Abstract
A pickleball paddle including a handle portion and a head portion is disclosed. The head portion is operably connected to the handle portion and includes a core portion, a first layer, a second layer, and a reinforcing member. The core portion defines an edge, a first surface, and a second surface. The first layer is disposed adjacent the first surface of the core portion and is made from a first material. The second layer is disposed adjacent the second surface of the core portion, is parallel to the first layer, and is made from the first material. The reinforcing member is disposed within the core portion and is in contact with the first layer and the second layer. A first section of the reinforcing member is oriented at a non-perpendicular angle relative to the first layer.
Claims
1. A pickleball paddle, comprising: a handle portion; a head portion operably connected to the handle portion, the head portion including: a core portion defining an edge [outer perimeter], an inner portion, an outer portion, an upper surface, and a lower surface, the core portion including a plurality of foam sections, each foam section of the plurality of foam sections having a first lateral side and a second lateral side, the outer portion of the core portion including a first part disposed between a first lateral end of the inner portion of the core portion and a first portion of the edge of the core portion, the outer portion of the core portion including a second part disposed between a second lateral end of the inner portion of the core and a second portion of the edge of the core portion; a first layer disposed adjacent the upper surface of the core portion, the first layer made from at least one composite fiber material; a second layer disposed adjacent the lower surface of the core portion, the second layer made from at least one composite fiber material; and at least one reinforcing member disposed at least partially within the core portion and in contact with the first layer and the second layer, the at least one reinforcing member made from at least one composite fiber material, wherein the foam from each foam section of the plurality of foam sections is in contact with at least one of the first layer or a portion of the at least one reinforcing member disposed between the foam section and the first layer, wherein the foam from each foam section of the plurality of foam sections is in contact with at least one of the second layer or a portion of the at least one reinforcing member disposed between the foam section and the second layer, wherein the plurality of foam sections includes at least three foam sections, wherein the first lateral side of each foam section of the inner portion of the core portion is in contact with the at least one reinforcing member, wherein the second lateral side of each foam section of the inner portion of the core portion is in contact with the at least one reinforcing member, wherein the at least one reinforcing member is in contact with only one lateral side of the first part of the outer portion of the core portion, and wherein the at least one reinforcing member is in contact with only one lateral side of the second part of the outer portion of the core portion; and an edging disposed along at least a majority of a perimeter of the head portion, the edging made from at least one composite fiber material.
2. The pickleball paddle according to claim 1, wherein in the edging is in contact with the first layer of the core portion and the second layer of the core portion.
3. The pickleball paddle according to claim 1, wherein the plurality of foam sections includes at least five foam sections.
4. The pickleball paddle according to claim 1, wherein the handle portion defines a longitudinal axis, and wherein each foam section of the plurality of foam sections is positioned generally parallel to the longitudinal axis.
5. The pickleball paddle according to claim 2, wherein the plurality of foam sections includes at least five foam sections.
6. The pickleball paddle according to claim 2, wherein the handle portion defines a longitudinal axis, and wherein each foam section of the plurality of foam sections is positioned generally parallel to the longitudinal axis.
7. The pickleball paddle according to claim 3, wherein the handle portion defines a longitudinal axis, and wherein each foam section of the plurality of foam sections is positioned generally parallel to the longitudinal axis.
8. The pickleball paddle according to claim 1, wherein the at least one composite fiber material that the first layer is made from is carbon fiber, wherein the at least one composite fiber material that the reinforcing member is made from is carbon fiber, and wherein the at least one composite fiber material that the edging is made from is carbon fiber.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] Embodiments of the present disclosure are described hereinbelow with reference to the drawings wherein:
[0034] FIG. 1 is a front view of a pickleball paddle in accordance with embodiments of the present disclosure;
[0035] FIGS. 2A-3B are schematic, cross-sectional views of a portion of the pickleball paddle taken along line B-B in FIG. 1 shown with an edge guard separated therefrom in FIG. 2B in accordance with various embodiments of the present disclosure;
[0036] FIGS. 4A and 4B are perspective views of a plurality of strips of a core portion of the pickleball paddle of FIG. 1 in accordance with various embodiments of the present disclosure;
[0037] FIGS. 5A-5D are top views of various patterns of a reinforcing member of the core portion of the pickleball paddle of FIG. 1 in accordance with various embodiments of the present disclosure;
[0038] FIGS. 6A-6C are schematic, assembly views of a part of a first core assembly of the pickleball paddle of FIG. 1 in accordance with an embodiment of the present disclosure;
[0039] FIGS. 7A-7C are schematic, assembly views of a part of a second core assembly of the pickleball paddle of FIG. 1 in accordance with an embodiment of the present disclosure;
[0040] FIGS. 8A-8C are schematic illustrations of various steps of forming the structure of the pickleball paddle of FIG. 1 in accordance with embodiments of the present disclosure;
[0041] FIG. 9A is a top view of an embodiment of a head of the pickleball paddle of FIG. 1 in accordance with an embodiment of the present disclosure;
[0042] FIG. 9B is a perspective view of a portion of the head of the pickleball paddle of FIG. 9A illustrating the insertion of a cylindrical reinforcing member;
[0043] FIG. 9C is a schematic, cross-sectional view of the head of the pickleball paddle of FIGS. 9A and 9B including a plurality of cylindrical reinforcing members taken along line B-B in FIG. 1;
[0044] FIGS. 10A and 10B are top views of a head of the pickleball paddle of FIG. 1, illustrating an extended thread portion, in accordance with embodiments of the present disclosure;
[0045] FIG. 10C is a perspective view of a portion of the head of the pickleball paddle of FIGS. 10A and 10B; and
[0046] FIG. 10D is a schematic, cross-sectional view of the head of the pickleball paddle of FIGS. 10A-10C taken along line B-B in FIG. 1.
DETAILED DESCRIPTION
[0047] Embodiments of the presently disclosed pickleball paddle and components thereof are now described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views.
[0048] In general, the embodiments of pickleball paddles described herein may result in higher absorption of the impact energy of the ball hitting the pickleball paddle, increased duration of the ball in contact with the pickleball paddle, and/or greater angular momentum imparted on the ball when the pickleball paddle rolls over or under the ball.
[0049] Various embodiments of pickleball paddles (or paddles) are shown in the accompanying figures, and are generally referenced by numeral 100. As shown in FIG. 1, the paddle 100 includes a head portion 110 coupled to a handle portion 130. Generally, the length L of the paddle 100 may be between 15 inches and 17 inches, and the combined length plus width W of the paddle 100 does not exceed 24 inches. The present disclosure also contemplates paddles 100 having larger and/or smaller dimensions for the length L and width W. Additionally, while the head portion 110 is shown having a rectangular shape with rounded corners, a head portion 110 having other shapes, such as oval, isometric, round, teardrop, for example, is encompassed by the present disclosure. With continued reference to FIG. 1, the paddle 100 defines a longitudinal axis A-A extending through the handle portion 130, and a latitudinal axis B-B extending perpendicularly to the longitudinal axis A-A.
[0050] Referring now to FIGS. 2A-3B, schematic cross-sectional views of a portion of the head portion 110 of the paddle 100 of FIG. 1 are shown in accordance with various embodiments of the present disclosure. Here, the head portion 110 of the paddle 100 includes a first or top layer 112, a second or bottom layer 118, a core portion 115, and an edge portion 120. In embodiments, the thickness t (see FIG. 2A) of the head portion 110, measured between an upper surface 111 of the first layer 112 and a lower surface 119 of the second layer 118, is between about 10 mm and about 20 mm. Additionally, the head portion 110 can define a thickness t that is greater than or less than this range without departing from the scope of the present disclosure.
[0051] The core portion 115 of the paddle 100 can be made from any suitable material that can recover its initial shape after impact, such as foam (e.g., elastomeric foam). For instance, the foam of the core portion 115 can be open-celled (e.g., Polyurethane or PU, natural rubber or NR, nitrile, Ethylene-Propylene-Diene Monomer or EPDM, Polyvinyl Chloride or PVC, etc.) or closed-celled (e.g., Ethyl-Vinyl Acetate or EVA, neoprene, Styrene-Butadiene Rubber or SBR, etc.). The foam may also be thermoplastic or thermoset. Further, the core portion 115 can be made from any combination of the disclosed materials or other materials, and may include a multi-layer structure.
[0052] Various embodiments of the core portion 115 and the edge portion 120 of the paddle 100 are shown in the accompanying figures. While certain combinations of the different embodiments of the core portion 115 and the edge portion 120 are shown, other combinations are also encompassed by the present disclosure.
[0053] Additionally, while it is contemplated that embodiments of the paddle 100 include the first layer 112 being different from the second layer 118, the embodiments described herein include each paddle 100 having the first layer 112 being the same as the second layer 118. For clarity, when one of the first layer 112 or the second layer 118 is described herein with regard to a particular embodiment, the other of the first layer 112 or the second layer 118 in the same embodiment is identical or substantially identical.
[0054] Generally, the first layer 112, the second layer 118 and the core portion 115 form a sandwiched structure.
[0055] In each of the embodiments shown in FIGS. 2A-3B, the first layer 112 includes the outer surface 111 and an inner surface 113, and the second layer 118 includes the outer surface 119 and an inner surface 117. In embodiments, each of the first layer 112 and the second layer 118 is made from a woven or non-woven composite fiber material including fibers impregnated with resin, such as epoxy, polyester, and/or metal matrix resins. For instance, the material may include any fiber-reinforced composite (including fiber-reinforced polymers, fiber-reinforced plastics, etc.). Additionally, the material of each of the first layer 112 and the second layer 118 can include multiple layers of material (e.g., where adjacent layers include 45, 90, etc. offset grain orientation, for instance).
[0056] In disclosed embodiments, the outer surfaces 111, 119 of the respective first layer 112 and the second layer 118 have a roughened texture. The roughened texture can be formed by grit, sand, and/or other particles applied to, or positioned under one or more coatings applied to the outer surfaces 111, 119.
[0057] Another way of forming a roughened texture is by applying an additional layer of a fabric material, such as a peel ply fabric, on the outer surfaces 111, 119. In embodiments, the peel ply fabric is a woven fabric, nylon, or polyester, which, during the cure cycle of the manufacturing process, absorbs some of the matrix epoxy resin, for instance, and becomes an integral part of the laminate of each layer 112, 118. Following the cure cycle, the peel ply fabric is peeled off or otherwise removed from the first layer 112 and the second layer 118, which fractures the resin between the peel ply fabric and the outer surfaces 111, 119, respectively, and which leaves a fresh, clean, roughened surface of matrix epoxy resin. A further way of forming a roughened texture is by making the outer surfaces 111, 119 from woven, high-grade raw carbon fiber, other fibrous materials, and/or combinations thereof.
[0058] In disclosed embodiments, a ply of planar fiber material is first cut into the shape of the mold corresponding to the shape of the pickleball paddle 100. The fibers can be co-axially aligned in sheets or layers, braided, or weaved in sheets or layers, and/or chopped and randomly dispersed in one or more layers. In a multiple layer construction, the fibers can be aligned in different directions with respect to the longitudinal axis A-A of the paddle 100, and/or in braids or weaves from layer to layer. The fibers may be formed of a high tensile strength material such as carbon (e.g., T700, T800, 3K, 6K, 12K or 18K carbon fiber). Alternatively, the fibers can be formed of other materials such as glass, graphite, Zylon, Nylon, Aramid, Arylate, Kevlar, graphene, boron and combinations thereof. Further, any suitable fiber-reinforced composite can be used.
[0059] A roughened texture on the outer surfaces 111, 119 may be useful to some pickleball players by generating a relatively large amount of friction (as opposed to a smooth surface) may making contact with the ball. This roughened texture and increased friction can help a player generate spin, and create an increased amount of angular momentum resulting in the ball travelling with higher angular velocities.
[0060] Alternatively, the outer surfaces 111, 119 of the paddle 100 can be smooth, and not roughened or textured, which may be preferred by some players.
[0061] With continued reference to FIGS. 2A-3B and with additional reference to FIGS. 9C and 10D, the edge portion 120 of the paddle 100 is shown. An edge foam 122 is positioned within an edge tube 121, which extends along the perimeter of the head portion 110 of the pickleball paddle 100. The edge tube 121 interconnects the first layer 112 and the second layer 118, and may be made from a fiber-reinforced composite, such as the same material that the first layer 112 and the second layer 118 are made from. The edge foam 122 is at least partially encapsulated by the edge tube 121 and is made from either the same material used to make the core portion 115, or from a different material. For instance, the edge foam 122 can be open-celled (e.g., Polyurethane or PU, natural rubber or NR, nitrile, Ethylene-Propylene-Diene Monomer or EPDM, Polyvinyl Chloride or PVC, etc.) or closed-celled (e.g., Ethyl-Vinyl Acetate or EVA, neoprene, Styrene-Butadiene Rubber or SBR, etc.). The edge foam 122 may also be thermoplastic or thermoset.
[0062] In embodiments, the edge foam 122 cures within the edge tube 121, thereby allowing the edge tube 121 to attain its oval-like shape (as shown in FIGS. 2A-3B). Additionally, in embodiments, the edge tube 121 bonds to the first layer 112 and the second layer 118 of the paddle 100 during the curing process.
[0063] The edge portion 120 may provide additional strength, stability, and/or balance to the paddle 100 or portions thereof. The edge portion 120 may also be helpful to contain the material from the core portion 115 when the material (e.g., foam) tends to expand outwardly during manufacturing.
[0064] In embodiments described herein, the core portion 115 includes a reinforcing member (indicated by reference character 114 in FIGS. 2A-2C, indicated by reference character 116 in FIGS. 3A and 3B, indicated as reference character 140 in FIGS. 9A-9C, and indicated by reference character 160 in FIGS. 10-10D) or a core composite therein.
[0065] In embodiments, the reinforcing member 114, 116, 140, 160, or at least portions thereof, is made from a woven or non-woven composite fiber material including fibers impregnated with resin, such as epoxy, polyester, and/or metal matrix resins. For instance, the material may include any fiber-reinforced composite (including fiber-reinforced polymers, fiber-reinforced plastics, etc.). In embodiments, the reinforcing member 114, 116, 140, 160 is made from the same material as the first layer 112 and the second layer 118. Additionally, the reinforcing member 114, 116, 140, 160 may be in the form of a sheet of material that is folded, bent, rolled, woven, molded, braided, etc. in a particular orientation, as discussed below.
[0066] The reinforcing member 114, 116, 140, 160 extends between the first layer 112 and the second layer 118, and is in contact with each of the first layer 112 and the second layer 118. For instance, the reinforcing member 114, 116, 140, 160 is bonded to the first layer 112 and the second layer 118. The bonding may be accomplished by a resin, such as a thermosetting resin (e.g., an epoxy or polyester resin), a thermoplastic resin, etc. While the resin cures, the resin is configured to flow, to fully disperse, and/or to impregnate the matrix of fibers of the inner surfaces 113, 117 of the first layer 112 and the second layer 118, respectively, and the matrix of fibers of the reinforcing member 114, 116, 140, 160, for example. The reinforcing member 114, 116, 140, 160 is configured to provide strength in the vertical direction (as viewed in FIGS. 2A-3B, for instance; parallel to the thickness t dimension) and/or to minimize the amount of deflection in response to a force (e.g., contacting a pickleball ball) being applied to the first layer 112 or the second layer 118.
[0067] As shown in FIGS. 2A-10D, the reinforcing member 114, 116, 140, 160 can extend between the first layer 112 and the second layer 118 in a variety of orientations.
[0068] With particular reference to FIG. 2A, the reinforcing member 114 forms a trapezoidal shape including a first leg 114a disposed at a first angle 1 relative to the first layer 112, a second leg 114b extending along (e.g., in contact with) the first layer 112, a third leg 114c disposed at a second angle 2 relative to the first layer 112, and a fourth leg 114d disposed along (e.g., in contact with) the second layer 118. In embodiments, the first angle 1 and the second angle 2 are equal to each other and are between about 25 and about 75 (e.g., equal to about) 50; other angles are also envisioned and incorporated by the present disclosure. Additionally, in embodiments, the second leg 114b and the fourth leg 114d may be equal to each other in length (i.e., in the direction along the first layer 112 and the second layer 118, respectively), and may define a length of between about 1 mm and about 20 mm (e.g., equal to about 5 mm). While the intersections between adjacent legs 114a, 114b, 114c, 114d are shown as forming sharp angles, any or all of these intersections may be rounded, e.g., to facilitate manufacturing.
[0069] With specific reference to FIG. 2B, the reinforcing member 114 forms a triangular shape including a first leg 114e disposed at a third angle 3 relative to the first layer 112, and a second leg 114f disposed at a fourth angle 4 relative to the first layer 112. In embodiments, the third angle 3 and the fourth angle 4 are equal to each other and are between about 20 and about 75 (e.g., equal to about) 45. In this embodiment, the intersections between adjacent legs 114e and 114f (at the first layer 112 and the second layer 118) are decipherable (e.g., by look and/or feel) through the respective first layer 112 and the second layer 118, and may be perceived to resemble strings of a tennis racquet (parallel to axis A-A), which may help a consumer decide to purchase such a pickleball paddle 100. This feature may also result in a textured surface to help a user generate spin, for instance.
[0070] While the intersections between adjacent legs 114e and 114f are shown as forming sharp angles, any or all of these intersections may be rounded, e.g., to facilitate manufacturing.
[0071] Referring now to FIG. 2C, the reinforcing member 114 forms a rectangular- or stepped-shape including a first leg 114g, a second leg 114h, a third leg 114i, and a fourth leg 114j. The first leg 114g is disposed along (and in contact with) the first layer 112, the second leg 114h is perpendicular to the first leg 114h, the third leg 114i is perpendicular to the second leg 114h and is disposed along (and in contact with) the second layer 118, and the fourth leg 114j is perpendicular to the third leg 114i.
[0072] In FIGS. 2A-2C, the reinforcing member 114 is shown as a grid structure. As used herein, the term grid or grid structure encompasses various grid, grid-like, and mesh patterns/designs, for instance, where spaces are defined between adjacent portions of the grid. That is, the reinforcing member 114 in FIGS. 2A-2C defines a plurality of open spaces. The open spaces within the reinforcing member 114 reduce the overall weight of the pickleball paddle 100. Additionally, in disclosed embodiments, while the overall weight of the pickleball paddle 100 is decreased, which is generally desirable by players, the strength of the pickleball paddle 100 (e.g., in the vertical direction) is not compromised.
[0073] Additionally, the open spaces within the grid structure of the reinforcing member 114 allow the material (e.g., foam) of the core portion 115 on a first side (e.g., left side) of the reinforcing member 114 to contact and effectively merge or fuse with the material on a second side (e.g., right side) of the reinforcing member 114 (e.g., during curing). The merging or fusing of part of the core portion 115 with another part of the core portion 115 may help further strengthen the pickleball paddle 100.
[0074] In FIGS. 3A and 3B, the reinforcing member 116 is shown as a sheet material. In contrast to the grid structure of the reinforcing member 114 of FIGS. 2A-2C, the sheet material of the reinforcing member 116 of FIGS. 3A and 3B does not define open spaces.
[0075] With particular reference to FIG. 3A, the reinforcing member 116 forms a trapezoidal shape including a first leg 116a disposed at a fifth angle 5 relative to the first layer 112, a second leg 116b extending along (e.g., in contact with) the first layer 112, a third leg 116c disposed at a sixth angle 6 relative to the first layer 112, and a fourth leg 116d disposed along (e.g., in contact with) the second layer 118. In embodiments, the fifth angle 5 and the sixth angle 6 are equal to each other and are between about 25 and about 75 (e.g., equal to about) 50; other angles are also envisioned and incorporated by the present disclosure. Additionally, in embodiments, the second leg 116b and the fourth leg 116d may be equal to each other in length (i.e., in the direction along the first layer 112 and the second layer 118, respectively), and may define a length of between about 1 mm and about 20 mm (e.g., equal to about 5 mm). While the intersections between adjacent legs 116a, 116b, 116c, 116d are shown as forming sharp angles, any or all of these intersections may be rounded, e.g., to facilitate manufacturing.
[0076] With specific reference to FIG. 3B, the reinforcing member 116 forms a triangular shape including a first leg 116e disposed at a seventh angle 7 relative to the first layer 112, and a second leg 116f disposed at an eighth angle 8 relative to the first layer 112. In embodiments, the seventh angle 7 and the eighth angle 8 are equal to each other and are between about 20 and about 75 (e.g., equal to about) 45. In this embodiment, the intersections between adjacent legs 116e and 116f (at the first layer 112 and the second layer 118) are decipherable (e.g., by look and/or feel) through the respective first layer 112 and the second layer 118, and may be perceived to resemble strings of a tennis racquet (parallel to axis A-A), which may help a consumer decide to purchase such a pickleball paddle 10. This feature may also result in a textured surface to help a user generate spin, for instance.
[0077] While the intersections between adjacent legs 116e and 116f are shown as forming sharp angles, any or all of these intersections may be rounded, e.g., to facilitate manufacturing.
[0078] Additionally, while not explicitly shown in the accompanying figures, the reinforcing member 116 may be oriented in other ways such as the rectangular- or stepped-shape shown in FIG. 2C with relation to reinforcing member 114. Moreover, additional orientations (e.g., different shapes or a combination of shapes) of reinforcing members 114, 116 are also contemplated by the present disclosure.
[0079] In embodiments, the reinforcing member 114, 116, 140, 160 is formed from a high strength material such as carbon, such as a particular grade of carbon fiber (e.g., T700, T800, 3K, 6K, 12K, 18K). Alternatively or additionally, fibers of the reinforcing member 114, 116, 140, 160 can be made from glass, graphite, Kevlar, graphene, boron, and combinations thereof, for instance. The reinforcing member 114, 116, 140, 160 can be formed from multiple plies (e.g., two or three unidirectional carbon fiber plies overlaid with offset axes). The material(s) making up the reinforcing member 114, 116, 140, 160 can be the same as or different from the material(s) making up the first layer 112 and the second layer 118. Further, the material(s) making up the reinforcing member 114, 116, 140, 160 can be any suitable fiber-reinforced composite (including fiber-reinforced polymers, fiber-reinforced plastics, etc.). The strength of the material of the reinforcing member 114, 116, 140, 160 helps strengthen, balance, and minimize deflection at various locations of the head portion 110 of the paddle 100.
[0080] In addition to the edge portion 120, the paddle 100 may also include an edge guard 151 (FIG. 2B). The edge guard 151 is applied to the edge portion 120 and helps protect the edge portion 120, and the portions of the paddle 100 adjacent thereto. The edge guard 151 may also help provide additional weight and/or balance to the paddle 100, for instance. In embodiments the edge guard 151 is removable from the remainder of the paddle 100 and is replaceable with a different edge guard 151. While the edge guard 151 is only shown in FIG. 2B, all embodiments disclosed herein may include the edge guard 151.
[0081] Referring now to FIGS. 4A and 4B, a plurality of strips of the core portion 115 is shown. In FIG. 4A, the core portion 115 is shown in a plurality of trapezoidal strips 115a. In FIG. 4B, the core portion 115 is shown in a plurality of triangular strips 115b. The trapezoidal strips 115a of FIG. 4A are usable with the embodiments shown in FIGS. 2A and 3A where the reinforcing member 114, 116 is shown as being orientated in a trapezoidal pattern. The triangular strips 115b of FIG. 4B are usable with the embodiments shown in FIGS. 2B and 3B where the reinforcing member 114, 116 is shown as being oriented in a triangular pattern. In embodiments the strips 115a, 115b are manufactured or molded in the particular shapes. In other embodiments, the strips 115a, 115b are manufactured or molded into sheets (e.g., rectangular prisms) and are then cut into the particular shapes. As shown, end strips 115ae, 115be are slightly different in shape than their adjacent strips 115a, 115b, respectively, to enable the perimeter of the core portion 115 to be generally vertical, for instance.
[0082] With reference to FIGS. 5A-5D, various embodiments of the reinforcing member 114 having different grid structures are shown. In FIG. 5A, the reinforcing member 114 defines a grid structure having a plurality of diamond-shaped openings 114w. In FIG. 5B, the reinforcing member 114 defines a grid structure having a plurality of rectangular openings 114x. In FIG. 5C, the reinforcing member 114 defines a grid structure having a plurality of circular openings 114y. In FIG. 5D, the reinforcing member 114 defines a grid structure having a plurality of elongated rectangular openings 1142. Reinforcing members 114 having either of these openings 114w, 114x, 114y, 114z are usable in the embodiments of the reinforcing member 114 having a grid structure disclosed herein.
[0083] Moreover, depending on the particular embodiment, the open spaces or openings 114w-114z defined between adjacent portions of the grid structure of the reinforcing member 114 make up between about 1% and about 99% of the total area of the solid portions of the reinforcing member 114. For instance, in FIG. 5A, the open spaces 114w defined between adjacent portions of the reinforcing member 114 may be between about 50% and about 75% of the total area of the reinforcing member 114. In FIG. 5B, the open spaces 114x defined between adjacent portions of the reinforcing member 114 may be between about 60% and about 85% of the total area of the reinforcing member 114. In FIG. 5C, the open spaces 114y defined between adjacent portions of the reinforcing member 114 may be between about 15% and about 45% of the total area of the reinforcing member 114. In FIG. 5D, the open spaces 114z defined between adjacent portions of the reinforcing member 114 may be between about 5% and about 35% of the total area of the reinforcing member 114.
[0084] Further, the embodiments illustrated in FIGS. 5A-5D are only examples of different types of grid structures; reinforcing members 114 having other types of grid structures are also encompassed by the present disclosure.
[0085] The reinforcing member 114, 116, 140, 160 may help provide the paddle 100 with desired strength, stiffness and/or flexibility, and the core portion 115 (e.g., foam) may result in a desirable amount of strength, speed, and noise reduction (versus a plastic core, for instance).
[0086] The present disclosure also includes methods of assembling and/or manufacturing the paddle 100, or components thereof. Various steps in the assembly and/or manufacturing process of the paddle 100 are described with reference to FIGS. 6A-8C.
[0087] Initially, FIGS. 6A-6C show the formation of a first core assembly 209a, and FIGS. 7A-7C show the formation of a second core assembly 209b. For clarity, the first core assembly 209a and the second core assembly 209b are collectively referred to as the core assembly 209 (see FIGS. 8A-8C).
[0088] In FIGS. 6A-6C, the first core assembly 209a is constructed by effectively wrapping the reinforcing member 114 around portions of the strips 115a and the end strips 115ac (only a single end strip 115ae and two other strips 115a are shown in FIGS. 6A-6C for clarity). Moreover, the reinforcing member 114 is positioned in contact with the end strip 115ac (FIG. 6A), is wrapped over the adjacent strip 115a (FIG. 6B), and is wrapped under the adjacent strip 115a (FIG. 6C). This over-under wrapping of the reinforcing member 114 continues until all strips 115a and the other end strip 115ae are in contact with the reinforcing member 114, thereby forming the first core assembly 209a. Additionally, as shown in FIG. 6C, adjacent strips 115a are rotated or offset 180 from each other (also see FIG. 4A).
[0089] In FIGS. 7A-7C, the second core assembly 209b is constructed by effectively wrapping the reinforcing member 114 around portions of the strips 115b and the end strips 115be (only a single end strip 115be and two other strips 115b are shown in FIGS. 7A-7C for clarity). Moreover, the reinforcing member 114 is positioned in contact with the end strip 115be (FIG. 7A), is wrapped over the adjacent strip 115b (FIG. 7B), and is wrapped under the adjacent strip 115b (FIG. 7C). This over-under wrapping of the reinforcing member 114 continues until all strips 115b and the other end strip 115be are in contact with the reinforcing member 114, thereby forming the second core assembly 209b. Additionally, as shown in FIG. 7C, adjacent strips 115b are rotated or offset 180 from each other (also see FIG. 4B).
[0090] Referring now to FIGS. 8A-8C, various steps during the assembly process of the paddle 100 are illustrated. In FIG. 8A, the core assembly 209, including the core portion 115 and the reinforcing member 114, is shown. The core assembly 209 has been cut to the appropriate size and shape.
[0091] Next, as shown in FIG. 8B, the first and second layers 112, 118 are positioned onto the core assembly 209. The first layer 112 can be formed by using carbon fiber plies that are impregnated with resin (e.g., epoxy) and laminated (e.g., by hand). In embodiments, three unidirectional carbon fiber prepreg plies or sheets are used for the first layer 112 and the second layer 118.
[0092] Alternatively, the first layer 112 and the second layer 118 can be prefabricated. An example of a prefabrication process is described herein. Three plies of unidirectional carbon fiber prepregs in the rectangular shape are laid on top of one another in alternating perpendicular directions. A common dimension used in the industry is 500 mm by 600 mm. Carbon fiber prepregs may include carbon fiber ply that have been pre-impregnated with epoxy resin. The three unidirectional carbon fiber prepreg plies are positioned such that the first sheet has its fibers along the A-A axis, the second sheet has its fibers along the B-B axis, and the third sheet has its fibers along the A-A axis again. Further, a peel ply can be placed on the outer most layer.
[0093] Three plies of unidirectional carbon fiber prepregs, along with the peel ply, are placed into a hot press molding machine. The upper mold is aligned with the lower mold symmetrically and the mold halves are closed. Pressure is applied using hydraulic presses while the mold is cured at high temperature for a certain amount of time. While curing, the epoxy resin is configured to flow and fully disperse and impregnate the matrix of fibers (e.g., carbon fibers). After the cooling cycle, the (carbon) fiber-reinforced composite facesheet is removed from the mold. This results in a prefabricated facesheet. The prefabricated facesheet is then cut into the shape of a paddle. This is then used as the first layer 112 and the second layer 118.
[0094] Next, with reference to FIG. 8C, the edge portion 120 is positioned along at least a portion of the perimeter of the paddle 100. As discussed above, the edge portion 120 includes the edge tube 121 and the edge foam 122.
[0095] After the edge portion 120 is in its position, the entire paddle 100 is placed into a lower mold cavity. After the lower mold has been filled, the upper mold is aligned with the lower mold, symmetrically, and is tightened to close the mold. The mold is then placed into an oven or furnace at a high temperature for a certain amount of time to cure. While curing, the resin (if used) is configured to flow and fully disperse and impregnate the matrix of fibers of the first layer 112, the second layer 118, and/or the reinforcing member 114. Further, when foam is used for the core portion 115, the foam material expands as a result of it being heated. The foam then disperses helps ensure that all of the layers (i.e., the first layer 112, the second layer 118, the core assembly 209), and the edge portion 120 are securely fastened together.
[0096] Another embodiment of the pickleball paddle 100 is shown in FIGS. 9A-9C. In FIG. 9A, the core portion 115 of the head portion 110 of the pickleball paddle 100 is shown. The core portion 115 includes a plurality of holes 150 extending therethrough (in the vertical direction as viewed in FIGS. 9B and 9C. While each hole of the plurality of holes 150 is shown having a particular shape and size, the present disclosure also encompasses non-uniform holes, and holes of different sizes and shapes than those shown. Also, the spacing of the plurality of holes 150 may be uniform, as shown, or may be non-uniform. For instance, the spacing of adjacent holes may be smaller at and near the center of the head portion 110, and larger the closer to the perimeter of the head portion 110, or vice versa, depending on desired areas of strength, flexibility, stiffness, etc. Additionally, the amount of holes included in the plurality of holes 150 may be more or fewer than the amount shown.
[0097] With particular reference to FIGS. 9B and 9C, reinforcing members 140 are inserted into the plurality of holes 150. More particularly, one reinforcing member 140 including a sleeve 155 and a filling 156, is inserted into each hole of the plurality of holes 150. In embodiments, the sleeve 155 is made from the same or similar material as the first layer 112 and the second layer 118, such as a high tensile strength material such as carbon fiber prepreg plies, carbon (e.g., T700, T800, 3K, 6K, 12K or 18K carbon fiber), etc. Alternatively, the sleeve 155 can be formed of other materials such as glass, graphite, Zylon, Nylon, Aramid, Arylate, Kevlar, graphene, boron and combinations thereof. Further, any suitable fiber-reinforced composite can be used.
[0098] Additionally, in embodiments, the filling 156 is made from the same or similar material as the core portion 115, such as foam.
[0099] Moreover, in embodiments (such as the embodiment shown in FIG. 9C), the sleeve 155 of the reinforcing member 140 includes an upper lip 157 and a lower lip 159. The upper lip 157 covers the top of the filling 156, extends radially outwardly of the sleeve 155, and is in contact with the first layer 112 of the head portion 110. The lower lip 159 covers the bottom of the filling 156, extends radially outwardly of the sleeve 155, and is in contact with the second layer 118 of the head portion 110. In embodiments, the upper lip 157 and the lower lip 159 are made from the same material as the sleeve 155 and are connected to the sleeve 155.
[0100] Referring now to FIGS. 10A-10D, another embodiment of the pickleball paddle 100 is shown. In FIGS. 10A and 10B, the core portion 115 of the head portion 110 of the pickleball paddle 100 is shown. Here, the core portion 115 includes the reinforcing member 160 woven therethrough. In embodiments, the reinforcing member 160 is made from a strand of material (e.g., a linear or a braided strand) such as the same or similar material as the first layer 112 and the second layer 118, such as a high tensile strength material such as carbon (e.g., T700, T800, 3K, 6K, 12K or 18K carbon fiber). Alternatively, the reinforcing member 160 can be formed of other materials such as glass, graphite, Zylon, Nylon, Aramid, Arylate, Kevlar, graphene, boron and combinations thereof. Further, any suitable fiber-reinforced composite can be used.
[0101] In embodiments, the reinforcing member 160 can be knitted or threaded through pre-made holes in the core portion 115, or the reinforcing member 160 can be threaded or sewn through the core portion 115 (without pre-made holes). The reinforcing member 160 can be a single, continuous thread, or the reinforcing member 160 can be made from a plurality of threads.
[0102] As shown in FIG. 10D, each section 160i of the reinforcing member 160 of this embodiment includes a first leg 160j, a second leg 160k, and a third leg 160m. The first leg 160k extends along an upper surface of the core 115 and in contact with the inner surface 113 of the first layer 112, the third leg 160m extends along a lower surface of the core 115 and is contact with the inner surface 117 of the second layer 118, and the second leg 160k interconnects the first leg 160j and the third leg 160m, and extends through the core portion 115 (e.g., in a direction perpendicular to the first layer 112).
[0103] Referring back to FIGS. 10A-10C, the spacing between adjacent sections 160i of the reinforcing member 160 may be uniform, as shown, or may be non-uniform. For instance, the spacing of adjacent sections 160i may be smaller at and near the center of the head portion 110, and larger the closer to the perimeter of the head portion 110, or vice versa, depending on desired areas of strength, flexibility, stiffness, etc. Additionally, the number of sections 160i may be more or fewer than the amount shown. Further, while FIGS. 10A and 10B show two different orientations of the sections 160i of the reinforcing member 160, other orientations (e.g., diagonal) are also encompassed by the present disclosure.
[0104] The embodiments described herein result in better absorption of the impact energy of the paddle 100 hitting the ball, increase the duration of the ball in contact with the paddle 100, and/or provide greater angular momentum imparted on the ball when the paddle 100 rolls over the ball. Further, by adjusting the grid pattern and shape, the thickness and density of the various layers, and the angle of the reinforcing member 114, 116, 140, 160 relative to the first layer 112 and the second layer 118, the mechanical properties of the paddle 100 will be changed accordingly. For instance, the strength and stiffness of the paddle 100 can be tailored by adjusting any or all of these parameters to provide different amount of power, spin, and control levels to meet the needs of various playing styles.
[0105] Various other embodiments of pickleball paddles are described in International Patent Application Number PCT/US23/30143, filed on Aug. 14, 2023, the entire contents of which are incorporated herein by reference.
[0106] It will be understood that various modifications may be made to the embodiments disclosed herein. Therefore, the above description should not be construed as limiting, but merely as exemplifications of various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.
