1506 may terminate at the aperture rings 1518 creating the irregularly-shaped trapezoidal shapes 1512 from the triangles 1212 depicted in FIG. 12. The aperture rings 1518 may be formed from the same or a different material with respect to the crosspieces 1506. The aperture rings 1518 may be formed to match the curve of the spherical shape of the pickleball 1500.

In one example, the size of the aperture rings 1518 may vary as a whole or between different aperture rings 1518. Further, in one example, the aperture rings 1518 may have any number, size, and pattern (e.g., geodesic or random). In one example, the pickleball 1500 may include thirty aperture rings 1518 that have an internal diameter of 7.4 mm included in the hexagons 1514. Further, in one example, the pickleball 1500 may include twelve aperture rings 1518 that have an internal diameter of 6.9 mm included in the pentagons 1516.

In one example, the rims of the aperture rings 1518 may be connected to or independent of the ribs 1508 on the interior surface 1504. In one example, the rims of the aperture rings 1518 may be supported by bridge struts 1520 connected to the ribs 1508. The bridge struts 1520 may vary in shape and angle and may be connected to or form continuous supports through the wall (e.g., wall 1302 of FIG. 13) including the crosspieces 1506 and ribs 1508.

In one example, the crosspieces 1506 and the aperture rings 1518 may be monolithically formed as a single piece. Still further, in one example, the crosspieces 1506 and the aperture rings 1518 may be individually formed and coupled together after formation via, for example, adhesives, fasteners, welding, and other manufacturing processes.

The aperture rings 1518 formed in the exterior surface 1502 of the pickleball 1500 may have different diameters of openings. Further, as depicted in FIGS. 15 and 16, the aperture rings 1518 may be located at geodesic-based locations and what would be intersections of the crosspieces 1506.

Further, a number of ribs 1508 may be coupled to the crosspieces 1506 where the crosspieces 1506 directly couple to one another and/or may be coupled to the aperture rings 1518 at which the crosspieces 1506 indirectly couple to one another. The ribs 1508 may extend into an interior of the pickleball 1500. Further, the ribs 1508 may be coupled to one another at various angles to form internal hubs in a manner similar to the crosspieces 1506 described herein. In one example, the ribs 1508 may extend into an interior of the pickleball 1500 at an angle perpendicular with respect to the outer surface of the pickleball 1500. In one example, the ribs 1508 may extend into an interior of the pickleball 1500 at non-perpendicular angles with respect to the outer surface of the pickleball 1500.

The ribs 1508 may terminate at the interior surface 1504 defined by mutual terminuses of the ribs 1508 at the interior hubs. Further, the interior surfaces of the ribs 1508 may form the interior of the pickleball 1500 where the crosspieces 1506 lie on a common spherical surface. In this manner, the crosspieces 1506, the bridge struts 1520, and the ribs 1508 form a wall (e.g., wall 1302 of FIG. 13) within the pickleball 1500 such that there exists a void in the center of the pickleball 1500. Further, in one example, the ribs 1508 may be coupled to one another at intersections 1510. In one example, the intersections 1510 form the boundary of the interior surface 1504 or wall (e.g., wall 1302 of FIG. 13) of the pickleball 1500.

In one example, the crosspieces 1506, the bridge struts 1520, the ribs 1508, and respective hubs intersections 1510 may form a lattice or matrix of structures to form a 3D geodesic structural framework with a general outer surface defined by the crosspieces 1506 and an inner surface defined by the ribs 1508. In one example, the 3D geodesic structural framework including the crosspieces 1506 and the ribs 1508 may be formed via an additive manufacturing process such as, for example, 3D printing methods. In one example, the crosspieces 1506, the bridge struts 1520, and the ribs 1508 may be individually formed and coupled together after formation via, for example, adhesives, fasteners, welding, and other manufacturing processes. In one example, the crosspieces 1506, the bridge struts 1520, and the ribs 1508 may be monolithically formed as a single piece.

Further, in one example, the 3D geodesic structural frame including the crosspieces 1506, the bridge struts 1520, and the ribs 1508 may be made from a polymer, an elastomer, other materials, and compounds thereof that provide both flexibility and noise reduction while maintaining structural stability. The internal frame formed by the ribs 1508 and bridge struts 1520 and supported by the crosspieces 1506 allows the pickleball 1500 to compress upon impact and return to its original shape, enhancing properties such as bounce, durability, and impact resilience.

As the 3D structural framework is created, the grid elements created by the crosspieces 1506 at the exterior surface 1502 may be interconnected to form the trapezoidal shapes 1512 in a geodesic configuration. The trapezoidal shapes 1512 may be considered as analogous to the triangles 1212 of FIG. 12 but with truncated ends due to the inclusion of the aperture rings 1518 along with the crosspieces 1506. This geodesic pattern produces clusters of the trapezoidal shapes 1512 on the exterior surface 1502 in the form of the hexagons 1514, the pentagons 1516, and/or other shapes such as squares. Further, as described herein, in one example, the pickleball 1500 may include the structural framework without a solid exterior surface 1502 where the trapezoidal shapes 1512 form apertures (e.g., the apertures defined by the aperture rings 1518). Further, in one example, the interior regions of the trapezoidal shapes 1512 may be filled with a material as described in more detail herein.

The crosspieces 1506 and the aperture rings 1518 on the exterior surface 1502 of the pickleball 1500 may contact a paddle or other play surfaces during play. In one example, the geodesic layout created by the crosspieces 1506 and the aperture rings 1518 on the exterior surface 1502 may be curved to match the contour or outer spherical surface of the pickleball 1500 in order to evenly distribute forces, enhance performance, and increase overall strength and stability within the pickleball 1500. In one example, the crosspieces 1506 on the exterior surface 1502 may be straight to improve internal support or curved to influence bounce characteristics.

The thickness of the crosspieces 1506, the aperture rings 1518, the bridge struts 1520, and the ribs 1508 that form the wall (e.g., wall 1302 of FIG. 13) of the pickleball 1500 may vary according to a desired weight and/or performance characteristics. In one example, the crosspieces 1506, the aperture rings 1518, the bridge struts 1520, and the ribs 1508 may have diameters or thicknesses of less than 4 mm, approximately 4 mm, or greater than 4 mm and may be engineered to influence the design of the pickleball 1500. In one example, a pickleball 1500 with a longer total length of the crosspieces 1506, the aperture rings 1518, the bridge struts 1520, and the ribs 1508 may include relatively thinner crosspieces 1506, aperture rings 1518, bridge struts 1520, and ribs 1508 compared to a pickleball 1500 of the same weight with a relatively shorter total length of crosspieces 1506, aperture rings 1518, bridge struts 1520, and ribs 1508. The thickness of the crosspieces 1506, the aperture rings 1518, the bridge struts 1520, and the ribs 1508 may be uniform or may be different as between the crosspieces 1506, the aperture rings 1518, the bridge struts 1520, and the ribs 1508 as a classification or as individual crosspieces 1506, aperture rings 1518, bridge struts 1520, and ribs 1508. For example, relatively thicker crosspieces 1506, aperture rings 1518, bridge struts 1520, and ribs 1508 may be located on the exterior surface 1502 in order to obtain enhanced durability compared to thinner elements on the interior surface 1504.

The wall (e.g., wall 1302 of FIG. 13) formed by the crosspieces 1506, the aperture rings 1518, the bridge struts 1520, and the ribs 1508 may have a thickness of less than 5 mm, approximately 5 mm, or greater than 5 mm. The stiffness of the pickleball 1500 may be improved by increasing the thickness of the wall (e.g., wall 1302 of FIG. 13) formed by the crosspieces 1506 and ribs 1508, with the crosspieces 1506 and ribs 1508 acting as oblique bridge struts perpendicular to the exterior surface 1502 of the pickleball 1500.

The pickleball 1500 of FIGS. 15 and 16 may further include infill faces 1522. The various exterior grid elements of the pickleball 1500 formed by the crosspieces 1506 and the aperture rings 1518 on the geodesic exterior surface 1502 of the pickleball 1500 may allow for the infill faces 1522 to be coupled to or formed with other elements of the pickleball 1500, concealing the interior grid elements of the pickleball 1500 formed by the ribs 1508 and bridge struts 1520 on the interior surface 1504. In one example, the exterior grid elements of the pickleball 1500 formed by the crosspieces 1506 and the aperture rings 1518 may protrude while the infill faces 1522 are recessed with respect to the exterior grid elements. Alternatively, in one example, the infill faces 1522 may be aligned with respect to an outer surface of the exterior grid elements creating a smooth transition without any gaps or protrusions between the infill faces 1522 and the exterior grid elements. Further, in one example, the infill faces 1522 may be curved to match a contour of the pickleball 1500 and/or match the contour of the spherical projection of the icosahedron of the pickleball. Further, in one example, the exterior grid elements of the pickleball 1500 formed by the crosspieces 1506 and the aperture rings 1518 on the geodesic exterior surface 1502 of the pickleball 1500 and the infill faces 1522 may create a continuous, solid exterior surface that is seamless, with all of the exterior grid elements being hidden from view and potentially enhancing aerodynamic performance and/or reducing wind resistance.

While the present systems and methods are described with respect to the specific examples, it is to be understood that the scope of the invention is not limited to these specific examples. Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the present systems and methods are not considered limited to the example chosen for purposes of disclosure and covers all changes and modifications which do not constitute departures from the true spirit and scope of this disclosure. Although the application describes embodiments having specific structural features and/or methodological acts, it is to be understood that the claims are not necessarily limited to the specific features or acts described. Rather, the specific features and acts are merely illustrative some embodiments that fall within the scope of the claims of the application.

Conclusion

The examples described herein provide different examples of noise-attenuating pickleballs. The noise-attenuating pickleballs may include a spherical shell, apertures defined in the spherical shell, and various types of surface treatments defined on the spherical shell configured to reduce noise when the ball impacts a surface. These surface treatments drastically reduce noise during play. This results in the ability for game play to be performed in areas or locations where noise restrictions may be enforceable. Further, the surface treatments provide for a better experience for players, spectators, and bystanders since noise created by striking the pickleball during play is significantly reduced, such that game play is no longer a nuisance.

While the present systems and methods are described with respect to the specific examples, it is to be understood that the scope of the present systems and methods is not limited to these specific examples. Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the present systems and methods are not considered limited to the example chosen for purposes of disclosure and covers all changes and modifications which do not constitute departures from the true spirit and scope of the present systems and methods.

Although the application describes examples having specific structural features and/or methodological acts, it is to be understood that the claims are not necessarily limited to the specific features or acts described. Rather, the specific features and acts are merely illustrative of some examples that fall within the scope of the claims of the application.