The subject matter described herein relates generally to improved paddles and rackets, and similar devices, particularly to rackets or paddles for activities such as pickleball, as well as methods of making and using the same.
Rackets and paddles are used in a variety of activities and sports. Some sports such as pickleball have garnered increased interest in recent years. The paddles used in such activities are made of a variety of materials such as wood, fiberglass, graphite, carbon fiber, etc.
Described herein generally are newly used materials, and improved components, parts and complete paddles and rackets, as well as methods of making and using the same. The embodiments herein will be described in the context of pickleball paddles, but it should be understood that the materials, designs, components, parts and concepts can be used in paddles and rackets (or articles used to strike a ball or other object) for other activities and sports.
Systems, methods, and articles of manufacture, are provided for a pickleball paddle incorporating in some cases, materials that have not been used in such paddles, as described herein. The use of the designs and materials can provide for paddles with different and/or improved characteristics such durability, weighting, and performance.
Currently, most pickleball paddles included a core and an exterior around the core. The exterior generally includes two sides of the exterior face or head of the paddle, and a handle. The exterior also can include a bumper or wrap around the perimeter or edge of the head or face of the paddle. A common core for many paddles includes a lightweight honeycomb patterned material (See, e.g.,
Among the disclosure herein, provided herein are improved paddles, including with novel core materials and designs. For example, cores using lightweight foam materials. Such materials can include one or more materials. One or more materials can be used. Whether one material is used or multiple materials, the materials can be configured to have different weight and/or density characteristics such that the core can have dual or multiple densities of material.
The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims. While certain features of the currently disclosed subject matter are described for illustrative purposes, it should be readily understood that such features are not intended to be limiting. The claims that follow this disclosure are intended to define the scope of the protected subject matter.
The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations. In the drawings,
When practical, similar reference numbers denote similar structures, features, or elements.
Pickleball paddles may include a contact surface made of a variety of materials, including carbon fiber, among other materials, and a core made of a variety of materials. Pickleball paddles must meet USA Pickleball Association (USAPA) Certification Standards in order to be used in sanctioned tournament play. USAPA Certification Standards for a paddle include certain weight, size, deflection, and durability requirements. Pickleball paddles made of polymer foams, such as an ethylene vinyl acetate (EVA) foam, are lightweight, but excessively deflect, compress, and are not durable. Pickleball paddles made of polypropylene or other dense polymers are rigid and durable, however, weight requirements preclude a pickleball paddle with a solid polypropylene core. To reduce total weight, pickleball paddles can be constructed with a honeycomb core of polypropylene fixed in the core of the paddle, as shown in
Consistent with implementations of the current subject matter, the herein described paddle cores, including the dual density core pickleball paddles, can lead to improved performance characteristics, durability and strength. The paddles can be specifically made to be lightweight and durable while undergoing minimal compression and deflection.
Frame 50 and/or filling 60 of core 40 can be composed of high density composite foams such as expanded polypropylene (EPP), ethylene-vinyl acetate (EVA), nanocarbon-containing polymer composite foams (NCP), and/or microcellular polypropylene (MPP). High density composite foams can be used in any combination thereof. For example, components of the frame 50 and/or filling 60 can have foam materials with various densities. Optionally, frame 50, filing 60, or components of the core 40 can be composed of high-density composite foams such as elastomers, polystyrene, polyethylene, polypropylene, polyamide, polyurethane, ethylvinyl-acetate, polyethylene oxide, polyacrylate, cellulose, ethylene vinyl alcohol, polybutylene, polycaprolactone, polycarbonate, polyketone, polyester, polylactic acid, polyvinyl chloride, polyphenylene, and copolymers thereof.
The dual density core 40 for paddle 10 can be manufactured using a CNC milling process. The frame 50 can be CNC milled out of the frame 50 material. The filling 60 can be CNC milled out of the filling 60 material, creating pieces of filling 60 that are shaped to fit into the cells of frame 50. The pieces of filling 60 can be inserted into the cells of frame 50, and the filling 60 and frame 50 can be bonded together with epoxy. The bonded frame 50 and filling 60 can be planed down to a uniform thickness, forming a dual density core 40 to be used in the manufacture of paddle 10.
The dual density core 40 for paddle 10 can be manufactured using an injection molding process, for example. EPP beads can be injection heat molded and can expand and solidify within a mold to form the frame 50. The density of frame 50 can be any suitable density, for example, EPP beads can be selected to produce a frame density ranging, for example, from 6.0 lbs./ft3 to 20.0 lbs./ft3, or any subvalue or subrange therein in tenths. Lower density EPP beads can be injection heat molded into a mold sized for the cells of frame 50 to form cell-shaped pieces of filling 60. The lower density EPP can be selected to produce a filling density ranging from, for example, 1.0 lbs./ft3 to 6.0 lbs./ft3, or any subvalue or subrange therein in tenths. Alternatively, EPS foam, EVA foam, or other foams and fill materials can be selected to produce the desired filling density. The filling 60 can be press fit into the cells of frame 50 and bonded with epoxy. The bonded frame 50 and filling 60 can be planed down to a uniform thickness, forming a dual density core 40 to be used in the manufacture of paddle 10.
Some embodiments relate to articles or devices for striking an object such as a ball. The article or devices can be rackets or paddles, such as for example, a pickleball paddle. While applicable to any of the articles, the following is discussed in the context of a pickleball paddle, but should not be limited thereto.
The paddles 10 can include a core 40, which can include, among other things, a material such as a foam like expanded polypropylene (EPP). EPP is recognized as being a very different material from the more rigid, crystalline polypropylene that is used to form many of the honeycomb cores of many paddles. The EPP that is used can have any suitable density to arrive at a paddle with an overall desired structure and weight. The paddle cores 40 can include, for example, an EPP that has a density of about 0.5 to about 20 lbs./ft3, or any subrange or subvalue to the tenth value there between. The core 40 can include a lower density material 60 to fill in spaces around and adjacent to the skeletal structures 50. Skeletal structures 50 may alternatively be referred to as exoskeleton, frame, or other name designating a structure that provides support to the paddle 10. For example, in most existing paddles that support is provided by a honeycomb structure. Such support structures provide a vertical support between the faces of the paddle. The EPP fill 60 that fills in at least some of the non-skeletal space can have for example, a density of between about 0.5 and about 5.0 lbs./ft3, about 3.5 lbs./ft3, or any subrange or subvalue to the tenth value there between. In some embodiments, the fill material 60 can fill in substantially all of the non-skeletal space within the core 40 of the paddle 10.
In some embodiments the paddles 10 can include a higher density EPP that provides vertical support. Such EPP can have, for example, a density of, for example, between about 5.0 and 20 lbs./ft3, or any subrange or subvalue to the tenth value there between.
In some embodiments the paddles 10 can include EPP having different densities. For example, the paddle 10 can have a skeleton 50 made of the higher density EPP and filler 60 comprising the lower density EPP. In
Turning back to
In other embodiments, the total core weight is between about 2.0 and 4.0 ounces, and any subvalue or subrange there between in values to the tenths. The total paddle weight can be between about 5 and 11 ounces, or any subvalue or subrange there between, including values to the tenths. The paddle 10 can further include a face material over the core 40, a grip/handle and optionally a perimeter wrap or bumper/guard (e.g., a rubber or carbon fiber material that optionally can have a foam beading beneath it to provide cushion. The handle can be made of any suitable material. Those can include wood or other materials as described. The handle can be formed as part of the skeleton. The handle can include a grip tape as well for improved gripping and comfort. The faces be made of carbon fiber, graphite, fiberglass or any other suitable material. The faces further can optionally include other coatings, graphics, etc.
The skeleton structure of the paddle can comprise any shape, including, but not limited to those depicted and described herein. For example, the shape could be one as shown in the figures. It could be a honeycomb, including a honeycomb with a cell or hole diameter greater than 10.0 mm. In some embodiments, the cell diameter can be between about 15.0-30.0 mm, for example, or any subvalue or subrange there between to the tenths value. In some embodiments the skeleton 50 can have a uniform structure and/or feature distribution, such as is found in a honeycomb structure. Although other shapes are contemplated. In other embodiments, the structure of the skeleton 50 can be non-uniform or partially uniform, for example as shown in the figures. In some embodiments, the volume of the skeleton 50 can be greater on the perimeter of the paddle 10 than it is in the middle and the fill 60 can fill a greater volume of space in the middle portion, for example. In some embodiments, the volume of the skeleton 50 can be greater in the center or a sweet spot of the paddle 10 than it is on the perimeter and the fill 60 can fill a greater volume of space on the perimeter, as shown in
As illustrated in
Among the disclosure herein, provided herein are improved paddles, including with novel core materials and designs. For example, cores using lightweight foam materials. Such materials can include one or more materials. One or more materials can be used. Whether one material is used or multiple materials, the materials can be configured to have different weight and/or density characteristics such that the core can have dual or multiple densities of material.
Without being bound by theory, it is believed that the shape and/or feature distribution may affect the function of the paddle 10. For example, the placement of the skeleton 50 may affect performance when using the paddle, including spin (e.g. amount of spin put on the ball), speed, weight, weight distribution, position of the sweet spot, and the like. The sweet spot may be defined as the center of mass of the paddle or may be defined as the “center of percussion” (cp). In some embodiments, the sweet spot may provide additional control or precision when striking a ball that makes contact with the sweet spot. In some embodiments, the sweet spot may provide additional force when striking a ball that makes contact with the sweet spot. In some embodiments the sweet spot may provide a favored combination of rotation, speed, and/or trajectory, when striking a ball that makes contact with the sweet spot.
Some embodiments relate to a method of making and/or manufacturing a pickleball paddle, as claimed, shown and/or described herein.
Some embodiments relate to a method of using or playing with the paddle or article described herein. Such methods can include using a paddle or other article as described, claimed or shown herein to strike an object such as a ball.
It is envisioned that embodiments of the present disclosure can include skeletons with various gap configurations. The skeleton, and/or gaps can be composed of foam having varying density within the same embodiment of the paddle. For example, a skeleton can include areas filled with high density foam and areas filled with low density foam within the same paddle. High density foam can provide weight, stability, and resistance from deflection to a user. However, foam densities can be regulated by competitive sport associations. Low density foam can be used to provide power and sound dampening. Alternatively, gaps filled with air, or forming a void passage, can be used for power and/or sound dampening.
Embodiments of the present disclosure can include pickleball paddles having a specified rigidity. For example, pickleball paddles can be built with a rigidity corresponding to a deflection of 5 thousandths of an inch or less at a test weight of 3 kg. In some embodiments, pickleball paddles built in accordance with the methods described herein can have a deflection of 10 thousandths of an inch or less at a test weight of 5 kg. In some embodiments, target deflection ranges for a pickleball paddle may correspond to requirements of sports governing bodies such as the USA Pickleball (USAP). In some embodiments, deflection in inches per weight can be indicative of how quickly a ball making contact with the pickleball paddle departs from the paddle face upon contact. In some embodiments, deflection testing for the paddle can be between about 0.003 inches to 0.005 inches.
The subject matter described herein can be embodied in systems, apparatus, methods, and/or articles depending on the desired configuration. The implementations set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been described in detail above, other modifications or additions are possible. In particular, further features and/or variations can be provided in addition to those set forth herein. For example, the implementations described above can be directed to various combinations and subcombinations of the disclosed features and/or combinations and subcombinations of several further features disclosed above. In addition, the logic flows depicted in the accompanying figures and/or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. For example, the logic flows may include different and/or additional operations than shown without departing from the scope of the present disclosure. One or more operations of the logic flows may be repeated and/or omitted without departing from the scope of the present disclosure. Other implementations may be within the scope of the following claims.
When a feature or element is herein referred to as being “on” another feature or element, it can be directly on the other feature or element or intervening features and/or elements may also be present. In contrast, when a feature or element is referred to as being “directly on” another feature or element, there are no intervening features or elements present. It will also be understood that, when a feature or element is referred to as being “connected”, “attached” or “coupled” to another feature or element, it can be directly connected, attached or coupled to the other feature or element or intervening features or elements may be present. In contrast, when a feature or element is referred to as being “directly connected”, “directly attached” or “directly coupled” to another feature or element, there are no intervening features or elements present. Although described or shown with respect to one embodiment, the features and elements so described or shown can apply to other embodiments. References to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.
Spatially relative terms, such as, for example, “under”, “below”, “lower”, “over”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms “upwardly”, “downwardly”, “vertical”, “horizontal” and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.
As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word “about” or “approximately,” even if the term does not expressly appear. The phrase “about” or “approximately” may be used when describing magnitude and/or position to indicate that the value and/or position described is within a reasonable expected range of values and/or positions. For example, a numeric value may have a value that is +/−0.1% of the stated value (or range of values), +/−1% of the stated value (or range of values), +/−2% of the stated value (or range of values), +/−5% of the stated value (or range of values), +/−10% of the stated value (or range of values), etc. Any numerical values given herein should also be understood to include about or approximately that value, unless the context indicates otherwise. For example, in some implementations, the phrase “approximately” may include +/−0.03 mm, +/−0.05 mm, or the like.
This application claims priority to U.S. Provisional Application No. 63/520,604, entitled “PADDLE TECHNOLOGY” filed on Aug. 18, 2023, and U.S. Provisional Application No. 63/637,812, entitled “PADDLE TECHNOLOGY” filed on Apr. 23, 2024, and the contents of which are hereby incorporated by reference.
Number | Date | Country | |
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63637812 | Apr 2024 | US | |
63520604 | Aug 2023 | US |