PICKLEBALL PADDLE HAVING INTEGRAL HANDLE AND RIM ASSEMBLY

BACKGROUND

Fabricating a core serves as a manufacturing platform for assembly of a pickleball paddle. These methods often include attaching a handle, an edge guard, and face plate to the paddle core. One drawback of manufacturing pickleball paddles according to these methods is that the core must be sufficiently rigid to support the paddle. Therefore, rigidity and stiffness of the core are prioritized over other structural design choices such as the frame for performance. Accordingly, performance designs only relay on the face plate innovations. The core and face plate are typically the most expensive and most difficult paddle components to produce. Therefore, it would be desirous to drive performance characteristics using less expensive components of the paddle. Thus, there is need in the art for pickleball paddles having improved manufacturability, reduced cost, with improved performance characteristics and durability.

BRIEF DESCRIPTION OF THE DRAWINGS

To facilitate further description of the embodiments, the following drawings are provided in which:

FIG. 1 illustrates a front perspective view of a pickleball paddle according to an embodiment of the present disclosure.

FIG. 2 illustrates a front perspective view of a pickleball paddle of FIG. 1 with the head subassembly and grip removed.

FIG. 3 illustrates a front perspective view of a coordinate system for the pickleball paddle of FIG. 1.

FIG. 4 illustrates an enlarged detail view of the handle of the pickleball paddle illustrated in FIG. 2.

FIG. 5 illustrates an exploded perspective view of the exterior surfaces of a first handle member a second handle member of the pickleball paddle of FIGS. 2 and 4.

FIG. 6 illustrates an enlarged view of the interior of the first handle member illustrated in FIG. 5.

FIG. 7 illustrates a front view of a pickleball paddle frame according to another embodiment.

FIG. 8 illustrates a cross-sectional view of the pickleball paddle of FIG. 7, sectioned along a longitudinal plane.

FIG. 9 illustrates an exploded view of the rim and head subassembly of the pickleball paddle of FIG. 1.

FIG. 10 illustrates an exploded enlarged side, cross-sectional view of the rim and head subassembly of FIG. 9.

FIG. 11 illustrates an exploded side view of a pickleball paddle according to another embodiment.

FIG. 12 illustrates a perspective view of a cross-section of an integral pickleball paddle core and frame, according to another embodiment.

FIG. 13 illustrates a top view of the integral pickleball paddle core and frame of FIG. 12.

FIG. 14 illustrates a perspective bottom view of throat chamfers of the pickleball paddle of FIG. 11.

FIG. 15 illustrates a detail cross-sectional view of a pickleball paddle frame according to an embodiment of the present disclosure.

FIG. 16 illustrates an enlarged cross-sectional view of a pickleball paddle frame of FIG. 15

FIG. 17 illustrates a perspective view of the assembled pickleball paddle frame of FIG. 15

FIG. 18 illustrates perspective view of a pickleball paddle frame of FIG. 17.

FIG. 19 illustrates an alternative top view of the pickleball paddle frame of FIG. 17.

FIG. 20 illustrates a rear view of a single frame member according to another embodiment showing the interior surface.

FIG. 21 illustrates a perspective view of a frame member of the pickleball paddle of FIG. 20.

FIG. 22 illustrates an enlarged side view of the interior surface of the first frame member of the pickleball paddle of FIG. 20.

FIG. 23 illustrates an enlarged cross-section detail of the frame of the pickleball paddle of FIG. 20.

FIG. 24 illustrates a perspective view of another pickleball paddle embodiment.

FIG. 25 a front view of the pickleball paddle of FIG. 24.

FIG. 26 illustrates an exploded perspective view of the pickleball paddle of FIG. 24.

FIG. 27 illustrates stress map of a comparative pickleball paddle.

FIG. 28 illustrates stress map of a another pickleball paddle embodiment.

BRIEF SUMMARY

Described herein is a pickleball paddle comprising a multi-member frame, a head subassembly, and a handle with a grip. The frame provides rigidity to the pickleball paddle, allowing the head subassembly to be optimized for striking the ball without having to bear the entire load of striking the ball. The multi-member frame comprises first and second frame members joined together at a coupling surface to form the complete frame surrounding an interior cavity. The interior cavity comprises internal structures to stiffen the frame, to mechanically attached the frame members to one another, and to provide bonding surfaces to attach the frame members to one another and to the head subassembly.

Definitions

For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the paddle. Additionally, elements in the drawing figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present disclosure. The same reference numerals in different figures denote the same elements.

The terms “first,” “second,” “third,” “fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein.

Furthermore, the terms “include,” and “have,” and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, device, or apparatus that comprises a list of elements is not necessarily limited to those elements but may include other elements not expressly listed or inherent to such process, method, system, article, device, or apparatus.

The terms “front,” “back,” “top,” “bottom,” “over,” “under,” “north,” “south,” “east,” “west,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the paddle described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

The term “centerward” as used herein describes a direction toward the geometric center of the paddle.

The term “inward” as used herein describes a direction toward the coupling plane.

The terms “couple,” “coupled,” “couples,” “coupling,” and the like should be broadly understood and refer to connecting two or more elements or signals, electrically, mechanically and/or otherwise.

The term “coupling plane” as described herein, can be defined as an imaginary plane extending through the midpoint of the exterior perimeter of a pickleball paddle and its geometric centerpoint dividing the paddle into a front half and back half. Alternately, the “coupling plane” is a plane through the seam or exterior joint of a two-piece paddle frame at the frame members exterior perimeter contact. “Coupling plane” can also refer to an imaginary plane parallel to the face plates, centered between the face plates, and passing through the paddle geometric center. In some cases, the coupling plane is congruent with the XY plane.

The term “geometric centerpoint,” or “geometric center” of the face plate, as used herein, can refer to a geometric centerpoint of the face plate perimeter, and at a midpoint of the face height of the face plate.

The “length” of the pickleball paddle head, as described herein, can be defined as a top-to-bottom dimension of the pickleball paddle. In many embodiments, the length of the paddle can be measured according to a pickleball governing body such as USA PICKLEBALL.

The term “face plate” of the pickleball paddle, as described herein, can refer to one or both of the face plates. The face plate is positioned external relative to the core, and may be externally exposed or may be covered by a hitting surface.

The term “internal cavity” refers to the void defined by the interior surfaces of the first and second frame members.

The terms “paddle stiffness” or “paddle rigidity,” as used herein, are interchangeable and refer to a the resistance of a paddle secured at the handle to a cantilever force pressing against the paddle surface.

An “XYZ” coordinate system of a pickleball paddle, as described herein, is based upon the geometric center of the face plate. The pickleball paddle face dimensions as described herein can be measured based on a coordinate system as defined below. The geometric center 10 of the face plate defines a coordinate system having an origin located at the geometric center 10 of the face plate. The coordinate system defines an X axis 20, a Y axis 30, and a Z axis 40. The X 20 axis extends through the geometric center 10 of the face plate the lateral edges of the paddle face. The Y axis 30 extends through the geometric center of the face plate in a direction from the butt end to upper rim of the pickleball paddle head. The Y axis 30 is perpendicular to the X axis 20. The Z axis 40 extends through the geometric center 10 of the face plate in a direction from one face plate to the other on the pickleball paddle head. The Z axis 40 is perpendicular to both the X axis 20 and the Y axis 30, extending in a front to back direction.

The XYZ coordinate system of the pickleball paddle head, as described herein defines an XY plane extending through the X axis and the Y axis. The coordinate system defines XZ plane extending through the X axis and the Z axis. The coordinate system further defines a YZ plane extending through the Y axis and the Z axis. The XY plane, the XZ plane, and the YZ plane are all perpendicular to one another and intersect at the coordinate system origin located at the geometric center of the face plate. In these or other embodiments, the pickleball paddle head can be viewed from a front view when the face plate is viewed from a direction perpendicular to the XY plane. Further, in these or other embodiments, the pickleball paddle head can be viewed from a side view or side cross-sectional view when the lateral edge is viewed from a direction perpendicular to the YZ plane.

DESCRIPTION

Pickleball paddles described herein have improved performance characteristics and manufacturability. More specifically, a structural frame retaining the paddle core within reduces the need for the core of the paddle to both bear the stresses of impact and provide desirable impact performance. Accordingly, the core may instead be designed primarily for impact performance, while the structural frame is configured to provide paddleshaping rigidity and improved durability. Additionally, the structural frame can be formed using manufacturing techniques such as injection molding, co-molding, or additive manufacturing which are cost and time effective. These manufacturing techniques can be used to form complex geometries without incurring significant costs. Therefore, reinforcing structures can be added to the structural frame which enable the frame to be both rigid and lightweight. Reducing the need for the paddle core to be as rigid and including a rigid and lightweight structural frame creates significant mass savings and manufacturing flexibility. Additional discretionary mass created by implementing a structural frame can then be strategically implemented elsewhere to improve paddle impact performance. For example, discretionary mass can be placed around the paddle perimeter to increase paddle moment of inertia and/or alter the location of the paddle's center of gravity.

I. Multi-Component Paddle

In the embodiment described below, pickleball paddle frames can provide mechanical means for assembling the paddle by attachment bosses, ribs, and other frame features. These frame further provide adhesive bond surfaces for securing the other load bearing components such as the core and handle of the paddle. Referring to FIGS. 1-11, the pickleball paddle (100, 200) can comprise multiple components including a head subassembly (101, 201) and a frame (106, 206). The frame (106, 206) has a rim surrounding a frame aperture, a handle, and a y-shaped throat connecting the rim and the handle. The head subassembly (101, 201) comprises multiple layers including at least two face plates (102, 202), and a core (104, 204), which are joined together. In some embodiments, adhesive, damping, and structural layers may also be added to the head subassembly between the face plates and the core. The face plates (102, 202) are joined to opposite sides of the core (104, 204) and can form surfaces that impact the ball during play. The core (104, 204) is located between the face plates (102, 202). The edges of the core (104, 204) not covered by the face plates (102, 202) comprise a core (104, 204) perimeter portion.

The complete paddle (100, 200) can comprise the frame (106, 206), the core (104, 204), and the face plates (102, 202). The frame (106, 206) has a rim surrounding a frame aperture, a handle, and a y-shaped throat connecting the rim and the handle. The complete paddle can comprise a total mass, a center of gravity, a geometric centerpoint, a swing weight (a static measure approximating rotational inertia in the YZ plane), a twist ozoz (a measure of torsional strength), a recoil weight (a measure of linear moment of inertia), and a spin weight (a measure of resistance to rotational motion in the XY plane), all of which can be modified by strategically positioning discretionary mass.

The total mass of the complete paddle can range from 7.0 oz to 9.5 oz (198 grams to 270 grams). In some embodiments, the total mass of the complete paddle can be between 7.0 oz and 7.5 oz, 7.5 oz and 8.0 oz, 8.0 oz and 8.5 oz, 8.5 oz and 9.0 oz, or 9.0 oz and 9.5 oz. In some embodiments, the total mass can be greater than 7.0 oz, greater than 7.5 oz, greater than 8.0 oz, greater than 8.5 oz, or greater than 9.0 oz.

In many embodiments, the paddle center of gravity (CG) can be located near a center point of the hitting surface. Using a frame containing the paddle head subassembly (core and face), allows more control over mass distribution than a paddle design with a monolithic core and handle because the frame mass is independent from the paddle head subassembly mass. The CG can be positioned along a longitudinal plane halfway between the first and second lateral regions (113, 115). In some embodiments, the center of gravity can be positioned between 9 and 10 inches above the end cap or butt end of the paddle, along the longitudinal plane.

The assembled pickleball paddle (100, 200) has a rim, a handle, and a y-shaped throat connecting the rim and handle, and further comprises front and back sides, a top rim region 114, a butt end (159, 259) having an end cap (117, 217), and two lateral sides (113, 115) of the rim. The pickleball paddle (100, 200) can comprise a maximum paddle length measured from a distal handle end or butt end 159 to a topmost rim exterior point. The paddle length can be in a range of 14 inches to 17.5 inches. The paddle length may be 14.0 inches, 14.5 inches, 15.0 inches, 15.5 inches, 16.0 inches, 16.5 inches, 17.0 inches, or 17.5 inches. The pickleball paddle (100, 200) can comprise a maximum paddle width measured perpendicular to the paddle length. The paddle width can be in a range of 6.5 inches to 8.5 inches. The paddle width may be 6.5 inches, 7.0 inches, 7.5 inches, 8.0 inches, or 8.5 inches. A pickleball paddle has two planar faces. One face is the front side face and the other is the back or rear side face. The pickleball paddle (100, 200) can comprise a maximum paddle thickness measured perpendicularly between the front side and the back side. The maximum paddle thickness can be between 0.5 inch and 1.25 inches. In some embodiments, the assembled paddle thickness can be between 0.5 inch and 0.75 inch, 0.75 inch and 1.0 inch, 1.0 inch and 1.25 inches. The maximum paddle thickness may be 0.5 inch, 0.6 inch, 0.7 inch, 0.8 inch, 0.9 inch, 1.0 inch, 1.1 inches, 1.2 inches, or 1.25 inches.

Paddle Head Subassembly

As mentioned previously, the paddle (100, 200, 300) can comprise a paddle head subassembly (101, 201) surrounded by the frame rim and throat. Referring to FIGS. 9-12, the paddle head subassembly (101, 201) can comprise a plurality of layers on the front side and back side of the core. The layers may be striking surface layers, adhesive layers, damping layers, or layers of materials that provide a variety of mechanical properties such as rigidity, wear resistance, sound control, etc. The paddle head subassembly (101, 201) can comprise a single layer on the front side and back side of the core (104, 204). The paddle head subassembly (101, 201) can comprise two face plates (102, 202) and a core 204. The core 204 can be positioned between the two face plates (102, 202). In many embodiments, the two face plates (102, 202) are identical to one another. An exterior side of each face plates (102, 202) comprises a hitting surface (162, 262). An interior side of each face plate (102, 202) contacts either the core 204, a sheet coupled to the core 204, or a backing layer (120, 220).

In many embodiments, the core 204 can have a corrugated structure. In some cases the corrugated structure resembles a honeycomb structure, as shown in FIG. 12. The corrugated structure can comprise a plurality of repeated structures arranged side by side. In some embodiments, the corrugated structure can comprise polypropylene. In other embodiments, the corrugated structure can comprise nylon, polymer, or aluminum. The core 204 can comprise a constant thickness or a varying thickness.

In some embodiments, an adhesive layer, such as an epoxy sheet film, can be used to adhere the core to the face plates (102, 202) while also increasing the surface area of the core. The core can be adhered to the face plates (102, 202) using adhesives, tapes, epoxies, mechanical fastener assemblies, and any combination thereof. In other embodiments, the face plates (102, 202) may be clamped to the core by the rim (103, 203), fasteners within the rim (103, 203), or weighting members. Manufacturing and assembly methods are discussed in more detail below.

In some embodiments, the core (104, 204) comprises a core extension 222 enclosed within the interior of the throat (116, 216). Referring to FIG. 12, in some embodiments, the core extension 222 entirely fills the interior of the throat (116, 216), whereas in other embodiments the core extension 222 stretches only partially into the throat (116, 216). In other embodiments, the core (104, 204) does not comprise a core extension 222 which stretches into the interior of the throat (116, 216) and the core (104, 204) is contained entirely within the rim (103, 203). A paddle assembled with a core extension 222 moves the largest stress concentration from the top of the throat to an area further down the throat toward the butt end, allowing the frame 106 to have a greater bondline contact with the head subassembly 101, and to provide reinforcement structures 141 to mitigate the higher stress concentration than is possible to provide at the top of the throat along the frame aperture 154.

The core can comprise a core length. The core length is measured from a bottom end to a top end. In some embodiments, the core length can be between 7 inches to 17 inches. In some embodiments, the core length can be between 7 inches to 8 inches, 8 inches to 9 inches, 9 inches to 10 inches, 10 inches to 11 inches, 11 inches to 12 inches, 12 inches to 13 inches, 13 inches to 14 inches, 14 inches to 15 inches, 15 inches to 16 inches, or 16 inches to 17 inches. In one exemplary embodiment, the core length is 11.75 inches.

The core can comprise a core width. The core width is measured from the first lateral region 113 to the second lateral region 115. In some embodiments, the core width can be between 7 inches to 17 inches. In some embodiments, the core width can be between 7 inches to 8 inches, 8 inches to 9 inches, 9 inches to 10 inches, 10 inches to 11 inches, 11 inches to 12 inches, 12 inches to 13 inches, 13 inches to 14 inches, 14 inches to 15 inches, 15 inches to 16 inches, or 16 inches to 17 inches. In one exemplary embodiment, the core width is 7.5 inches.

The core can comprise a core thickness. In some embodiments, the core thickness can be between 0.50 inch and 1.0 inch. In some embodiments the core thickness can be between 0.50 inch to 0.6 inch, 0.6 inch to 0.7 inch, 0.7 inch to 0.8 inch, 0.9 inch to 1.0 inch. In some embodiments, the core thickness can be less than 1.0 inch, less than 0.9 inch, less than 0.8 inch, less than 0.7 inch, or less than 0.6 inch.

Hitting Surface

The face plates provide the exterior surfaces of the paddle head subassembly, covering the core and any other internal or backing layers. The face plates conform to the shape of the rim, and are partially covered by the rim around a paddle head subassembly perimeter. The face plates (102, 202) can comprise a generally rounded-edge rectangular shape with the second lateral region 115 and the first lateral region 113 generally parallel to each other and the throat (116, 216) and the top rim region 114 being curved. In some embodiments, the entire perimeter can be curved to different radii throughout. In other embodiments, the second lateral region 115 and the first lateral region 113 comprise straight regions, while the remaining perimeter is curved.

The face plates (102, 202) may be comprised of metals, polymers (e.g. thermoplastic polyurethane, thermoplastic elastomer), composites, plastics, carbon fiber, Kevlar, or any combination thereof. In some embodiments, the face plates (102, 202) can be made of a metal material such as aluminum, titanium, magnesium, nickel alloy, titanium alloys, aluminum alloy, or any other metal or combination of metals suitable for use in a pickleball paddle face. In some embodiments, as described in detail below, the face plate (102, 202) can comprise multiple layers. These layers can be metals, or a combination of a metal, plastic, carbon fiber, and/or fiberglass. In some of these embodiments, each face plate (102, 202) (102, 202) comprises a backing layer. In many of these embodiments, one of the face plates (102, 202) and the backing layer is metal, while the other is a composite or polymer material. In other embodiments, the face plate (102, 202) (102, 202) materials are chosen from a group consisting of carbon fiber, fiberglass, or graphite.

The face plates (102, 202) can comprise a face plate maximum length. The face plate maximum length is measured from a bottom edge of the rim to a top rim region 114 along the Y-axis. In many embodiments, the face plate (102, 202) length matches the core length, covering the entire core. In other embodiments, the face plate (102, 202) length is smaller than the core length, leaving part of the core uncovered. In some embodiments, the face plate (102, 202) length can be between 7 inches to 17 inches. In some embodiments, the face plate (102, 202) length can be between 7 inches to 8 inches, 8 inches to 9 inches, 9 inches to 10 inches, 10 inches to 11 inches, 11 inches to 12 inches, 12 inches to 13 inches, 13 inches to 14 inches, 14 inches to 15 inches, 15 inches to 16 inches, or 16 inches to 17 inches. In one exemplary embodiment, the face plate (102, 202) length is 11.75 inches.

The face plates (102, 202) can comprise a face plate (102, 202) width. The face plate (102, 202) width is measured from a first lateral region 113 to a second lateral region 115 parallel to the X-axis. In many embodiments, the face plate (102, 202) width matches the core length covering the core entirely. In other embodiments, the face plate (102, 202) width is smaller than the core width, leaving part of the core uncovered. In some embodiments, the face plate (102, 202) width can be between 7 inches to 17 inches. In some embodiments, the face plate (102, 202) width can be between 7 inches to 8 inches, 8 inches to 9 inches, 9 inches to 10 inches, 10 inches to 11 inches, 11 inches to 12 inches, 12 inches to 13 inches, 13 inches to 14 inches, 14 inches to 15 inches, 15 inches to 16 inches, or 16 inches to 17 inches. In one exemplary embodiment, the face plate (102, 202) width is 7.5 inches.

The face plates (102, 202) can comprise a face plate (102, 202) thickness. In some embodiments, the face plate (102, 202) thickness can be between 0.001 inch and 0.013 inch. In some embodiments the face plate (102, 202) thickness can be between 0.001 inch to 0.003 inch, 0.003 inch to 0.005 inch, 0.005 inch to 0.007 inch, 0.007 inch to 0.009 inch, 0.009 inch to 0.011 inch, 0.011 inch to 0.013 inch. In some exemplary embodiments, metallic face plates (102, 202) can have a thickness between 0.003 inch and 0.010 inch.

Frame

The paddle head subassembly provides a portion of the structural rigidity to the pickleball paddle. The head subassembly (101, 201) is joined to the frame (106, 206), which supports the head subassembly (101, 201) and imparts additional structural rigidity to the pickleball paddle. The frame (106, 206) includes both a rim (103, 203) that at least partially surrounds the head subassembly (101, 201), and a handle (105, 205) for gripping the paddle (100, 200). The rim (103, 203) and handle (105, 205) together define a perimeter of the frame (106, 206). The handle (105, 205) can be attached to or formed integrally with the rim (103, 203). The handle (105, 205) and rim (103, 203) can also be joined by a throat (116, 216). The throat (116, 216) provides a transition region between the handle and rim (103, 203), which can reduce stress concentrations where the handle (105, 205) and rim (103, 203) meet. The throat (116, 216) has a generally y-shaped structure, where the two upward arms attach to the two lateral sides of the frame. The upper boundary of the throat begins when each of the two lateral sides cease being parallel and begin to curve toward the bottom region. The lower boundary of the throat begins at the uppermost constant width section of the handle. In further embodiments, the second lateral region 115, first lateral region 113, and top rim region 114 comprise straight regions while the remaining rim perimeter is curved.

A handle, (105, 205) extends downward from the throat as a solid or hollow projection having an approximately cylindrical or rounded, rectangular prism shape. The handle (105, 205) can provide the user with a surface that can be used to grip the paddle. In some embodiments the handle (105, 205) can include a grip 138 which is overlaid on the handle to improve comfort, as discussed in further detail below. The handle can include an end cap (117) proximate the distal or butt end of the paddle, as shown in FIG. 7. Additionally, the handle can comprise several geometries to improve player comfort and ensure the player does not drop the paddle during play. As shown in FIG. 3, the handle can include a first handle transition surface 152 where the handle (105, 205) tapers from its largest size proximate the distal handle end. The handle (105, 205) can further include a second handle transition surface 153 where the handle (105, 205) ends and the throat (116, 216) begins.

As shown in FIG. 6, the rim (103, 203) can comprise four regions: a top rim region 114, a second lateral region 115, a first lateral region 113, and a throat (116, 216). The top rim region transitions into each of the first and second lateral regions. The first and second lateral regions each transition into the throat. These four regions form a continuous rim (103, 203) surrounding and defining a frame aperture (154, 254). When the paddle is assembled and the head assembly fills the frame aperture (154, 254) and is partially encased by frame rim 203. Each of the subcomponents of the rim (103, 203) can be formed separately to facilitate manufacturing and assembly. Alternatively, the four subcomponents can be integrally formed to improve the rigidity of the frame. In some embodiments, as exemplified in FIGS. 10 and 18-20, the rim (103, 203) can be formed as two members, dividing the frame approximately about the XY plane, which are then joined together. Each of the two frame members can define a ‘Y’ shaped throat (116, 216), including the handle (105, 205) or handle support 139, the top rim region, and the first and second lateral regions (113, 115). The throat region of each frame member (218, 219) may further comprise a convex throat protrusion 232 extending centerward to further support the lower portion of the core 204. Alternately, the upper throat edge 171 may be flat between the throat arms, or may form a concave dip, lowering the upper throat edge 171 towards the handle 105. The throat (116, 216) comprises a throat maximum width and a throat maximum length. The throat maximum length is measured along the Y-axis 30 from the topmost portion of the second handle transition surface 153 to the rim inner perimeter surface. The throat maximum length is in the range of 0.75 inch to 1.50 inches. The throat maximum length may be 0.75 inch, 0.80 inch, 0.85 inch, 0.90 inch, 0.95 inch, 1.00 inch, 1.05 inches, 1.10 inches, 1.15 inches, 1.20 inches, 1.25 inches, 1.30 inches, 1.35 inches, 1.40 inches, 1.45 inches, or 1.50 inches. The throat maximum width is measured from the internal rim points on each side of the longitudinal plane where the bonding surface width transitions to the throat 235 such that the bonding surface width is increasing moving toward the longitudinal plane. The maximum throat width is in a range of 1.5 inches to 2.5 inches. The maximum throat width may be 1.5 inches, 1.6 inches, 1.7 inches, 1.8 inches, 1.9 inches, 2.0 inches, 2.1 inches, 2.2 inches, 2.3 inches, 2.4 inches, or 2.5 inches.

As discussed above, the frame (106, 206) structurally supports the paddle and provides a portion of the paddle stiffness or rigidity. Paddle stiffness or rigidity requirements are, in part, driven by the need to absorb the forces applied to the paddle during impact with a ball. These impact forces are transferred from the face plates (102, 202) to the core (104, 204) during impact. To aid the core (104, 204) in absorbing impact forces, current paddles implement a core (104, 204) that also forms the paddle handle (105, 205), where it is anchored by the user's grip. Consequently, these paddles require a core material that is sufficiently strong and durable to absorb impact forces. Furthermore, these forces may concentrate stresses in a region where the unsupported core meets core anchored in the handle. On the other hand, paddles constructed according to the present disclosure include a head subassembly (101, 201). The head subassembly (101, 201) may be mechanically or adhesively joined to the rim (103, 203). Joining the rim (103, 203) to the head subassembly (101, 201) allows impact forces to be transferred from the face plates (102, 202) to the frame (106, 206). By eliminating stress concentrations in the core and supporting the paddle with a structural frame the pickleball paddles disclosed herein can comprise a less rigid head subassembly (101, 201). Therefore, the head subassembly (101, 201) can be designed with a greater focus on paddle performance characteristics including feel, sound, forgiveness, spin, and power and less focus on rigidity.

Single Component Frame

In some embodiments, the frame (106, 206) may can be comprised of a single, monolithic piece having the rim, throat, and handle molded or cast as a single component. In this embodiment, the head subassembly (101, 201) is inserted into the frame aperture (154, 254), with the head subassembly perimeter surrounded by the rim (103, 203), securing the head subassembly (101, 201) within the frame (106, 206).

Single Rim with Handle

In some embodiments, the frame can include a unitary rim as shown in FIGS. 1-5. The unitary rim 103 is coupled to a single or multi-component handle. Multi-component handles can be manufactured with one or more identical pieces to reduce the need for additional tooling and increase ease of assembly. The handle 105 can comprise a first handle member 107 and a second handle member 108, as best shown in FIGS. 4 and 5. As shown in FIGS. 4 and 5, the first handle member 107 and the second handle member 108 can be identical pieces with complementary coupling geometry including fastener bores 110. The first handle member 107 and the second handle member 108 can cooperate to define a slot proximate the rim 103. The rim 103 can include a throat extension 222, similar to that shown in FIG. 9. The slot of the handle 105 can be configured to receive the throat extension 222. The throat extension 222 can be secured to the handle 105 by mechanical fastener(s) and/or adhesive(s), or it can be secured by adhesive, press-fit, or another means.

In another embodiment, the rim 103 can comprise an internal handle support 112 that extends partially or entirely through the handle 105. The internal handle support 112 can be integrally formed with the rim 103, or be integrally formed with the handle 105. The internal handle support 112 can provide strength that assists in stress distribution to prevent stress accumulation in the handle-rim joint 170. The handle support 112 can further comprise a plurality of bosses 111 that serve as receivers for mechanical fasteners. One or both of the rim 103 and the handle 105 can be injection molded or cast. They can be formed from an injection moldable plastic or composite, or can be a cast metal, such as titanium or aluminum, to provide additional strength. Because the rim 103 only surrounds the paddle head subassembly periphery, it comprises a relatively small amount of material, allowing a heavier material to be used to increase strength, stiffness, and perimeter weighting, while maintaining a low total mass.

Referring to FIGS. 7-9, the core 104 and the face plates 102 can be shaped to join with the loop formed by the rim 103. The core 104 is sized to be small enough to fit within the rim 103 and fill the entire space within the rim 103. In many embodiments, the face plates 102 are larger than the core 104, and they do not fit within the rim 103. Instead, in these embodiments, the face plates 102 extend beyond the core periphery and cover the edge of the rim 103. The edges of the face plates 102 can form the periphery of the rim 103, and lay flush with the periphery of the rim 103. In these embodiments, the rim 103 does not make up any part of the hitting surface, nor does it surround the hitting surface. In these embodiments, the core 104 can comprise a depth that matches the depth of the rim 103 to create an even surface across the core 104 and the rim 103, when joined. In some embodiments, the core 104 can comprise a depth that is slightly less than the depth of the rim 103, leaving room for a backing layer, damping layer, filler, or adhesive to be positioned between the core 104 and the face plates 102, while allowing the face plates 102 to sit even with the rim 103.

Mirrored, Two-Piece Component Frame

The multi-component paddle is designed to maximize performance for the user, minimize manufacturing cost, and reduce complexity to support consistent quality of the paddle. Separating the functionality of head subassembly (face response) from the functionality of frame (mechanical support and rigidity) provides both improved functionality and design flexibility. To improve manufacturing quality and reduce manufacturing cost, the frame can be configured to be mating members that encompass the head subassembly.

Disclosed herein are embodiments of a pickleball paddle comprising a multi-component frame (106, 206) that structurally supports a head subassembly (101, 201) to provide a sufficiently rigid pickleball paddle (100, 200). In one embodiment, as shown in FIGS. 10 and 16-24, the multi-component frame 106 comprises first and second frame members (218, 219) that are bonded together and encase the periphery of a paddle head subassembly (101, 201). In another embodiment, as shown in FIGS. 1-5, and 8, the multi-component frame comprises a single piece rim (103, 203) that wraps around a paddle head subassembly (101, 201) and comprises a handle support 139 that is received by a separate handle 105.

In some embodiments, the frame (106, 206) can be formed entirely from two components or members to reduce manufacturing costs and increase frame (106, 206) rigidity. A two-component structural frame (106, 206) formed of two members, wherein each member of the two-component structural frame (106, 206) comprises a rim 203, a throat (116, 216), and a handle (105, 205), is illustrated in FIGS. 10-20. This simple two-component frame construction facilitates quick and easy assembly and production while providing necessary structural support to the paddle. The two members (218, 219) engage each other along a coupling surface and are mechanically or adhesively joined to the paddle head subassembly 201, thereby forming the outer surface of the paddle 200. In doing so, the present disclosure provides a two-component frame pickleball paddle 200 that is easier to manufacture by way of cost and time than existing designs, while maintaining desirable performance and feel properties.

In some embodiments the entire frame (106, 206) can be made up of two separate members as exemplified in FIGS. 10-20. Specifically, the frame (106, 206) can include a first frame member 218 and a second frame member 219, which are joined to form the paddle rim 203 and handle 205. Each of the first and second frame members (218, 219) can include integrally formed halves of the rim 203 and handle 205. The first and second frame members (218, 219) can be coupled together along a frame mating surface 255 that divides the frame into front and rear portions to form the frame (106, 206). In these embodiments, each frame member (218, 219) can be identical or similar in structure. Since the paddle (100, 200) is formed by joining two similar portions together in a mirrored configuration, manufacturing time and tooling can be reduced. Namely, a single mold can be used to form both portions. Two component frame 206 construction with two identical mirrored members can be used in combination with a wide variety of materials and structures for the head subassembly 201, strengtheners and reinforcers, fillers, and dampers. This enables modularity with the frame member (218, 219) that can be tailored for weighting, damping, strengthening and creation of paddles with potentially different performance characteristics having the two identical frame members (218, 219).

Each frame member (218, 219) comprises a rim 203 and a throat 216. In some embodiments, each frame member may also comprise a handle 205. Each frame member comprises a frame exterior surface 164 that is exposed when the paddle is assembled, and a frame interior surface 165 that is concealed when the paddle is assembled. When the two frame members are assembled, the complete frame will have a frame front exterior surface 177 comprising a rim exterior front surface 178, a throat exterior front surface 179, and a handle exterior front surface 168. When the two frame members are assembled, the complete frame will have a frame front interior surface 180 comprising a rim interior front surface 181, a throat interior front surface 182, and a handle interior front surface 183. When the two frame members are assembled, the complete frame will have a frame rear exterior surface 184 comprising a rim exterior rear surface 185, a throat exterior rear surface 186, and a handle exterior rear surface 187. When the two frame members are assembled, the complete frame will have a frame rear interior surface 187 comprising a rim interior rear surface 188, a throat interior rear surface 189, and a handle interior rear surface 189. The complete frame will further comprise a frame exterior perimeter surface 191 and a frame interior perimeter surface 192. The frame interior cavity 240 is defined by the front and rear rim, throat, and handle interior surfaces.

Each frame member (218, 219) comprises a frame member exterior surface 164 comprising the frame member rim, throat, and handle exterior surfaces, and a frame member interior surface 165 comprising the frame member rim, throat, and handle exterior surfaces. The frame member exterior surface 164 forms a portion of the paddle outer surface 163. The frame member interior surface 165 may include voids and/or structures that are not visible on the fully assembled paddle. Each frame member (218, 219) comprises a frame front outer perimeter 173, a frame front inner perimeter 174, a frame rear outer perimeter 175, and a frame rear inner perimeter 175. Referring to FIG. 19, an outer rim wall 256 and an inner rim wall 257 connect to one another to form an angle between 60 degrees and 110 degrees. When the paddle 200 is assembled, the outer rim wall 256 of each frame member (218, 219) abuts the other along a frame coupling surface 255 between the frame member interior surface 165 and the frame member exterior surface 164 and forms the paddle outer rim surface. Each outer rim wall 256 comprises an outer rim wall thickness. Each outer rim wall 256 comprises an outer rim wall height. The outer rim wall height for each frame is in a range of 0.30 inch to 0.50 inch. Each outer rim wall height may be 0.30 inch, 0.35 inch, 0.40 inch, 0.45 inch, or 0.50 inch. The rear surface of each frame member outer rim wall is defined by the outer rim wall thickness, and may be adhesively secured to the matching outer rim wall rear surface of the opposing frame member when the paddle is assembled. The outer rim wall thickness measured perpendicularly from a point on the exterior surface to the inner surface and is in a range of 0.030 inch and 0.150 inch. The outer rim wall thickness may be 0.030 inch, 0.040 inch, 0.50 inch, 0.60 inch, 0.70 inch, 0.80 inch, 0.90 inch, 0.100 inch, 0.110 inch, 0.120 inch, 0.130 inch, 0.140 inch, or 0.150 inch.

When joined, the first frame member 218 and the second frame member 219 can define an outer shell and an internal cavity 240 defined by the internal surfaces of the rim, throat, and handle. The internal cavity 240 can comprise reinforcing structures, bonding structures, and/or dampening materials used to modify the feel and sound of the paddle, as discussed further below.

a) Internal Cavity Structures

Discretionary mass created via the mass-saving features disclosed herein can be allocated to adding various structures to the internal cavity 240. Weight savings from the frame (106, 206) construction may partially or entirely offset the weight of the internal cavity structures 241, thereby maintaining the same overall paddle weight. Internal cavity structures (241) can be used to create a variety of advantages. These internal cavity structures 241 can aid in producing a paddle with more desirable feel or sound. In some embodiments, discretionary mass can be allocated to add damping features, locating specific weighting members, structures to improve bonding, or materials to reduce sound and vibration. These internal cavity structures 241 can aid in producing a paddle with better playability. In some embodiments, reinforcing structures may be disposed within the internal cavity 240 to increase rigidity and/or improve one or more performance characteristics. These reinforcing internal cavity structures 241 can increase strength in high stress regions to prevent failure.

As discussed above, the structurally supportive frame (106, 206) disclosed herein reduces the burden traditionally placed on the core (104, 204) to serve as the paddle backbone. Therefore, internal cavity 240 construction can allow core design to prioritize impact performance characteristics instead of structural rigidity. Further, structural material within the internal cavity 240 can be replaced with damping materials to damp sound and vibration. The damping materials can comprise foams, polymers, plastics, or the like. In one exemplary embodiment, the internal cavity structures (141, 241) can comprise a damping material comprised of cork. In another exemplary embodiment, the core (104, 204) can comprise a damping material comprised of injected acoustic foam. The damping material(s) can minimize vibrations to improve sound upon impact with a pickleball.

Reinforcing Structures

Internal cavity structures (141, 241) formed within the internal cavity 240 can strengthen the frame 206 and absorb vibration without adding significant amounts of mass. Further, the internal cavity structures (141, 241) can improve rigidity and durability of the paddle and can be lightweight to increase available discretionary mass. Referring to FIGS. 8, 11, and 17-22, some internal cavity structures (141, 241) may be provided as one or more reinforcing structures (141, 241). Reinforcing structures (141, 241) can comprise ribs, trusses, bars, channels, bosses, rods, beams, coils or the like that extend across the entire frame internal cavity 240 from one portion of the paddle rim 203 to another non-adjacent portion of the paddle rim 203. In some embodiments, the reinforcing structures (141, 241) can be suspended, such that they do not contact either of the face plates (102, 202). In other embodiments, the reinforcing structures (141, 241) can be suspended across the internal cavity 240 such that they do not contact any portion of the paddle rim 203. In one example, suspended reinforcing structures (141, 241) can be positioned within the core (104, 204), and can extend from one face plate (102, 202) to the other face plate (102, 202). In another example, handle-nested reinforcing structures (141, 241) which do not contact any portion of the paddle rim 203 can extend from the first handle member (107, 207) to the second handle member (108, 208) or otherwise across the handle (105, 205). Reinforcing structures (141, 241) can further comprise secondary reinforcing structures which can connect one or more primary reinforcing structures.

The internal cavity (240) can comprise a first primary reinforcing structure and a second primary reinforcing structure. The first and second primary reinforcing structures can extend from one portion of the paddle rim (103, 203) to another non-adjacent portion of the paddle rim (103, 203). The first and second primary reinforcing structures can extend parallel to one another across the internal cavity (240). The internal cavity (240) can further comprise two secondary reinforcing structures extending in a direction perpendicular to the direction of the first primary reinforcing structure. Further, the two secondary reinforcing structures can connect the first primary reinforcing structure to the second primary reinforcing structure. In this manner the first and second primary reinforcing structures in conjunction with the secondary reinforcing structures can segment the internal cavity (240) into multiple internal pockets (151, 251). In one example, the primary reinforcing structures can be ribs 233 extending within the internal cavity (240) such that they join the first frame member 218 and second frame member 219. The primary reinforcing structures can extend along a longitudinal axis of the rim, and secondary reinforcing structures can extend between adjacent primary reinforcing structures. One additional benefit of reinforcing structures (141, 241) is the formation of channels or pockets within the internal cavity (240).

As discussed above, the structural frame disclosed herein is meant to be the primary means of support for the paddle and must be capable of withstanding impact forces and other loads associated with paddle use. When anchored by a user's hand placed on the grip, the paddle responds to loading similarly to a cantilevered beam. This creates high stress concentrations in the throat (116, 216) as well as the surrounding portions of the grip and rim. Therefore, reinforcing structures 241 are particularly effective when placed proximate these high stress areas, as shown in FIGS. 21-22. A throat reinforcement wall 234 can be formed in the throat (116, 216) to provide additional rigidity and absorb stress near the throat (116, 216). The throat reinforcement wall 234 can extend from both sides of the throat (116, 216) into the handle 205, joining together to form a handle reinforcing structure 237. The rim 203 to provide support to these portions of the frame (106, 206). The throat reinforcement wall 234 can be integrally formed with the frame (106, 206). Additional reinforcement structures 241 can be used in addition to the throat reinforcement wall 234 to more evenly distribute stresses throughout the frame (106, 206). As shown in FIGS. 21-22, ribs 233 can extend between the throat reinforcement wall 234, bonding surface 229, and/or lateral bonding surface 230. Wall strengthening ribs 236 can protrude from the interior surface of the throat without contacting other reinforcing structures 241 or frame surfaces. Forming the ribs 233 and/or throat reinforcement wall 234 such that they are integral with bonding surface 229 and/or lateral bonding surface 230 allows impact forces to be efficiently transferred from the face plates (102, 202) to the frame (106, 206).

Bonding Surface Structures

Bonding surfaces are used to attach the frame to the head subassembly, and to attach frame components to each other. The interior surface of the inner rim wall 257 can define the bonding surface 229 primarily used in adhering the head subassembly to the frame. The interior surface of the outer rim wall 256 can define the lateral bonding surface 230. The lateral bonding surface 230 comprises a lateral bonding surface height in a range of 0.25 inch to 0.45 inch measured in an exterior surface to interior surface direction. The lateral bonding surface height may be 0.25 inch, 0.30 inch, 0.35 inch, 0.40 inch, or 0.45 inch. The bonding surface 229 comprises a bonding surface width measured in and exterior rim wall to interior rim wall direction perpendicular to the exterior rim wall in a range of 0.100 inch to 0.200 inch. The bonding surface width may be 0.100 inch, 0.110 inch, 0.120 inch, 0.130 inch, 0.140 inch, 0.150 inch, 0.160 inch, 0.170 inch, 0.180 inch, 0.190 inch, or 0.200 inch. The bonding surface width may be constant around the rim perimeter, only changing when the bonding surface (229?, 230?) transitions to the throat 216.

Mechanical attachment structures such as bosses can be added to provides the internal cavity to provide stabilization, alignment, and registration during an adhesive bonding process. As shown in FIGS. 25-27, a plurality of bosses 211 can be located within the frame internal cavity 240 defined by the first and second frame members (218, 219) to help guide and secure the first and second frame members (218, 219) together. The plurality of bosses 211 can, for example, define fastener bores (110, 210) and be configured to receive mechanical fasteners to secure the two halves of the frame together. In one embodiment, each opposing boss is in a female configuration, with an identical bore in each boss. In this embodiment, a peg can be press-fit into both bores in the opposing bosses, serving to mechanically couple the two bosses together. The bores in the bosses and the pegs are configured to match the bore interior shape to the peg exterior shape. The pegs and bores may be cylindrical or have a polygonal shape. A boss has a base attached to the frame member and a boss top end extending towards the coupling plane. Each boss top end may extend equally toward the coupling plane, or one boss can extend past the coupling plane while its matching boss on the other frame member is recessed from the coupling plane. A boss 211 on one frame member may comprise a blind hole to receive a boss 211 configured as a solid peg on the other frame member. The bosses within the internal cavity may have a boss external diameter. The plurality of bosses may have the same external diameter. The boss external diameter may vary among the plurality of bosses. Bosses located in the rim may have a smaller external boss diameter than bosses located in the throat or handle. The external boss diameter may vary in a range between 0.1 inch and 0.5 inch. The external boss diameter may be 0.1 inch, 0.2 inch, 0.3 inch, 0.4 inch, 0.5 inch. Bosses may serve both to mechanically couple two frame halves together and serve to constrain lateral movement when the frame halves are bonded together.

In other embodiments, the frame members (218, 219) can be coupled by mechanical fasteners, ultrasonic welding, adhesives, or any other suitable method for coupling. In one embodiment, the one or more injection molded pieces can comprise the same thermoset resin component to allow bonding without the need for an intermediate adhesive. As discussed in further detail below, frames which are mated via adhesive means (such as epoxy) may require internal cavity structures 241 which direct adhesive flow to ensure proper bonding and reduce the amount of epoxy needed. These internal cavity structures 241 can include the bosses 211, ribs 233, or reinforcing structures (243, 244) discussed above. Alternatively, internal cavity structures dedicated to epoxy retention may be included, such as epoxy retention lip 228, best shown in FIG. 17. The epoxy retention lip 228 can prevent epoxy from spreading beyond the bonding surface 229. The epoxy retention lip 228 comprises an epoxy retention lip height measured perpendicular to the bonding surface interior surface. The epoxy retention lip height is in a range from 0.010 inch to 0.050 inch. The epoxy retention lip height may be 0.010 inch, 0.015 inch, 0.020 inch, 0.025 inch, 0.030 inch, 0.035 inch, 0.040 inch, 0.045 inch, or 0.050 inch.

II. Bonding

The multiple paddle parts described above can be coupled by any one or combination of the following methods: adhesive (such as epoxy or tape), heating and pressing, ultrasonic welding, mechanical fasteners, and mechanical locking or retaining structures. Adhesive bonding may create bonds between the frame and the head subassembly. When the frame comprises multiple components, adhesive bonding may also adhere the frame components to each other. In some cases, internal cavity features may serve to increase the bonding area to provide additional surface area for one component to be attached to another component. In other cases, internal cavity features may provide adhesive positioning or control features to confine the adhesive into the desired locations, while inhibiting the spread of the adhesive to other, non-desirable locations.

The internal cavity 240 may further comprise internal cavity features such as ribs 233, channels, fins, a lip 228, ledges, or other surfaces to increase the magnitude of bonding surfaces when joining the two frame halves adhesively. The ribs or fins may extend past the coupling plane and be configured to be received in channels or recesses when two frame halves are mirrored and fitted together to form a tongue and groove joint. In the case where ribs fit into channels to form a tongue and groove joint, the ribs do not entirely fill the channel, leaving space for an adhesive bondline to form between the rib surface and the channel surface. Further, each bonding surface may further comprise gas relief channels allowing air to escape when two bonding surfaces are coated with an adhesive and then pressed together. Each bonding surface may comprise standoff features that ensure two surfaces aren't compressed together to the point that a liquid adhesive is squeezed out from an area, preserving the bondline. Mechanical attachment features, such as tabs or mating bosses, may further enhance a bonded joint between the two halves, providing stability and positioning while the adhesive bond sets. The frame members (218, 219) may be joined by multiple joining methods across the entire frame perimeter, or in particular locations.

A. Adhesive Bonding

Adhesive may be applied to bond the frame members (218, 219) to each other. Adhesive may be applied to bond the frame members (218, 219 to the head subassembly. To facilitate and improve such bonding, the internal cavity structures 241 may be bonding structures. The bonding structures may provide additional surfaces to increase the bond area and they may provide bondline stand off features that allow a minimum depth of adhesive to be retained between the head subassembly and frame members, or between frame members. The bonding structures may be surface ribs 236 or nubs protruding from the frame interior surface a height of 0.01 inch to 0.20 inch. These surface ribs or nubs provide a minimum adhesive depth. The bonding features may be vertical (parallel to the Z-axis) or horizontal (parallel to the XY plane). The bonding features may be rib and channels arranged opposite one another such that a rib on one frame member is received within the channel on the other frame member to form a tongue and groove joint. In this configuration, the rib does not entirely fill the receiving channel, allowing for a minimum bondline to form. A rib received within channel will have a smaller width than the receiving channel.

In some embodiments, the first frame member 218 and the second frame member 219 can be coupled by epoxy. Referring to FIGS. 17-19, the epoxy can be applied to the bonding surface 229, the lateral bonding surface 230, a top region of each rib 233, a top region of the retaining structure, and a top region of the paddle periphery surrounding the entirety of the frame. The first frame member 218 and/or the second frame member 219 can receive epoxy. In some embodiments, the second frame member 219 receives epoxy on the bonding surface 229, the lateral bonding surface 230, a top region of each rib 233, a top region of the retaining structure, and a top region of the paddle periphery, while the first frame member 218 only receives epoxy on the bonding surface 229 and the lateral bonding surface 230. In these embodiments, all the epoxy bonding the first frame member 218 and the second frame member 219 is applied to only one frame member, while epoxy bonding the first frame member 218 and the second frame member 219 to the paddle head subassembly 201 is applied to both frame members.

The frame members overlap with the head subassembly, such that the perimeter of the head subassembly is received within the frame interior cavity. Referring to FIGS. 15-17, the head subassembly is placed in contact with the lateral bonding surface 230 and the bonding surface 229. Lip 228 protrudes above the bonding surface 229, serving to form and minimum bondline thickness between 0.01 inch and 0.2 inch, and also serving to retain the adhesive within the bonding surface 229. The total covering width of the lip 228 and bonding surface 229 bounded by the most centerward lip edge and the lateral bonding surface is in a range of 0.25 inch to 0.75 inch. The total covering width may be 0.25 inch, 0.30 inch, 0.35 inch, 0.40 inch, 0.45 inch, 0.50 inch, 0.55 inch, 0.60 inch, 0.65 inch, 0.70 inch, or 0.75 inch.

Applying the epoxy as described above prepares paddle components for assembly. Once epoxy is applied, the second frame member 219 can be set down, with its interior surface facing up. The paddle head subassembly 201 can be set into its predefined space on the second frame member 219. The reinforcing structures and additional ribs 233 can be used to assist in alignment of the head subassembly 201 and can prevent incorrect assembly. Next, the first frame member 218 can be carefully aligned with the second frame member 219 and placed atop the second frame member 219 and the paddle head subassembly 201. Clamps can be applied to the paddle 200 to press the first frame member 218, the paddle head subassembly 201, and the second frame member 219 together as the epoxy cures. After a pre-determined amount of time, dictated by the epoxy cure time, the paddle 200 can be removed from the clamps and any leftover epoxy can be removed.

As discussed above, the frame can comprise internal cavity structures 241 and additional geometries which help guide and retain the epoxy in desirable locations. The reinforcing structures 241 described above can assist in retaining the epoxy upon the bonding surface of face plates (102, 202) and prevent it from spreading to other areas of the internal cavity 240, thereby reducing weight from excess epoxy and improving bonding. The outer rim wall 256 of each frame member can further comprise an epoxy retention lip 228 that protrudes from the outer rim edge, in a direction toward the adjacent frame member. The epoxy retention lip 228 can contact the face plates (102, 202) and prevent epoxy from spreading to the visible, uncovered surface of the face plates (102, 202).

B. Mechanical Fasteners

In some embodiments, separate mechanical fasteners 209 can be attached to the frame 206 to assist in attachment. In some examples, these mechanical fasteners 209 can be in the form of clips, clamps, tape, screws, pins, or another fastener 209. Clips and clamps can be applied to the outside of the frame, following coupling of the first frame member 218 and the second frame member 219. In many embodiments, the clips or clamps would be used after another coupling method is used to initially couple the frame members and would provide additional security to prevent decoupling. Adhesive tape can be applied externally such that it extends across the coupling plane, contacting both the first frame member 218 and the second frame member 219. In some embodiments, the tape can comprise a single elongated piece that extends around at least the entire rim 203 exterior surface to cover the coupling plane and provide additional security to prevent decoupling. The tape may be used in conjunction with another bonding or coupling method. In other embodiments, the tape can comprise a plurality of separate strips attached at predetermined locations around the rim 203. In some embodiments, fasteners 209 such as screws or pins can be positioned at multiple locations around the frame. Referring to FIGS. 24-26, the fasteners 209 can extend through apertures in the frame, contacting both the first frame member 218 and the second frame member 219, and/or contacting the paddle head subassembly 201. Any of the mechanical components can also function to provide targeted weighting to the paddle periphery, as well as additional protection from damage.

C. Internal Cavity Retaining Structures

In some embodiments, the frame 206 can further comprise internal cavity structures 241 that contribute to the security of the coupling of the first frame member 218 and the second frame member 219. These internal cavity structures 241 can comprise integral protrusions, integral protrusions and accompanying receiving structures, epoxy anchors, and/or integral protrusions that prevent sliding or decoupling. Protrusions integrally formed on a frame member may extend past the coupling plane in the assembled paddle. Receiving structures on frame may recede from the coupling plane in the assembled paddle. In some embodiments, integral protrusions can extend from one frame member, across the coupling plane, to contact the adjacent frame member. The protrusions can increase bonding surface area and prevent lateral movement of the frame members (218, 219) relative to one another. In some embodiments, only one frame member (218 or 219) comprises protrusions. In these embodiments, the protrusions can be removed from one frame member (218, 219) following molding. In other embodiments, both frame members (218, 219) can comprise protrusions.

In some embodiments, the integral protrusions and receiving structures can be injection molded or co-molded with the first frame member 218 and the second frame member 219. Protrusions on one frame member can interact with corresponding receiving structures on another frame member to provide additional security. The protrusions and receiving structures can interact by increasing bonding surface area, acting as a wall that blocks lateral movement, and/or increasing friction between the frame members (218, 219) by a press-fit geometry or by pressing against one another. These structures can be positioned within a single mold to interact with each other when two frame members (218, 219) are coupled. In some embodiments, the protrusion(s) and receiving structure(s) can interact as tongue and groove couplers.

The use of identical frame members (218, 219) results in mirrored symmetry across the coupling plane. In some embodiments, each frame member also comprises symmetry across a longitudinal plane, perpendicular to the coupling plane. In other embodiments, structures can be formed on opposite sides of the longitudinal plane to interact with one another when the first frame member 218 and the second frame member 219 are coupled. In these embodiments, when the first frame member 218 and second frame member 219 are coupled, they will be mirror images of one another. Complementary internal cavity structures 241 can be formed within the internal cavity 240 at locations that are evenly positioned across the longitudinal plane. These internal cavity structures 241 should be positioned upon a single plane, at an equal distance from the longitudinal plane. The plane upon which they are positioned extends perpendicularly to the longitudinal plane.

In some embodiments, the frame 206 can further comprise integral locking features that guide the formation of epoxy anchors. The integral locking features can be shaped as loops or hooks that become surrounded by epoxy. The epoxy acts as a bridge that is adhered to both the first frame member 218 and the second frame member 219, and the hooks or loops work with the epoxy to prevent the frame members (218, 219) from moving away from one another.

D. Internal Anchoring Components

In some embodiments, the paddle 200 can comprise internal anchoring components in the form of separate internal components or fills that aid in coupling security. These internal anchoring components can extend across multiple regions of the paddle to contact several parts. For example, a component or fill can be inserted into the handle and extend beyond the handle and into the paddle head subassembly 201.

In other embodiments, the internal anchoring component can be a fill material that fills some or all of the cavity defined by the handle 205, and extends beyond the handle 205 to contact the core. The fill material can be expandable foam or an elastomeric material. The fill material can further position additional weight in the handle 205, causing the CG to move toward the end cap 217. The fill material can also damp sound and vibrations.

a. Throat Chamfers

Most shots are played with a single-hand grip, however, for certain shots it is preferable to grip the paddle (100, 200) with two hands. Therefore, it is desirable to create a paddle (100, 200) which provides an ergonomic grip for both two-handed and single-handed shots. One solution is to increase the handle length to provide ample room for two-handed shots. However, tradeoffs must be considered. Since modern pickleball paddles (100, 200) are typically constructed at or near maximum regulatorily limited length restrictions lengthening the handle means that the frame must be made shorter. This solution is not ideal as decreasing frame length generally reduces perimeter weighting about the paddle (100, 200) Y-axis, thereby decreasing the paddle's (100, 200) sweet spot size. One alternative solution to lengthening grip size is to increase “effective grip length” by designing the throat (116, 216) to be a more ergonomic area which can be used for two-handed shots. Designing the throat (116, 216) to be more ergonomic can be accomplished without requiring a lengthened grip, effectively mitigating any reduction in sweet spot size associated with a lengthened grip 238.

As shown in FIG. 13, the paddle (100, 200) can comprise throat chamfers 225 that form grip regions with improved ergonomic fit and comfort to a user. The throat chamfers 225 can be defined in the throat (116, 216) of the frame 206. In other embodiments throat chamfers 225 can extend from the grip 238 into the rim (103, 203). Increasing effective grip length by including throat chamfers 225 can improve comfort on two-handed shots without requiring a lengthened handle 205.

Inclusion of throat chamfers 225 is made possible by the structural frame (106, 206) disclosed herein. As discussed above, without a structural frame (106, 206), paddles (100, 200) traditionally rely on core material extending into the handle to provide rigidity. Throat chamfers 225 would reduce the amount of core material which can extend into the throat (116, 216) area, thereby reducing the stiffness provided by this core material and compromising the structural integrity of these paddles (100, 200). Therefore, throat chamfers would not be used in paddles (100, 200) which rely on the core material extending into the handle for rigidity.

As discussed above, the throat chamfers 225 of the present disclosure aid in fitting both hands on the paddle (100, 200) handle (or handle members) by providing an ergonomic area where one's thumb and pointer finger of the top hand can rest near the junction of the rim (103, 203) and handle. Throat chamfers 225 make the throat (116, 216) a more ergonomic area by removing sharp edges where fingers rest. Throat chamfers 225 can take on a variety of geometries and sizes.

The throat chamfers 225 of the present disclosure can be made more ergonomic by including transition radii between the throat notches and surrounding geometry. In some embodiments, the boundary of the throat chamfers 225 can include a transition radii which remains constant along the entirety of the throat chamfer boundary. In other embodiments, the boundary surface plates of the throat chamfers 225 can include a varying transition radii along the throat chamfers boundary. In an exemplary embodiment the throat chamfers 225 can have a constant transition radii of 0.063 inches. In other embodiments the throat chamfers radii can be between 0.05 inches to 0.125 inches.

The throat chamfers 225 can each comprise a length measured in-line with the throat (116, 216), from a top-most end of the throat chamfer 225 to a bottom-most end of the throat chamfer. The throat chamfers 225 can each comprise a width measured perpendicular to the throat chamfer length between a point on the throat chamfer nearest the hitting surface and a point on the throat chamfer 225 nearest the coupling plane. The throat chamfer 225 can comprise a length between 0.5 inch and 1.5 inches. The throat chamfer width can vary along its length. The throat chamfer 225 can comprise a maximum width, which is between 0.25 inch and 1.0 inch. The throat chamfer width can vary between 0.05 inch and 1.0 inch along its length. In many embodiments, the chamfered surface smoothly connects with throat (116, 216) geometry. In many embodiments, the throat chamfer 225 can be curved along its length. In some embodiments, the throat chamfer 225 can be curved along its width. In alternate embodiments, throat notches can be defined in the frame 206 that lack the chamfered surface extending away from the chamfer edge nearest the hitting surface. The throat notches are cutouts defined in the frame 206 that provide additional space for the user to grip the handle (105, 205) during two-handed shots.

b. Grip

Referring to FIGS. 1, 12, and 15, the multi-component paddle (100, 200, 300) can comprise a grip (138, 238) that encases the handle (105, 205). In some embodiments, the grip (138, 238) can be a separate member that slides onto, wraps around, or is otherwise coupled to the handle (105, 205). The grip (138, 238) can alter the feel of the paddle by providing comfort and vibration damping. In some embodiments, the grip (138, 238) can be in the form of a readily available grip tape that can be selected from a large variety of materials, cushion, tackiness, thickness, and textures. The grip tape can be applied by the user and easily removed and replaced. In other embodiments, the grip (138, 238) can be an elastic cover that is pulled over the handle (105, 205) and can be installed and replaced by the user. In other embodiments, the grip (138, 238) can comprise multiple grip members that are separate or partially connected. The grip members can be hinged and latch together, can be press-fit to one another or onto the handle (105, 205), or can be mechanically fastened to cover the handle (105, 205) and remain in place during use.

Methods of Manufacture and Assembly

In some embodiments, the paddle can comprise one or more injection molded components. The one or more injection molded components can make up the handle, the rim (103, 203) and/or the core. The injection molded components can be created out of a molded thermoplastic material. A molded thermoplastic material is one that relies on the polymer itself to provide structure and rigidity to the final component. The molded thermoplastic material is one that is readily adapted to molding techniques where the material is freely flowable when heated to a temperature above the melting point of the polymer. The thermoplastic material can be a filled thermoplastic (FT) material or an unfilled thermoplastic (UT) material. The thermoplastic material should preferably incorporate one or more engineering polymers that have sufficiently high material strengths and/or strength/weight ratio properties to withstand typical pickleball use while still providing weight savings that are beneficial to the present design.

In some embodiments, the paddle (100, 200) can comprise one or more cast components. The one or more cast components can make up the handle and/or the rim (103, 203). The cast components can be formed from a castable metal such as: titanium, aluminum, magnesium, steel, or an alloy thereof. Casting components can allow for selective weighting to be integrally formed with the frame (106, 206).

The various separately-formed parts can be coupled to form the paddle (100, 200). These parts, including some or any combination of the following: the first handle member, the second handle member, the first frame member 218, the second frame member, the end cap, and the head subassembly (101, 201) can be coupled to form the complete paddle (100, 200). These parts can be coupled by any one or combination of the following: mechanical fasteners, snap fitting, adhesives, ultrasonic welding, or any other suitable means for coupling.

Frame Members

Embodiments of the two-component frame design are formed by coupling two identical or similar frame members. The identical frame members (218, 219) can be injection molded in a single mold. Because the frame members (218, 219) are identical, there is no need for the creation of multiple expensive mold designs, thereby greatly reducing costs. Furthermore, the use of two identical frame members (218, 219) reduces assembly error by completely preventing the possibility of incorrect parts being coupled.

Suitable thermoplastic polymers can include polycarbonate (PC), polyester (PBT), polyphenylene sulfide (PPS), polyamide (PA) (e.g. polyamide 6 (PA6), polyamide 6-6 (PA66), polyamide-12 (PA12), polyamide-612 (PA612), polyamide 11 (PA11)), thermoplastic polyurethane (TPU), polyphthalamide (PPA), acrylonitrile butadiene styrene (ABS), polybutylene terephthalate (PBT), polyvinylidene fluoride (PVDF), polyethylene (PE), polyphenylene ether/oxide (PPE), polyoxymethylene (POM), polypropylene (PP), styrene acrylonitrile (SAN), polymethylpentene (PMP), polyethylene terephthalate (PET), acrylonitrile styrene acrylate (ASA), polyetherim (103, 203) ide (PEI), polyvinylidene fluoride (PVDF), polymethylmethacrylate (PMMA), polyether ether ketone (PEEK), polyether ketone (PEK), polyetherim (103, 203) ide (PEI), polyethersulfone (PES), polyphenylene oxide (PPO), polystyrene (PS), polysulfone (PSU), polyvinyl chloride (PVC), liquid crystal polymer (LCP), thermoplastic elastomer (TPE), ultra-high molecular weight polyethylene (UHMWPE), nylon, or alloys of the above described thermoplastic materials, such as an alloy of acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) or an alloy of acrylonitrile butadiene styrene (ABS) and polyamide (PA).

The composite material can include reinforcement fillers. The fillers can be: fibers, beads, or other structures comprising various materials that are mixed with the thermoplastic polymer. The fillers can provide structural reinforcement, weighting, or various other characteristics to the thermoplastic composite material. In many embodiments, the fillers can comprise carbon fibers or glass fibers. However, in other embodiments, the fillers can comprise other suitable materials. For example, the fillers can comprise aramid fibers (e.g. Nomex, Vectran, Kevlar, Twaron), bamboo fibers, natural fibers (e.g. cotton, hemp, flax), metal fibers (e.g. titanium, aluminum), glass beads, tungsten beads, or ceramic fibers (e.g. titanium dioxide, granite, silicon carbide).

The fillers can be combined with the plastics to various percentages by volume. In some examples, the composite material can comprise up to 35% fill by volume. For example, the composite material can comprise 0%-6%, 6%-12%, 12%-20%, 20% to 25%, 25% to 30%, or 30% to 35% fill by volume. The composite material can comprise 0%-2%, 2%-4%, 4%-6%, 6%-8%, 8%-10%, 10%-12%, 12%-14%, 14%-16%, 16%-19%, 18%-20%, 20%-22%, 22%-24%, 24%-26%, 26%-28%, 28%-30%, 30%-32%, 32%-34%, or 35% fill by volume.

In some embodiments, components such as the handle (105, 205) can be formed using additive manufacturing processes such as 3D printing. Additive manufacture can improve manufacturability of more complex geometries, and can allow manufacturers to offer custom, player specific, solutions. In some embodiments, a handle (105, 205) can be 3D printed based on a custom mold of a player's hand or grip. The 3D printed handle (105, 205) can engage a portion of, for example, a two-component frame. Additionally, a 3D printed or injection molded handle (105, 205) can include a recess in the lower portion of the handle (105, 205). The recess can be filled with foam, polymer, plastic, rubber, or any other material suitable to alter weight distribution or feel. For example, the foam fill can cushion the grip, reducing pressure experienced by the player's hands and thereby mitigating fatigue and the risk of injury.

Creating the frame (106, 206) by injection molding or additive manufacturing enables formation of complex geometries without incurring high manufacturing costs. Thereby, injection molded embodiments of the present disclosure can comprise features such as recesses, chamfers, or multi-radii curvatures without incurring high costs. Alternatively, these features can also be formed using other manufacturing methods such as casting, additive manufacturing, subtractive manufacturing, or the like.

Face Plates Texturing

Further, the metallic face plate (102, 202) can include a textured interface engaging the core (104, 204). This textured interface can comprise an increased roughness relative to a carbon fiber or fiberglass sheet. Accordingly, the bonding material (e.g., epoxy) between the core (104, 204) and metallic sheet can more effectively adhere the metallic sheet to the core (104, 204). Improved adhesion between the core (104, 204) and face can improve durability. Namely, increased roughness on the inner surface of the face plates (102, 202) can make the face less likely to detach from the core (104, 204).

The interior surface of the face plates (102, 202) can comprise bonding features such as grooves or raised embossing to aid in even and controlled adhesive distribution. In some embodiments these bonding features can be laser or chemically etched into the interior surface of face plates (102, 202). Etching of the face plates (102, 202) interior surface plates (102, 202) can be particularly advantageous as it allows for a high level of control over surface roughness. Some examples of these bonding features made by laser etching can be seen on the exterior surface of the face plates (102, 202) in FIGS. 10-12. The bonding features can aid in flow and distribution of epoxy across the surface, while also increasing bonding surface area, thereby improving strength of the bond. Texturing may be achieved by treatments such as: laser etching, chemical etching, sand blasting, electroplating, textured paint application, milling, abrasive application, or grinding.

Referring to FIGS. 10-12, in addition to creating bonding features, surface texturing can be used on the exterior surface of the face plates (102, 202). Surface roughness of the hitting surface can be increased through texturing, increasing friction and, as a result, spin imparted to a pickleball with certain hitting techniques. In some embodiments, etching can be selectively applied to regions on the face that, when impacted, typically result in lower spin to achieve a uniform spin distribution across the striking surface of the paddle.

In other embodiments, texturing can be selectively applied to the face plate (102, 202) to heat treat areas of the hitting surface. Selective heat treatment of the face plate (102, 202) can alter its material properties (such as hardness) in targeted regions and can also be used to apply cosmetic designs to the face plate (102, 202) which may be used to clearly indicate a sweet spot or face center.

EXAMPLES
Example 1

A first exemplary injection molded thermoplastic paddle was formed twice, once from a premium engineered plastic and once from a less expensive, commodity plastic and both were compared to a prior art carbon-composite paddle formed from a pre-preg carbon fiber material. The exemplary paddle comprises a paddle head subassembly mounted in a surrounding frame. The exemplary paddle, formed from each of the two plastic materials, has several advantages over a comparative paddle formed through thermoset composite compression molding from the pre-preg carbon fiber material. Advantages of the exemplary paddle over the comparative paddle include total material cost, processing cost, transportation costs, inventory costs, reduced tooling costs, increased tooling life, consistency of quality improvements, design detail flexibility, surface finish improvements, and the ability to separately manufacture the frame and the panel.

The first exemplary paddle material cost is significantly less than that of the comparative carbon fiber composite paddle. The cost for the carbon fiber and epoxy needed to form the comparative paddle is in a range of $30.00 to $40.00. In contrast, when using premium-engineered, fiber-filled plastic, the material cost for the first exemplary paddle is in a range of $2.50 to $5.00 per paddle. The paddle formed using lower strength, less expensive plastics can reduce the paddle material cost to a range of $0.50 to $2.00 per paddle. Further, any trim material from the carbon composite paddle is simply lost. Trim material from the plastic injection molded paddle can be reground and reclaimed for use. This recycling may further reduce the total material cost of the first exemplary paddle.

The first exemplary paddle processing cost is significantly lower than the comparative carbon fiber composite paddle. The comparative carbon fiber composite paddle is formed using a multiple layer, carbon fiber pre-preg layup method, typically requiring at least 10 minutes of layup time and 15 minutes of cure time. Further, the comparative carbon fiber composite paddle is a single piece construction, forming the paddle faceplate and handle as a single piece. In contrast, the first exemplary paddle frame injection molding time is 1 minute to 2 minutes and allows for repeated injection cycles without manual intervention. This contrast in manufacturing cycle time, in turn, also significantly reduces the tooling costs for a given production volume. The manual carbon fiber pre-preg layup method requiring 25 minutes of processing time would require 12 to 25 times the number of molds to equal the output of a single injection mold. Furthermore, the 10 minutes of layup time required by that method is not needed in the production of the first exemplary paddle. Fewer molds needed for a given production volume reduces the total molds cost for that production volume, and faster cycle times with the lower labor cost reduces the first example total cost. The first exemplary paddle's lower manufacturing cycle time and labor costs provide another advantage. The needed component production volume is able to be produced locally to the assembly operation on demand. This allows a faster response to demand fluctuations, eliminates the transportation cost of finished inventory from a sub-contractor to the order fulfillment site, and reduces the amount of finished goods inventory.

The first exemplary paddle frame and head subassembly are manufactured by plastic injection molding. This manufacturing process is capable of producing smaller features. Features as small as 0.005 inch in any dimension can be produced. This allows greater design freedom than the comparative carbon fiber composite layup that can only support features almost two orders of magnitude larger. The first exemplary paddle's smaller feature size provides the more complex features discussed above, such as adhesive channels, ribs, snap fit features, and weight insertion locations. Furthermore, the first exemplary paddle surface finish is at its final state without post molding finishing operations, saving still more labor costs while providing a more consistent product. The first exemplary paddle design also provides precise control over important dimensional variables such as wall thickness and mass. These, in turn, provide a consistent hitting response for the user. The first exemplary paddle provides significant cost and manufacturing throughput advantages over the comparative carbon fiber layup paddle.

Example 2

A second exemplary paddle frame was made from 12% carbon fiber filled nylon and a 6-layer carbon fiber face. The second exemplary paddle comprises a head subassembly having a core bonded between two frame halves. A comparative carbon fiber paddle was constructed using the industry standard method. The comparative carbon fiber paddle was formed from a carbon fiber layup over a core wherein the paddle face and the paddle handle were a single piece. The comparative carbon fiber paddle did not have a frame, rather, it had a non-structural, soft edge tape adhesively attached to the paddle perimeter. The stiffness of each paddle was measured using an industry standard test. The paddles were each clamped at the handle, leaving the face suspended, cantilevered parallel to a table surface. A force probe was pushed against the paddle face at the standard measurement location approximating the standard striking point or face center. During the test, as the force probe is pushed against the paddle face, the paddle deflects downward toward the table surface. The vertical deflection distance was measured vs. the force applied. The stiffer the paddle, the larger force is necessary for any given deflection distance.

Testing the stiffness of the second exemplary paddle and the comparative carbon fiber paddle showed a large difference in stiffness. The second exemplary paddle had a measured stiffness of 50.9 pounds-force per inch (lbf/inch). The comparative carbon fiber paddle had a measured stiffness of 38.2 lbf/inch. The construction technique of the second exemplary paddle, having a paddle head subassembly joined to a structural frame allows the frame to bear the flexural load. In contrast, the comparative carbon fiber paddle relies on the single piece faceplate/handle to bear the flexural load. The comparative carbon fiber paddle construction technique forces the paddle designer to tradeoff paddle stiffness with face response. For the comparative carbon fiber paddle, softening the faceplate requires a reduction of stiffness. In the second exemplary paddle, the paddle stiffness is largely engineered into the separate frame, allowing the faceplate characteristics to be independently engineered.

Example 3

A third exemplary paddle frame was made from polycarbonate that was not fiber filled and completed with a 6-layer carbon fiber face having a head subassembly with core, which is bonded between two frame members. The third exemplary paddle had a stiffness of 28.8 lbf/inch when tested according to the procedure outlined in Example 2. The third exemplary paddle had the same paddle head subassembly as the second exemplary paddle. The second exemplary paddle frame was formed with 12% fiber filled plastic and the third exemplary paddle frame was formed with the same plastic, but without the fiber fill. The difference in stiffness between the second exemplary paddle and the third exemplary paddle (38.2 lbf/inch vs 28.8 lbf/inch) is entirely accounted for by the difference in frame material, as these two paddles were formed in the same mold. This example illustrates the ability for paddles constructed according to the present invention to isolate the paddle stiffness from paddle head subassembly design, thereby enabling paddle head subassemblies to be constructed for performance characteristics.

Example 4

A fourth exemplary pickleball paddle comprises a head subassembly having 101 a core extension 222 extending into the interior cavity of the throat 116, interior cavity structures 241 to reinforce the throat portion of the frame 106 providing more stiffness, and additional interior cavity structures 241 to increase the bondline between the head subassembly 101 and the frame 206. A control pickleball paddle was formed from the same material, but not having the core extension, the throat reinforcing structures, nor the bondline enhancement structures. Both the fourth exemplary paddle and the control paddle had a 10-pound cantilever force applied 13.5 inches above the butt end of the handle 105 along the Y-axis of the paddle at the load point 500 while the paddle was fixed at the butt end 159. As shown in FIG. 27, the stress concentration for the control paddle is high in the throat 116 along the frame aperture at a high stress region 501. This stress concentration coincides with the control paddle frame failure point by cracking under use. The fourth exemplary paddle was subjected to the same load at the same location. As illustrated in FIG. 28, the largest stress concentration 502 in the fourth exemplary paddle was lowered in the throat 116 toward the butt end 159 into a portion of the throat/handle having a broader cross section. Under the same usage that caused the control paddle to fail, the exemplary paddle did not crack.

CLAUSES

Clause 1. A method of assembling a pickleball paddle having paddle head subassembly, the method comprising: injection molding a first frame member having a first rim member extending from and integral with a first handle member; injection molding a second frame member having a second rim member extending from and integral with a second handle member; positioning the paddle head subassembly between the first frame member and the second frame member; coupling the first frame member to the second frame member with the paddle head subassembly secured therebetween; wherein the paddle head subassembly is joined to the first rim member and the second rim member; wherein the paddle head subassembly is located within, and a perimeter portion of the paddle head subassembly is surrounded by, the first rim member and the second rim member such that majorities of a first face plate and a second face plate of the paddle head subassembly are exposed; and wherein paddle head subassembly is not located within nor surrounded by the first handle member and the second handle member.

Clause 2. The method of clause 1, wherein the first frame member and the second frame member are joined using adhesives.

Clause 3. The method of clause 1, wherein the paddle head subassembly, the first frame member and the second frame member are secured via a method selected from one or more of the following: mechanical fasteners, adhesives, and ultrasonic welding.

Clause 4. The method of clause 3, wherein coupling the first frame member and the second frame member comprises mechanically coupling the first frame member to the second frame member.

Clause 5. The method of clause 1, wherein the core resembles a honeycomb structure comprising a plurality of repeated structures arranged side by side formed from polypropylene.

Clause 6. The method of clause 1, wherein the first face plate and the second face plate each define a hitting surface, and at least a portion of the hitting surface is made from a metallic material.

Clause 7. The method of clause 6, wherein the metallic material is selected from a group consisting of: titanium, aluminum, nickel alloys, and magnesium.

Clause 8. A pickleball paddle comprising: a paddle head subassembly comprising a first hitting surface, a second hitting surface, and a core disposed between the first and second hitting surfaces, wherein the paddle head subassembly further comprises a paddle head subassembly perimeter portion; a frame comprising: a first frame member having a first rim member extending from and integral with a first handle member; a second frame member having a second rim member extending from and integral with a second handle member; wherein the first frame member is coupled to the second frame member with the paddle head subassembly secured therebetween; wherein the paddle head subassembly is joined to the first rim member and the second rim member; wherein the paddle head subassembly is located within, and a perimeter portion of the paddle head subassembly is surrounded by, the first rim member and the second rim member, such that a majority of the first hitting surface and the second hitting surface are exposed; and wherein the paddle head subassembly is not located within nor surrounded by the first handle member and the second handle member.

Clause 9. The pickleball paddle of clause 8, wherein a first face plate and a second face plate of the paddle head subassembly each define the first hitting surface and the second hitting surface, respectively, and at least a portion of each hitting surface comprises a metallic material.

Clause 10. The pickleball paddle of clause 9, wherein the first hitting surface comprises a plurality of laser etched bonding features on a first hitting surface interior surface, and the second hitting surface comprises a plurality of laser etched bonding features on a second hitting surface interior surface.

Clause 11. The pickleball paddle of clause 8, wherein the first frame member and the second frame member are identical.

Clause 12. The pickleball paddle of clause 8, wherein: a plurality of struts is disposed within the core; a plurality of internal pockets is defined by adjacent struts of the plurality of struts; and an elastomeric damping material is disposed in at least one internal pocket of the plurality of internal pockets.

Clause 13. The pickleball paddle of clause 12, wherein the plurality of struts includes a plurality of primary struts extending in a direction parallel to a first axis, a plurality of secondary struts extending in a direction parallel to a second axis different from the first axis, and a plurality of tertiary struts extending in a direction parallel to a third axis different from the first and second axes; wherein the first axis and the second axis intersect to form a first angle between 10 degrees and 130 degrees; and wherein the first axis and the third axis intersect to form a second angle between 80 degrees and 180 degrees.

Clause 14. The pickleball paddle of clause 8, wherein each of the first frame member and the second frame member comprises a frame exterior side and a frame interior side; wherein, when the pickleball paddle is assembled, the frame interior side is not exposed.

Clause 15. The pickleball paddle of clause 14, wherein each of the first frame and the second frame comprises a coupling surface connecting the frame interior surface and the frame exterior surface; such that when the pickleball paddle is assembled, each coupling surface abuts with an opposite coupling surface without gaps or overlap.

Clause 16. The pickleball paddle of clause 15, wherein each frame interior surface comprises a lateral bonding surface extending approximately perpendicular to a respective planar rim surface; and wherein the lateral bonding surface defines a lateral bonding surface height measured perpendicularly from the planar rim surface.

Clause 17. The pickleball paddle of clause 16, wherein each frame further comprises a rim-to-face bonding surface, extending towards a paddle face center and perpendicularly from the lateral bonding surface, offset towards a paddle first or second hitting surface relative to the planar rim surface; and wherein the bonding surface defines a bonding surface width measured perpendicular to the frame interior wall.

Clause 18. The pickleball paddle of clause 17, wherein each frame further comprises an epoxy retention lip extending inward and perpendicular to the bonding surface; and wherein the epoxy retention lip defines an epoxy retention lip height measured perpendicularly from rim-to-face bonding surface.

Clause 19. The pickleball paddle of clause 18, wherein each frame interior surface further comprises a plurality of reinforcing structures.

Clause 20. The pickleball paddle of clause 19, wherein each frame interior surface further comprises a plurality of vertical ribs protruding from the lateral bonding surface and oriented approximately perpendicularly to the bonding surface.

Clause 21. The pickleball paddle of clause 19, wherein each frame comprises a throat portion transitioning between each rim member and each handle member.

Clause 22. A pickleball paddle comprising: a paddle head subassembly having a first face plate and a second faceplate sandwiching a core; a frame comprising: a first frame member having a first rim formed integrally with a first handle, the first rim including a first rim annular wall and a first rim flange wall; a second frame member having a second rim formed integrally with a second handle, the second rim including a second rim annular wall and a second rim flange wall; a frame joint coupling the first rim annular wall to the second rim annular wall with the paddle head subassembly disposed between the first and second frame members, to form a unitary frame structure securing the paddle head subassembly; a first face joint coupling the first faceplate to the first rim flange wall; a second face joint coupling the second faceplate to the second rim flange wall.

Clause 23. A pickleball paddle comprising: a pickleball paddle body comprising a frame, a head subassembly, and a grip; wherein the frame comprises a rim, a y-shaped throat, a frame aperture defined within the rim and y-shaped throat, and a handle extending from the y-shaped throat to a butt end; wherein the frame further comprises a first frame member having a first coupling surface with a first frame member perimeter shape and a second frame member having a second coupling surface with a second frame member perimeter shape; wherein the first coupling surface is joined to the second coupling surface to form the frame, and the first frame member perimeter shape joined to the second frame perimeter shape forms a frame outer perimeter around the rim, y-shaped throat, and handle; wherein the head subassembly is positioned with the frame aperture and comprises at least a core, a front hitting surface, and a rear hitting surface;

- wherein the grip comprises a grip upper end adjacent to the y-shaped throat, a grip butt distal from the y-shaped throat, and a grip body between the grip upper end and grip butt configured to cover the handle.

Clause 24. The pickleball paddle of clause 23, wherein the pickleball body comprises a pickleball paddle body geometric center; wherein a first location on the pickleball paddle body is centerward of second location on the pickleball paddle body if the first location on the pickleball paddle body is closer to the pickleball paddle body geometric center than the second location on pickleball paddle body; and wherein the rim and y-shaped throat define a frame top rim region, a first frame lateral side and a second frame lateral side each connected to the frame top rim region, and a bottom rim region bounded by the y-shaped throat opposite the frame top region; and an X-axis extending from the first frame lateral side through the geometric center to the second frame lateral side, a Y-axis extending perpendicular to the X-axis from the frame top rim region through the geometric center to the butt end, and a Z-axis perpendicular to both the X-axis and Y-axis also extending through the geometric center from the front hitting surface to the rear hitting surface; the X-axis and Y-axis defining an XY plane.

Clause 25. The pickleball paddle of clause 24, wherein the rim comprises an outer rim perimeter that is a portion of the frame outer perimeter and an inner rim perimeter centerward of the outer rim perimeter at least partially surrounding the frame aperture.

Clause 26. The pickleball paddle of clause 25, wherein a rim width is the shortest distance between any point on the outer rim perimeter to a point on the rim inner perimeter; wherein the rim width is measured perpendicularly from a tangent to the point on the outer rim perimeter.

Clause 27. The pickleball paddle of clause 25, wherein the rim comprises a front outer rim surface extending centerward from the outer rim perimeter and a rear outer rim surface opposite from and parallel to the front outer rim surface extending centerward from the outer rim perimeter.

Clause 28. The pickleball paddle of clause 27, wherein a rim total thickness is measured perpendicularly from the front outer rim surface to the rear outer rim surface.

Clause 29. The pickleball paddle of clause 28, wherein the rim inner perimeter is further defined by centerward edges on the front outer rim surface and the rear outer rim surface.

Clause 30. The pickleball paddle of clause 23, wherein the first frame member and a second frame member have an identical structure; and

wherein the first and second frame members are positioned such that the first frame member mirrors the second frame member about a coupling plane between them forming the frame.

Clause 31. The pickleball paddle of clause 30, wherein the frame comprises a frame interior cavity, defined by a first frame member interior surface and a second frame member interior surface that together form a frame interior surface.

Clause 32. The pickleball paddle of clause 31, wherein the frame interior cavity comprises a plurality of interior cavity structures on or protruding from the frame interior surface into the frame interior surface.

Clause 33. The pickleball paddle of clause 31, wherein the frame interior cavity is open centerward into the frame aperture before the head subassembly is assembled into the pickleball paddle body.

Clause 34. The pickleball paddle of clause 32, wherein the plurality of interior cavity structures comprise reinforcing structures.

Clause 35. The pickleball paddle of clause 32, wherein the plurality of interior cavity structures comprise bonding structures.

Clause 36. The pickleball paddle of clause 34, wherein the reinforcing structures comprise parallel surface ribs extending across a lower portion of the y-shaped throat into the handle protruding from the frame interior surface to a height in a range between 0.01 inch to 0.20 inch; and wherein the reinforcing structures further comprise male and female bosses configured such that each male boss located on the first frame member is opposite a female boss located on the second frame member such that when the first frame member is joined to the second frame member, each male boss is received within the opposite female boss.

Clause 37. The pickleball paddle of clause 35, wherein the bonding structures comprise surface stand off features such as ribs and nubs protrude above the frame interior surface in a range between 0.01 inch and 0.20 inch.

Clause 38. A pickleball paddle comprising: a pickleball paddle body comprising a frame, a head subassembly, and a grip; wherein the frame comprises a rim, a y-shaped throat, a frame aperture defined within the rim and y-shaped throat, and a handle extending from the y-shaped throat to a butt end; wherein the frame further comprises a first frame member having a first coupling surface with a first frame member perimeter shape and a second frame member having a second coupling surface with a second frame member perimeter shape; wherein the first coupling surface is joined to the second coupling surface to form the frame, and the first frame member perimeter shape joined to the second frame perimeter shape forms a frame outer perimeter around the rim, y-shaped throat, and handle; wherein the head subassembly is positioned with the frame aperture and comprises at least a core, a front hitting surface, and a rear hitting surface; wherein the grip comprises a grip upper end adjacent to the y-shaped throat, a grip butt distal from the y-shaped throat, and a grip body between the grip upper end and grip butt configured to cover the handle; wherein the pickleball body comprises a pickleball paddle body geometric center; wherein a first location on the pickleball paddle body is centerward of second location on the pickleball paddle body if the first location on the pickleball paddle body is closer to the pickleball paddle body geometric center than the second location on pickleball paddle body; and wherein the rim and y-shaped throat define a frame top rim region, a first frame lateral side and a second frame lateral side each connected to the frame top rim region, and a bottom rim region bounded by the y-shaped throat opposite the frame top region; and an X-axis extending from the first frame lateral side through the geometric center to the second frame lateral side, a Y-axis extending perpendicular to the X-axis from the frame top rim region through the geometric center to the butt end, and a Z-axis perpendicular to both the X-axis and Y-axis also extending through the geometric center from the front hitting surface to the rear hitting surface; the X-axis and Y-axis defining an XY plane.

Clause 39. The pickleball paddle of clause 38, wherein the first frame member and a second frame member have an identical structure; and wherein the first and second frame members are positioned such that the first frame member mirrors the second frame member about a coupling plane between them forming the frame; wherein the coupling plane is generally parallel to the XY plane.

Clause 40. The pickleball paddle of clause 38, wherein the first frame member and the second frame member are comprised of a thermoplastic material chosen from a group consisting of include polycarbonate (PC), polyester (PBT), polyphenylene sulfide (PPS), polyamide (PA) (e.g. polyamide 6 (PA6), polyamide 6-6 (PA66), polyamide-12 (PA12), polyamide-612 (PA612), polyamide 11 (PA11)), thermoplastic polyurethane (TPU), polyphthalamide (PPA), acrylonitrile butadiene styrene (ABS), polybutylene terephthalate (PBT), polyvinylidene fluoride (PVDF), polyethylene (PE), polyphenylene ether/oxide (PPE), polyoxymethylene (POM), polypropylene (PP), styrene acrylonitrile (SAN), polymethylpentene (PMP), polyethylene terephthalate (PET), acrylonitrile styrene acrylate (ASA), polyetherim (103, 203) ide (PEI), polyvinylidene fluoride (PVDF), polymethylmethacrylate (PMMA), polyether ether ketone (PEEK), polyether ketone (PEK), polyetherim (103, 203) ide (PEI), polyethersulfone (PES), polyphenylene oxide (PPO), polystyrene (PS), polysulfone (PSU), polyvinyl chloride (PVC), liquid crystal polymer (LCP), thermoplastic elastomer (TPE), ultra-high molecular weight polyethylene (UHMWPE), nylon, an alloy of acrylonitrile butadiene styrene (ABS) and polycarbonate (PC), or an alloy of acrylonitrile butadiene styrene (ABS) and polyamide (PA).

Clause 41. The pickleball paddle of clause 40, wherein the thermoplastic material may additionally be fiber filled in a range between 5% and 35% by volume.

Clause 42. The pickleball paddle of clause 38, wherein the paddle body comprises a body width, a body length, and a body mass; wherein the body length is in a range between 14 inches to 17.5 inches, the body width is in a range between 6.5 inches and 8.5 inches, and a body mass in a range between 198 grams and 270 grams.

Replacement of one or more claimed elements constitutes reconstruction and not repair. Additionally, benefits, other advantages, and solutions to problems have been described with regard to specific embodiments. The benefits, advantages, solutions to problems, and any element or elements that may cause any benefit, advantage, or solution to ocm3ur or become more pronounced, however, are not to be construed as critical, required, or essential features or elements of any or all of the claims, unless such benefits, advantages, solutions, or elements are stated in such claim.

As the rules to pickleball may change from time to time (e.g., new regulations may be adopted or old rules may be eliminated or modified by pickleball standard organizations and/or governing bodies such as the United States Pickleball Association (USPA)), pickleball equipment related to the apparatus, methods, and articles of manufacture described herein may be conforming or non-conforming to the rules of pickleball at any particular time. Accordingly, pickleball equipment related to the apparatus, methods, and articles of manufacture described herein may be advertised, offered for sale, and/or sold as conforming or con-conforming pickleball equipment. The apparatus, methods, and articles of manufacture described herein are not limited in this regard.

The above examples may be described in connection with a pickleball paddle. Alternatively, the apparatus, methods, and articles of manufacture described herein may be applicable to other types of sports equipment such as a tennis racquet, a badminton racquet, etc.

Moreover, embodiments and limitations disclosed herein are not dedicated to the public under the doctrine of dedication if the embodiments and/or limitations: (1) are not expressly claimed in the claims; and (2) are or are potentially equivalents of express elements and/or limitations in the claims under the doctrine of equivalents.

Number	Date	Country
63516825	Jul 2023	US
63613665	Dec 2023	US
63557390	Feb 2024	US

	Number	Date	Country
Parent	18791334	Jul 2024	US
Child	19046403		US

PICKLEBALL PADDLE HAVING INTEGRAL HANDLE AND RIM ASSEMBLY

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