FABRIC

Abstract

A graphene-infused fabric is provided as a sound reducing acoustic layer for object such as a pickleball paddle. The graphene-infused fabric is made from polymer fibers, at least one of which is a graphene-infused polymer fiber. Graphene is blended into a polymer material, and fibers are manufactured from said material such as by extrusion. The graphene-infused polymer is combined with other fibers to be made into a woven or non-woven fabric.

Claims

1. A graphene-infused fabric for a sound reducing layer of a pickleball paddle, wherein the graphene-infused fabric reduces sound generation from the pickleball paddle, the graphene-infused fabric comprising polymer fibers, wherein the polymer fibers comprise N66 fiber, polypropylene fiber, and graphene-infused polyethylene terephthalate fiber, wherein the graphene-infused fabric comprises by weight: i. between 5% to 15% graphene-infused polyethylene terephthalate fiber, ii. between 40% to 60% N66 fiber, and iii. between 30% to 40% polypropylene fiber, wherein the polymer fibers are blended and compressed to form the graphene-infused fabric.

2. The fabric of claim 1, wherein the graphene-infused polyethylene terephthalate fiber is a composite fiber made from polyethylene terephthalate and graphene.

3. The fabric of claim 2, wherein the graphene-infused polyethylene terephthalate fiber is an extruded fiber made from a mixture of graphene powder and molten polyethylene terephthalate.

4. The fabric of claim 1, comprising about 10% graphene-infused polyethylene terephthalate fiber by weight of the graphene-infused fabric.

5. The fabric of claim 1, comprising about 55% N66 fiber by weight of the graphene-infused fabric.

6. The fabric of claim 1, comprising about 35% polypropylene fiber by weight of the graphene-infused fabric.

7. The fabric of claim 1, comprising about 1-10% by weight waterproofing or water resistant additive sprayed onto the polymer fibers.

8. The fabric of claim 7, comprising by weight: i. between 5% to 10% graphene-infused polyethylene terephthalate fiber, ii. between 40% to 55% N66 fiber, iii. between 30% to 40% polypropylene fiber, and iv. about 5% waterproofing or water resistant additive.

9. The fabric of claim 1, wherein the graphene-infused fabric is a non-woven fabric.

10. The fabric of claim 9, comprising a felt.

11. The fabric of claim 10, wherein the polymer fibers are repeatedly compressed into a fabric by needle punching.

12. A pickleball paddle for reducing the loudness and/or frequency of sound generated when a ball strikes the pickleball paddle, wherein the paddle comprises a sound reducing fabric layer applied to a playing surface of the paddle, wherein the sound reducing fabric layer reduces sound generation from the exterior playing surface, wherein the sound reducing fabric layer comprises graphene-infused fabric of polymer fibers, wherein the polymer fibers comprise N66 fiber, polypropylene fiber, and graphene-infused polyethylene terephthalate fiber.

13. The pickleball paddle of claim 12 wherein the polymer fibers are blended, and compressed to form the sound reducing fabric layer.

14. The paddle of claim 12, further comprising an internal layer comprising graphene-infused fabric.

15. The paddle of claim 12, wherein the sound reducing fabric layer is applied on opposing outer surfaces of the paddle to cover the playing surface of the paddle.

16. The paddle of claim 12, wherein the sound reducing fabric layer comprises a shell encasing the playing surface of the pickleball paddle.

17. The paddle of claim 12, wherein the sound reducing fabric layer is applied along an edge of the paddle, and on the playing surface.

18. The paddle of claim 12, wherein the sound reducing fabric layer is removable.

19. The paddle of claim 12, wherein the graphene-infused fabric comprises by weight between 5% to 15% graphene-infused polyethylene terephthalate fiber, between 40% to 60% N66 fiber, and between 30% to 40% polypropylene fiber.

20. A sound reducing acoustic fabric for application to a surface, the fabric comprising polymer fibers, wherein the polymer fibers comprise N66 fiber, polypropylene fiber, and graphene powder-polyethylene terephthalate composite fiber, wherein the polymer fibers are blended and compressed to form the sound reducing acoustic fabric, the sound reducing acoustic fabric comprising a non-woven felt.

Description

DESCRIPTION OF THE FIGURES

[0016] Embodiments of devices, apparatus, methods, and kits are described throughout reference to the drawings.

[0017] FIG. 1 shows mixing of raw materials to produce a fabric.

[0018] FIG. 2 shows mixed raw materials rolled out into a flat layer.

[0019] FIG. 3 shows stacking of the raw material layers.

[0020] FIG. 4 shows the stack being stitched together to form a non-woven fabric.

[0021] FIG. 5 shows further stitching and pressure rolling of the non-woven fabric.

[0022] FIG. 6 shows cutting the non-woven fabric into desired shapes.

[0023] FIGS. 7A-7E shows frequency analysis of modified pickleball paddles having a fabric covering.

[0024] FIGS. 8A-8D show a pickleball paddle with an fabric layer sandwiched between two honeycomb layers. A) perspective view, B) side view, C) exploded side view, and D) exploded perspective view.

[0025] FIGS. 9A-9C show a pickleball paddle with an sound reducing layer on each playing surface of the paddle. A) perspective view, B) exploded side view, and C) exploded perspective view.

[0026] FIGS. 10A-10B show an exemplary graphene-infused fabric covering. A) exploded perspective view, and B) perspective view.

[0027] FIG. 11 shows a flow chart of a protocol for manufacturing a composite PET fiber.

DETAILED DESCRIPTION

[0028] Numerous details are set forth to provide an understanding of the examples described herein. The examples may be practiced without these details. The description is not to be considered as limited to the scope of the examples described herein.

Fabric Properties

[0029] In some embodiments, the fabrics disclosed herein are developed for increased strength. Fabric may refer to textile, cloth, material, and so on. In some embodiments, the fabrics disclosed herein are developed for sound management or modification. In some embodiments, the fabrics disclosed herein are developed for sound dampening or buffering. In some embodiments, the fabrics disclosed herein are developed for sound reduction. In some embodiments, the fabrics disclosed herein are developed for impact shielding. In some embodiments, the fabrics disclosed herein are developed for durability while maintaining sound reduction. In some embodiments, the fabrics disclosed herein are developed for electrical conductivity and smart fabrics. In some embodiments, the fabrics disclosed herein provide for sound dampening, impact shielding, and durability enhancement.

[0030] In some embodiments, the fabric is non-woven. An exemplary non-woven fabric includes felt. Felt is created by compressing and matting fibers together. Non-woven fabrics may be spunbond, meltblown, or thermal bonded. In some embodiments, the fabric is woven. In some embodiments, the fabric is flexible. In one embodiment, the fabric is at least semi-rigid, and/or able to hold its shape or structure. In one embodiment, the fabric is at least partially pliable, and/or capable of bending or moulding around an object.

[0031] When an object makes contact a surface it generates a vibrational wave that travels through surface, which subsequently produces a sound. Modifications of the surface, such as by applying a material with viscoelastic properties, introduces damping to this process. The viscoelastic material converts vibrational energy into heat, diminishing the amplitude of sound waves and thereby reducing the perceived noise level. Such modified surfaces dissipates vibrational energy, preventing it from being fully converted into sound waves, which reduces the noise generated upon impact.

[0032] The present inventors have developed a fabric that minimizes noise upon impact. This has different useful applications. For example, the fabric may be applied to the playing surface of paddles to minimize noise. Sports equipment should be durable. It is also important that materials applied to paddles to not impact game play. There may be regulations governing sports with requirements for the sports equipment. In an aspect, embodiments described herein provide a fabric layer for application to a playing surface of sports equipment such as a paddle. The fabric layer has enhanced durability while maintaining sound reduction from the playing surface. The fabric layer does not impact game play.

[0033] In an aspect, embodiments described herein provide an improved fabric that is durable and has sound reduction properties. In some embodiments, the fabric reduces the decibel sound or loudness of a striking object. In some embodiments, the fabric eliminates the sound of a striking object. In some embodiments, the fabric dampens the sound of a striking object. In some embodiments, the fabric changes the sound of a striking object. In some embodiments, the fabric changes the frequency sound of a striking objected. In one embodiment, the frequency sound of a striking object is reduced from about 1200 hz to 1000-500 hz, 800-500 hz, 800 hz or lower, 700 hz or lower, 600 hz or lower, about 500 hz, about 400-500 hz. By absorbing some of the impact energy, the fabric also reduces the overall vibration transferred to adjacent material, which is particularly useful for managing shock and impact.

[0034] In some embodiments, the fabrics disclosed herein are configured for application to a surface, where the fabric forms a sound reducing fabric covering or layer. In some embodiments, the fabrics disclosed herein are configured for application to a surface, where the fabric forms a sound reducing fabric layer on said surface. In some embodiments, a surface comprise the fabrics disclosed herein, where the fabric comprises a sound reducing layer.

Infused Fibers

[0035] Embodiments described herein provide infused fabrics, and in particular, fabrics that are infused with particles. As used herein, fiber refers to a thin elongated length of material capable of forming into thread or a fabric. In some embodiments, infused fabrics are manufactured from fibers infused with one or more types of particles. In some embodiments, infused fabrics are manufactured from composite fibers. Composite fibers are fibers spun or extruded from a mixture of two or more materials. In some embodiments, infused fabrics are manufactured from fibers impregnated or incorporated with one or more types of particles. In some embodiments, the particles are solid particles. In some embodiments, the particles are powders. In one embodiment, the particles are microparticles or nanoparticles. In some embodiments, the particles are elongated or fibrous particles. In some embodiments, the particles are chemically incorporated into the fibers. In one embodiment, the particles are provided in a chemical solution or liquid form and deposited into the fibers by wet impregnation and subsequently dried. In some embodiments, the particles are mechanically incorporated into the fibers, such as by blending. In one embodiment, the particles are spun into the fibers. In one embodiment, the particles are beaten and/or compressed into the fibers. In one embodiment, the particles are mixed with the fibers. In one embodiment, the particles are mixed in with molten material, and subsequently extruded into fibers.

[0036] In some embodiments, the fibers are short fibers or fiber fragments. In other embodiments, the fibers are long spun or extruded fibers. In some embodiments, the fibers are threads. In some embodiments, the fibers are polymer fibers. In some embodiments, the fibers are natural fibers. Exemplary natural fibers include, but are not limited to: cotton, silk, wool, hemp, jute, linen, flax, hair, or sisal fibers. In some embodiments, the fibers are synthetic fibers. Exemplary synthetic fibers include, but are not limited to: nylon, polyester, acrylic, polyethylene (PE), polyethylene terephthalate (PET), polypropylene (PP), aramid, carbon fiber, fiberglass, polyvinyl chloride (PVC) fibers. In one embodiment, the fiber is nylon. In one embodiment, the fiber is polyethylene. In one embodiment, the fiber is polypropylene. In one embodiment, the fiber is polyethylene terephthalate. In one embodiment, the fiber comprises a combination of synthetic fibers. Once fibers are infused with the one or more types of particles, the fibers are then manufactured into woven or non-woven fabric. In some embodiments, infused fibers are made into thread for weaving into a woven fabric. In some embodiments, the infused fibers beaten and condensed into a non-woven fabric, such as a felt fabric.

[0037] By first infusing the fiber with the particles and subsequently manufacturing the fibers into fabric, the characteristics of a standard flexible fabric is maintained while simultaneously imparting the properties of the particles to the fabric. For example, the fabric made from the particle infused fibers may be further manufactured into clothing, furniture, parts, insulation, etc. A fabric manufactured from infused fibers is advantageous over fabric that is directly impregnated with a substance, in that the former remains pliable and/or flexible. Fabrics directly impregnated with substances (for example, wax, resin, silicone) often becomes rigid. Oftentimes, fabrics that are directly impregnated with substances are designed for the fabric to act as a support structure or scaffold to hold the substances in place. As a result, the impregnated fabric loses its original fabric characteristics and is reduced to specific applications only. On the other hand, fabric manufactured from infused fibers maintain its wide range of application.

Graphene Infusion

[0038] In accordance with the present disclosure, a fabric is provided that is manufactured from fibers infused with graphene. Graphene is an allotrope of carbon consisting of a single layer of atoms arranged in a hexagonal lattice nanostructure. Graphene has been known as hardest or strongest material known to exist, being about 200 stronger than steel while lighter than paper. Graphene is a very useful nanomaterial due to its exceptionally high tensile strength, electrical conductivity, transparency, and being the thinnest two-dimensional material in the world. Prior to addition of graphene, the fabric was easily scratched and fragile. After addition of graphene, the present inventors have discovered that the fabric threads and bounds of the threads were significantly strengthened. In some embodiments, the fabric is a non-woven fabric. In some embodiments, the fabric is manufactured as non-woven fabric sheets with a degree of stiffness.

[0039] The present inventors have discovered that the graphene infused fabric of the present disclosure is particularly effective at minimizing noise or absorbing kinetic energy of moving objects. In particular, where a moving objection strikes a surface, the movement of the object and the subsequent contact with the surface triggers the sound reduction properties of the graphene infused fabric. In some embodiments, the fabric disclosed herein absorbs sound into kinetic energy. The graphene infused fabric is both is durable and sound reducing. A fabric covering a surface can reduce sound when an object contacts the surface. However, the fabric may not be durable if objects contact the surface numerous times. If a fabric (or surface covered in fabric) is coated in resin then the fabric or surface may be durable but the hardness of the coated fabric or surface can result in increased sound when an object makes contact with the surface.

[0040] In accordance with the present disclosure, a fabric is provided that is manufactured from fibers infused with a durability enhancing agent. For example, the durability enhancing agent can be graphene.

[0041] In some embodiments, the fabric absorbs noise or kinetic energy of a moving object striking a stationary surface applied with the fabric. In some embodiments, the fabric is applied to a mobile surface and absorbs noise or kinetic energy when the mobile surface impacts with a stationary object. In yet other embodiments, the fabric is applied to a mobile surface and absorbs noise or kinetic energy when the mobile surface impacts with a mobile object.

[0042] The present inventors have also discovered that a surface comprised of or applied with a fabric infused with graphene surprisingly also reduces vibration. The lower the vibration, the lesser the travel of the vibration, thereby reducing impact when an object strikes against the surface. The graphene infused fabric also adds durability, extending the material lifespan of the fabric thereby reducing waste.

[0043] In some embodiments, graphene is infused into a material by preparing a graphene-infused raw material. In some embodiments, the raw material is a polymer material for manufacture into polymer fibers. In some embodiments, the raw material is blended with graphene to form a composite raw material. The graphene comprise a reinforcing phase distributed within a continuous raw material (such as a polymer material) for manufacture into fibers. In one embodiment, graphene is blended with molten polymer material to form a mixture that is spun or extruded into fibers. In one embodiment, graphene powder is blended with molten polymer material to form a mixture that is spun or extruded into fibers. In some embodiments, the graphene powder is a white graphene powder. In one embodiment, the graphene powder is a graphene oxide powder. In one embodiment, the graphene powder is fine graphene powder.

[0044] Infusing the graphene first into a raw polymer material is advantageous as it allows for even distribution of graphene in the final product, and simultaneously allows for greater flexibility and variety of fiber compositions that can be used to made a fabric. Furthermore, infusing graphene into a raw polymer material also imparts mechanical durability and performance enhancements (e.g., conductivity, strength, thermal resistance) to the resulting extruded fibers themselves.

[0045] In some embodiments, a graphene-infused fabric is made of graphene-infused polymer fibers. In some embodiments, a graphene-infused fabric is made of two or more types of graphene-infused polymer fibers. In some embodiments, graphene-infused polymer fibers comprise composite fibers made from a synthetic fiber polymer and graphene. Exemplary synthetic fiber polymers include, but are not limited to: nylon, polyester, acrylic, polyethylene (PE), polyethylene terephthalate (PET), polypropylene (PP), aramid, carbon fiber, fiberglass, polyvinyl chloride (PVC) fibers. In some embodiments, a graphene-infused fabric is made of graphene-infused polymer fibers combined with other synthetic or non-synthetic fibers. In one embodiment, graphene-infused polymer fibers comprise composite fibers made from polyethylene terephthalate and graphene. In one embodiment, graphene-infused polymer fibers comprise composite fibers made from polypropylene and graphene. In one embodiment, graphene-infused polymer fibers comprise composite fibers made from nylon and graphene. In one embodiment, graphene-infused polymer fibers comprise composite fibers made from two or more types of polymer materials and graphene.

[0046] In some embodiments, a fabric is made of polyethylene terephthalate fiber, nylon fiber, polypropylene fiber, or combinations thereof. In some embodiments, one or more of the polymer fibers comprise graphene-infused polymer fiber. In some embodiments, a graphene-infused fabric is manufactured from polyethylene terephthalate fiber, nylon fiber, polypropylene fiber, or combinations thereof, where one or more of the polymer fibers comprise a graphene-infused polymer fiber. In some embodiments, a graphene-infused fabric is manufactured from polyethylene terephthalate fiber, nylon fiber, polypropylene fiber, or combinations thereof, where one or more of the polymer fibers comprise a graphene-infused polymer composite fiber. Introducing nylon fiber to a graphene-infused fabric has an added benefit of reducing stretch, thereby reducing warping or stretching of the graphene infused fabric over time. In some embodiments, the nylon fiber is N66 fiber In some embodiments, the fabric further comprises a waterproofing or water resistant additive. Exemplary waterproofing or water resistant additive includes durable water repellents, such as per-and polyfluoroalkyl substances (PFAs) and long-chain (C8) fluorocarbon-based treatments. In some embodiments, the fabric provided herein is made of non-woven material, hence lacking the traditional warp and weft found in woven fabrics. Instead, the density of the fabric is increased by applying pressure, and the waterproofing or water resistant additive is integrated into the raw materials. In some embodiments, the fabric provided herein has a waterproof or water resistant coating overing at least a majority of the surface, preferably the entirety of the surface. In some embodiments, the the waterproof or water resistant additive is spray coated onto the fibers of a fabric. The fabric provided herein is at least water-repellant, more preferably at least water-resistant. Water droplets applied to the fabric surface rolls off; however, if significant pressure is applied, forcing the water droplets into the non-woven fabric, the water can seep through due to pressure. In one embodiment, the fabric is waterproof, having a thicker protective coating that prevents water molecules from penetrating the fabric under pressure, at least for a short duration.

[0047] In some embodiments, a graphene-infused fabric is manufactured from polyethylene terephthalate fiber, nylon fiber, and polypropylene fiber, where the polyethylene terephthalate fiber comprise a graphene-infused polyethylene terephthalate fiber. In some embodiments, a graphene-infused fabric is manufactured from polyethylene terephthalate fiber, nylon fiber, and polypropylene fiber, where the polyethylene terephthalate fiber comprise a graphene-polyethylene terephthalate composite fiber. In some embodiments, a graphene-infused fabric is manufactured from polyethylene terephthalate fiber, nylon fiber, and polypropylene fiber, where the polyethylene terephthalate fiber comprise fibers extruded from a blend of molten polyethylene terephthalate and graphene, preferably graphene powder. In one embodiment, the nylon fiber comprise N66 fiber.

[0048] In one embodiment, a fabric is made of graphene, Nylon 66 (N66), and polypropylene, and graphene-infused polyethylene terephthalate fibers. In one embodiment, a graphene infused fabric comprises about 5%-15%, preferably about 5%-10%, more preferably approximately 10% graphene-infused polyethylene terephthalate fiber by total weight of the fabric. In one embodiment, a graphene infused fabric comprises about 5%-15%, preferably about 5%-10%, more preferably approximately 10% graphene-infused polyethylene terephthalate fiber by total weight of the fabric. In one embodiment, a graphene infused fabric comprises about 25-75%, about 40-60%, 50-60%, about 50%, or about 55% N66 fiber by total weight of the fabric. In one embodiment, a graphene infused fabric comprises about 25-50%, about 30-40%, about one third, or about 35% polypropylene fiber by total weight of the fabric. In some embodiments, the fabric comprises about 1-10%, about 2-8%, about 3-7%, or about 5% waterproofing or water resistant additive by total weight of the fabric. Ranges provided herein includes the endpoints. As used herein the term about with respect to a percentage value indicates variance of 3%. All polymer fibers remain in fiber form, and are mixed together. During the fiber mixing process, waterproof materials are incorporated (spray on the fibres). The fibres are then thoroughly opened and evenly blended, followed by multiple compression treatments and needle punching to produce a flat fabric.

[0049] Turning to FIG. 11, an exemplary protocol for the manufacture of a graphene-infused polyethylene terephthalate fiber is provided. In some embodiments, a graphene-infused fiber is provided made by the processes and protocols disclosed herein. First, polyethylene terephthalate polymer (PET) material is provided, for example, in pellet or granule form, or chemically created from terephthalic acid and ethylene glycol. The PET materials is heated until molten form 1101. Graphene powder is introduced into this molten form, preferably ensuring that the graphene powder is well blended into the molten PET material 1102. This blended material is then extruded into fibers 1103, such as by forcing the blended material through spinnerets to form continuous filaments. The filaments solidify into fibers. Optionally, the filaments are drawn or stretched as desired into fine fibers. Optionally, these graphene-infused fibers are mixed with a second fiber, or one or more other fibers 1104. In some cases, the fibers are woven into a fabric 1105. In some cases, the fibers are beaten (such as by needle punching) and condensed into a felt 1106. Infusing graphene into polyethylene terephthalate as advantages, such as excellent physical properties, wide availability, cost-effectiveness, and compatibility with existing manufacturing equipment, for example.

[0050] The relative proportion of the graphene-infused polymer fiber relative to the total fiber content of the fabric can be adjusted to adjust the graphene content of the graphene-infused fabric. If the graphene content of the fabric is too low, the fabric is at risk of deteriorating after repeated use. However, if the graphene content of the fabric is too high, the fabric may become too heavy for use. In some embodiments, the graphene infused fabric is 1.5 mm to 5 mm thick.

[0051] In some embodiments, the graphene is introduced into the N66 as a very fine powder.

[0052] The graphene infused fabric is manufactured such that the internal structure of the fabric is porous enough to capture, trap, and dissipate sound energy as heat. The surface of the fabric repels liquids. When the fabric is applied to a surface or structure, the combined surface or structure as a whole returns an adequate amount of kinetic energy when an object strikes against it. By introducing graphene to the fabric, this also allows for the manufacture of wearable technology using the fabric. For example, wearable technology may be utilized to gather wearer movement data which can be processed to analyze performance, health, and well-being.

Manufacturing Processes

[0053] Turning to FIG. 1, graphene-infused raw material 100 comprising graphene, N66, and polypropylene are mixed with non-graphene-infused raw material 110 comprising polypropylene. In some embodiments, the graphene-infused raw material is graphene-infused fibers or threads. In some embodiments, the graphene-infused raw material comprises graphene-infused polymer fibers or graphene-polymer composite fibers. In the shown implementation, graphene-infused raw material 100 comprises black threads or fibers while non-graphene-infused raw material 110 comprises white threads or fibers, such that when mixed together a gray coloured raw material is produced with target amount of graphene incorporated. The raw materials 100 and 110 may be mixed together in different proportion to produce a raw material mixture 120 having a desired shade of gray, or a desired graphene content. In some embodiments, the raw material mixture comprises a ratio of graphene-infused raw material to non-graphene-infused raw material of about 1:9, 1:4, 3:7, 2:3, 1:1, 3:2, 7:3, 4:1, or 9:1. In some embodiments, the graphene-infused raw material 100 is directly used without mixing with other raw material to produce a black fabric. In some embodiments, the graphene-infused raw material 100 comprises white threads or fibers infused with white graphene powder.

[0054] In some embodiments, one or more waterproofing or water resistant additive are sprayed onto the threads or fibers. In one embodiment, one or more waterproofing or water resistant additive are sprayed onto the graphene-infused raw material 100 and/or the non-graphene-infused raw material 110 prior to mixing. In one embodiment, one or more waterproofing or water resistant additive are sprayed onto the raw material mixture 120 after or during mixing.

[0055] The raw material mixture 120 has a weight of around 450-500 grams per square meter. In some embodiments, the weight is around 400, 425, 450, 475, or 500 grams per square meter. In some embodiments, the weight is around 450, 460, 470, 480, 490, or 500 grams per square meter. In one embodiment the weight is 471 grams per square meter. In one embodiment the weight is 495 grams per square meter.

[0056] The threads of the raw material mixture 120 is chopped into smaller, finer threads. In some embodiments, the raw material mixture 120 is chopped while mixing to produce even threads or fibers. As shown in FIG. 2, after chopping the raw material mixture 120 becomes finer, lighter, and fluffy, resembling spider webs. The raw material mixture 120 is laid out into a layer 200.

[0057] Turning to FIG. 3, the layer 200 is folded into stacks 300. In some embodiments, the stacks are staggered, producing a continuous line of stacked layers for assembly line efficiency. As shown in FIG. 4, the stacks 300 are stitched or beaten together by a needle assembly 410 into a felt or batting fabric. The needle assembly 410 has multiple needles that reciprocate up and down as the stacked layer 200 is fed through. Since the fabric is a non-woven fabric, warp and weft or weaving is not needed. In some embodiments, the batting fabric is passed through multiple needle assemblies to produce thinner and tighter fabric. Each needle assembly may comprise different densities or sizes of needles to produce fabric of different density. In some embodiments, the batting fabric is passed through progressively denser and/or smaller needles to produce thinner and tighter fabric.

[0058] Turning to FIG. 5, in addition to passing fabric 500 through a needle assembly, the fabric is also pressed through rollers 510. The rollers 510 apply pressure to compress the fabric 500 into a sheet of fabric with increased hardness. The rollers 510 also flatten the fabric 500 to a desired thickness. In some embodiments, the needle assembly 410 and the rollers 510 are provided in one machinery. For example, stacked fabric may be fed through the needle assembly of the machine first, followed by rollers. In other embodiments, he needle assembly 410 and the rollers 510 are provided in separate machinery. Lastly, the fabric sheet is heated, for example, with an iron to produce an end product. Preferably, the end product is lighter and/or thinner than the starting material. In some embodiments, the end product has a weight of around 430-450 grams per square meter. In some embodiments, the weight is around 400, 425, 450, or 475 grams per square meter. In some embodiments, the weight is around 420, 430, 440, 450, or 460 grams per square meter. In some embodiments, the weight is around 430, 435, 440, 445, or 450 grams per square meter. The iterative approach of stitching or beating the material through multiple passes together with one more passes through rollers to compress the material allows for the production of an end product with a desired weight and thickness. For example, for some applications (i.e. sport equipment) an end product that is too heavy will weigh down on the user. However, an end product that is too thin will not provide the desired properties, such as sound dampening.

[0059] Lastly as shown in FIG. 6, the fabric sheet 600 is cut into desired shapes and sizes.

Implementations and Applications

[0060] In some embodiments, the fabrics disclosed herein are used in the manufacture of textiles, clothing, or equipment requiring high material durability and/or impact shielding. For example, safety or protection clothing or equipment, camping gear, sport and/or out-door equipment, and construction material or tools.

[0061] In some embodiments, the fabrics disclosed herein are used where sound modification, dampening, or reduction are needed. For example, musical instrument manufacturing, acoustic room manufacturing, sound equipment manufacturing, and ear protection.

[0062] In some embodiments, a sound reducing acoustic fabric is for application to a surface (such as wall, floor, ceiling, etc.). In some embodiments, the sound reducing acoustic fabric disclosed herein is used in acoustic sound panels for walls, ceilings, floors, etc. The sound reducing acoustic fabric is molded into various shapes or contours to adapt to a object's surface. In one embodiment, the sound reducing acoustic the fabric for surface application is made of polymer fibers. The polymer fibers comprise N66 fiber, polypropylene fiber, and graphene powder-polyethylene terephthalate composite fiber. These polymer fibers are blended and compressed to form the sound reducing acoustic fabric. For example, these polymer fibers are blended and compressed into a felt. The felt is then shaped and applied onto a surface. The sound reducing acoustic fabric can be removably applied to the surface. Alternatively, the sound reducing acoustic fabric can be affixed to the surface. For example, adhesives can be used to secure the sound reducing acoustic fabric to the surface.

[0063] In some embodiments, the graphene-infused fabrics are for a sound reducing fabric layer of a pickleball paddle. In some embodiments, a pickleball paddle comprise a sound reducing acoustic layer of graphene-infused fabric applied to an exterior playing surface of the paddle. Sound reducing acoustic layers of pickleball paddles are disclosed in United States Publication No. 2024-0390753, and PCT Publication No. WO2024/239119, the entire contents of which are incorporated herein by reference.

[0064] In some embodiments, a pickleball paddle for reducing the loudness and/or frequency of sound generated when a ball strikes the pickleball paddle is provided, the pickleball paddle having a head portion, a handle portion, and an edge having a width, the edge extending from one side of the paddle around the head portion to an opposite side of the paddle. Wherein the paddle comprises two opposing playing surfaces, and wherein the edge and the two opposing playing surfaces comprise a graphene infused acoustic shell, wherein the graphene infused acoustic shell comprises a graphene infused fabric of graphene and optionally at least one polymer, wherein the graphene infused fabric comprises between about 1% to 25% graphene by weight. In one embodiment, the graphene infused acoustic shell is a single integral unit. In another embodiment, the graphene infused acoustic shell comprises two shell surfaces comprising the two opposing playing surfaces, and a length of perimeter shell piece comprising the pickleball edge, wherein the two shell surfaces and the length of perimeter shell are bonded together to form the graphene infused acoustic shell.

[0065] During play, the pickleball ball makes contact with the playing surface of a pickleball paddle. Noise is generated from impact between the ball and the playing surface of the paddle. As a result, there is a need for improved equipment that reduces noise and dampens vibration without compromising play. Fabric-based materials on the playing surface of a paddle may have low durability. To enhance the durability of the fabric layer while maintaining and/or enhancing sound dampening qualities such that it can be applied to a pickleball paddle, the present inventors have developed a graphene-infused fabric layer suitable for use with a pickleball paddle.

[0066] The playing surface is the (visible) paddle area that makes contact with the ball during play. The playing surface can be the two sides or paddle faces that make contact with the ball. The playing surface may also be referred to as the paddle face or hitting surface or exterior surface. As used herein, a striking surface of a pickleball paddle refers to a surface that makes direct contact with the pickleball ball. When the pickleball paddle is uncovered, the playing surfaces of the paddle are the striking surfaces of the paddle. When the playing surfaces of the pickleball paddle are covered, the material covering the playing surfaces acts as the striking surface making direct contact with a pickleball ball. A pickleball paddle has an exterior or outside paddle surface and also has an interior or inside paddle core of one or more interior layers. The graphene infused fabric can be part of the exterior or outside paddle surface to provide a graphene infused acoustic layer or fabric layer for the paddle. Embodiments of the pickleball paddle described herein includes a handle portion and a head portion. In some embodiments, the head and handle portions are molded or formed together as an integral piece. In other embodiments, the head and handle portions are separately formed and attached together. The head portion comprises two opposite surfaces, which can be referred to as playing surfaces. In some embodiments, the head comprises the playing surface. As used herein, a surface of the pickleball paddle refers to the face of the head portion of the pickleball paddle which makes contact with and/or used for hitting a ball during play. In some embodiments, the surface which makes contact with the ball is the playing surface. In some embodiments, the playing surface is a hitting surface. In some embodiments, the paddle has a surface of a graphene infused acoustic layer or fabric. In some embodiments, a graphene infused layer is applied onto the surface. A pickleball paddle is often manufactured from multiple layers, where different layers are made of different materials. For example, some pickleball paddles have an inner core foam layer, while other paddles have an inner honeycomb core layer of repeating honeycomb structures. Turning to FIG. 8A-8D, an exemplary pickleball paddle is shown 800 having a honeycomb core sandwiched between two surface layers 806. The exterior surfaces of the two surface layers 806 provide opposing playing surfaces. In one embodiment, paddle 800 has multiple honeycomb core layers 804 separated by an internal layer 802. In one embodiment, the internal layer comprises a graphene infused fabric. (See FIGS. 8A-8D.) In one embodiment, the internal layer comprises a graphene-infused felt. In some embodiments where the head and handle portions form an integral piece, the core extends down from the head portion to the handle portion between the two opposite surfaces or layers. In some embodiments where the head and handle portions are separately formed, only the head portion has a middle core or both the head and the handle portion may independently have a middle core. In some embodiments, a pickleball paddle has a plurality of layers. The core can be disposed in the middle or between any two layers in a multi-layer pickleball paddle. Where a plurality layers are present, the playing surface is the outer layers of the plurality of layers. In some embodiments, the acoustic layer is the outer layer. In some embodiments, the acoustic layer is a layer of the plurality of layers. The perimeter of the head portion of the pickleball paddles comprises an edge. In some embodiments, the edge comprises a graphene infused acoustic layer. In some embodiments, a graphene infused acoustic layer is applied along a length of the edge.

[0067] In an aspect, embodiments described herein provide a pickleball paddle for reducing the loudness and/or frequency of sound generated when a ball strikes the pickleball paddle. The paddle can have a sound reducing fabric layer applied to a playing surface of the paddle. The sound reducing fabric layer reduces sound generation from the playing surface. The sound reducing fabric layer is made of graphene-infused fabric of polymer fibers. In some embodiments, the polymer fibers comprise N66 fiber, polypropylene fiber, and graphene-infused polyethylene terephthalate fiber.

[0068] FIGS. 9A-9B illustrate an example pickleball paddle 900 with sound reducing fabric layers 906 for reducing the loudness and/or frequency of sound generated when a ball strikes the pickleball paddle. In one embodiment, sound reducing fabric layers 906 are applied to one or both playing surfaces of a paddle 900. For example, the paddle 900 has a sound reducing fabric layer 906 applied to both playing surfaces of the paddle 900. In one embodiment, the pickleball paddle 900 is a multilayered paddle having a honeycomb core 902 sandwiched between two surface layers 904. The exterior surfaces of the surface layers 904 provide the playing surfaces of the paddle 900. The exterior faces of the surface layers 904 have a sound reducing fabric layer 906 (e.g. graphene infused felt 906) applied thereon. The sound reducing fabric layer 906 reduces sound generation from the exterior playing surface. The sound reducing fabric layer 906 is graphene-infused fabric in accordance with embodiments described herein. The graphene-infused fabric can be made of polymer fibers such as N66 fiber, polypropylene fiber, and graphene-infused polyethylene terephthalate fiber. In one embodiment, the pickleball paddle 900 has a graphene infused fabric as the sound reducing fabric layer 906 applied on one or both sides of the playing surface the paddle 900.

[0069] In further embodiments, the pickleball paddle 900 has a sound reducing fabric layer applied along an edge or perimeter 908 of the paddle. For example, a graphene infused felt can be applied along at least a portion of the edge or perimeter 908 of the paddle. In further embodiments, the pickleball paddle 900 has a graphene infused fabric applied or affixed along at least a portion of the edge or perimeter of the paddle striking surface. In one embodiment, the pickleball paddle 900 has a sound reducing fabric layer applied along an edge or perimeter 908 of the paddle and sound reducing fabric layers 906 applied to one or both playing surfaces of a paddle 900.

[0070] In some embodiments, the sound reducing fabric layer 906 (e.g. graphene infused felt) is detachable or replaceable from the paddle 900, such that new sound reducing fabric layer 906 (e.g. graphene infused felt) can be applied to the paddle or to interchange with graphene infused fabric of different thickness (e.g. graphene infused felt of different thickness). In one embodiment, the graphene infused fabric (e.g. graphene-infused felt) is secured in place by a removable plastic guard around at least a portion of the paddle perimeter. Removal of the plastic guard allows for replacement of the graphene infused felt, with a new felt inserted in place by re-securing the plastic guard.

[0071] In some embodiments, the graphene infused fabric is made of polymer fibers (including graphene-infused polyethylene terephthalate fiber) that are blended and compressed to form the sound reducing fabric layer 906. The sound reducing fabric layers 906 are applied on opposing outer or exterior surfaces of the surface layers 904 of the paddle 900, such that the sound reducing fabric layers 906 cover the playing surface of the paddle 900.

[0072] In some embodiments, the graphene-infused fabric comprises by weight: between 5% to 15% graphene-infused polyethylene terephthalate fiber, between 40% to 60% N66 fiber, and between 30% to 40% polypropylene fiber.

[0073] FIGS. 10A and 10B illustrate an example of graphene-infused fabric covering 1000 for providing a sound reducing layer for a pickleball paddle. The graphene-infused fabric covering 1000 covers one or more playing surfaces of a paddle, such that the graphene-infused fabric covering becomes the striking surface 1001 upon which a pickleball ball makes direct contact. Since direct contact with the ball is made with the graphene-infused fabric providing the striking surface 1001, sound generated by the contact is modified or reduced by the graphene-infused fabric. That is, the graphene-infused fabric is used for a sound reducing layer.

[0074] Turning to FIG. 10A, in one embodiment, a graphene-infused fabric covering 1000 comprises a graphene-infused fabric face layer 1006 to cover one or both playing surfaces of a pickleball paddle. In another embodiment, a graphene-infused fabric covering 1000 comprises a graphene-infused fabric edge layer 1008 to cover at least a portion of the edge or perimeter of a pickleball paddle. In some embodiments, a graphene-infused fabric covering 1000 comprises a graphene-infused fabric face layer 1006 to cover one or both playing surfaces and a graphene-infused fabric edge layer 1008 to cover at least a portion of the edge or perimeter of pickleball paddle. In some embodiments, the graphene-infused fabric layers 1006, 1008 are separately applied to or affixed to a pickleball paddle. The graphene-infused fabric layers 1006, 1008 reduces sound generation from the pickleball paddle. The graphene-infused fabric comprises polymer fibers, The polymer fibers comprise N66 fiber, polypropylene fiber, and graphene-infused polyethylene terephthalate fiber.

[0075] In some embodiments, the sound reducing fabric layer comprises a shell encasing the playing surface of the pickleball paddle. In some embodiments, the sound reducing fabric layer comprises a shell encasing the head portion of a pickleball paddle. In some embodiments, graphene-infused fabric is formed into a covering 1000 or shell to encase the playing surface of the pickleball paddle. In some embodiments, graphene-infused fabric is formed into a covering 1000 or shell to encase the head portion of a pickleball paddle.

[0076] In one embodiment, a graphene-infused fabric covering 1000 comprises two graphene-infused fabric face layers 1006 and a graphene-infused fabric edge layer 1008 that are formed or joined together into a sealed pocket or shell to encase the head portion of a pickleball paddle or a honeycomb core of the paddle. The sealed fabric pocket or shell may not extend down through the handle as no ball is expected to contact the handle during standard play. This may save on materials used. In some embodiments, the sealed fabric pocket or shell may extend to the handle (for example, to reduce manufacturing complexity). In some embodiments, to form the sealed fabric pocket or shell, graphene-infused fabric is first glued onto the pickleball paddle in pieces (e.g. as surface layers 1006 and edge layer 1008), and overlapping fabric is glued together forming a seam. Preferably, a seam is formed along the edge of the paddle. To create this edge seam, both heat and pressure are simultaneously applied to create a uniform edge seam.

[0077] The graphene-infused fabric covering 1000 comprises by weight: between 5% to 15% graphene-infused polyethylene terephthalate fiber, between 40% to 60% N66 fiber, and between 30% to 40% polypropylene fiber. The polymer fibers are blended and compressed to form the graphene-infused fabric.

[0078] In some embodiments, the graphene-infused fabric is molded into containers.

[0079] In one embodiment, the graphene-infused fabric disclosed herein is used in the manufacture of shoes. In one embodiment, the fabric disclosed herein is used in the manufacture of cars.

[0080] In some embodiments, the graphene-infused fabrics disclosed herein are used in the manufacture of smart or interactive clothing.

Carbon Fiber Boards

[0081] In some embodiments, a surface comprises a carbon fiber board covered with the graphene-infused fabric disclosed herein. Carbon fiber is a material that comprises fiber made mostly of carbon atoms. Carbon fibers may also be implemented in combination with other materials to form a composite. Carbon fiber boards may be fabricated by bonding multiple layers of carbon fiber fabric together. For example, the carbon fiber boards may comprise three layers of carbon fiber fabric bonded together. The resulting board may be a relatively stiff carbon fiber board.

[0082] In some embodiments, the carbon fiber board is disposed on the exposed side of the surface with the graphene-infused fabric covering the internal side of the surface. In some embodiments, the graphene-infused fabric is disposed on the exposed side of the surface covering the carbon fiber board on the internal side of the surface.

Exemplary Testing on a Paddle

[0083] The following are exemplary results of embodiments of the graphene-infused fabric which had been applied to exemplary pickleball paddles for sound testing. These embodiments are not limiting on the full scope of the present invention, but they merely illustrate particular example embodiments. Nothing in the following is intended to narrow the scope of the concepts described throughout the rest of the description.

[0084] Frequency analysis was conducted on five paddles (see FIG. 7A-7E): A) Reference/Control Paddle; B) 16 mm paddle with fabric cover according to the present invention; C) 16 mm cover paddle with round top with fabric cover according to the present invention; D) 13 mm cover paddle with fabric cover according to the present invention; and E) 13 mm cover paddle with round top with fabric cover according to the present invention.

[0085] To measure which frequencies present and relative loudness contained in a sound sample of a pickleball paddle hitting a pickleball of some pickleball paddles and other pickleball paddles designed in accordance with the teachings contained herein, sound testing was performed.

[0086] The equipment used included a general purpose omnidirectional microphone Apex850 (frequency response: 80 Hz-12 kHz), Focusrite 212 audio interface 48 kHz (Sample Rate 128 Buffer), computer workstation with USB interface, a standard pickleball, a Reference/Control Paddle, and Paddle to be tested (test subject).

[0087] The microphone was on a stand at 36 above the ground, placed 18 away from the center of where the paddle surface was swung and contact the ball. Audio recording levels were tested and adjusted to make sure no clipping occurred.

[0088] The paddle was swung by hand hit the ball with the power of a strong serve. The first sound readings was a control test using the Reference/Control Paddle which is a 13 mm core standard paddle (see FIG. 7A). It was loud and had a higher frequency pop to it. The test paddles (16 mm, 16 mm Round Top, 13 mm, and 13 mm Round Top shown in FIG. 7B, FIG. 7C, FIG. 7D, and FIG. 7E respectively) were recoded into an audio sample using the same swing and ball. Results were recorded using a basic open-source DAW (digital audio workstation) called Audacity. The Sound samples were then inspected using the frequency spectrum analysis tool in the DAW. This tool shows the frequencies and their relative sound pressure levels.

[0089] Sound pressure level measurements are taken at the DAW's dBFS and may not represent on-court SPL.

[0090] Referring to FIG. 7A-7E, the reference paddle A) produces sound with a dominant frequency of 1200 hz@30.7 dB. In contrast, the 16 mm covering paddles B) and C) have a dominant frequency around 500 hz@34.9 dB and 35.4 dB respectively. Furthermore, the 16 mm covering paddles had the 1000-2000 hz spike reduced to 39 dB (8 dB/84% reduction) and 42 dB (11 dB/92% reduction) respectively. Furthermore, the 13 mm covering paddles D) and E) have a dominant frequency around 500 hz@34.2 dB and 34.8 dB respectively. Furthermore, the 13 mm covering paddles had the 1000-2000 hz spike reduced to 41 dB (10 dB/90% reduction) and 42 dB (11 dB/92% reduction) respectively. This may indicate an 8-11 decibel reduction in the sound pressure level (SPL) of the specific annoying frequency that some pickleball paddles produce. The sound energy may be reduced by 80-90% which may be perceived as a sound that is half as loud.

[0091] Although the embodiments have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein. Moreover, the scope of the present application is not intended to be limited to the particular embodiments or examples described in the specification. As can be understood, the examples described above and illustrated are intended to be exemplary only.

[0092] For example, the present invention contemplates that any of the features shown in any of the embodiments described herein, may be incorporated with any of the features shown in any of the other embodiments described herein, and still fall within the scope of the present invention.