PICKLEBALL PADDLE

Abstract

An example pickleball paddle may include a handle and a head coupled to the handle. The head may include an inner layer sandwiched between a first outer faceplate and a second outer faceplate. The inner layer may include a lattice. At least portions of the handle, the inner layer, the first outer faceplate and the second outer faceplate are integrally formed as a single unitary body.

Description

BACKGROUND

Pickleball is the fastest growing racquet sport. There is a continuing need to provide a pickleball paddle that improves a player's performance and/or confidence.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a front perspective view of an example pickleball paddle.

FIG. 1B is a top, side perspective view of set of example lattice structures for a pickleball paddle

FIG. 2 is a front, side perspective view of another example pickleball paddle.

FIG. 3A is a front, side perspective view of an example inner core of a pickleball paddle.

FIG. 3B is an enlarged side perspective view of the inner core of FIG. 3A.

FIG. 4A is a front, side perspective view of another example inner core of a pickleball paddle.

FIG. 4B is an enlarged side perspective view of the inner core of FIG. 4A.

FIG. 5 is a front, side perspective view of another example inner core of a pickleball paddle.

FIG. 6 is an enlarged side perspective view of another example inner core of a pickleball paddle.

FIG. 7 is a front, side perspective view of another example inner core of a pickleball paddle.

FIG. 8 is a front, side perspective view of another example inner core of a pickleball paddle.

FIG. 9A is a front, side perspective view of another example inner core of a pickleball paddle.

FIG. 9B is an enlarged front, side perspective view of the example inner core of a pickleball paddle of FIG. 9A.

FIGS. 9C is a front view of another example pickleball paddle produced from an additive manufacturing process.

FIGS. 9D is a front perspective view of another example pickleball paddle produced from an additive manufacturing process utilizing dynamic modeling and impact analysis.

FIGS. 9E is a side front perspective view of the pickleball paddle of FIG. 9D.

FIG. 9F is an enlarged view of a portion of the head of the pickle ball paddle of FIG. 9E.

FIG. 10A is a front view of a portion of another example inner core of a pickleball paddle.

FIG. 10B is a side view of the portion of the example inner core of a pickleball paddle of FIG. 10A.

FIG. 11 is a transverse sectional view of another example pickleball paddle.

FIG. 12 is a front, side perspective view of another example pickleball paddle.

FIG. 13 is an end perspective view of an inner core of another example pickleball paddle.

FIG. 14 is a front view of another example pickleball paddle.

FIG. 15 is a front, side perspective view of another example pickleball paddle.

FIGS. 16 through 20 are transverse sectional views of other example pickleball paddles taken alone line 16-16 of FIG. 15.

FIG. 21A is a front view of another example pickleball paddle.

FIG. 21B is a transverse sectional view of the pickleball paddle taken along line 21B-21B of FIG. 21A.

FIG. 22 is a transverse sectional view of another example pickleball paddle.

FIG. 23A is a front view of another example pickleball paddle.

FIG. 23B is a transverse sectional view of the pickleball paddle taken along line 23B-23B of FIG. 23A.

FIG. 24A is a front side perspective view of another example pickleball paddle.

FIG. 24B is a transverse sectional view of the pickleball paddle taken along line 24B-24B of FIG. 24A.

FIG. 24C is a transverse sectional view of the pickleball paddle taken along line 24C-24C of FIG. 24A.

FIG. 24D is a transverse sectional view of the pickleball paddle taken along line 24D-24D of FIG. 24A.

FIG. 25A is a front side perspective view of another example pickleball paddle.

FIG. 25B is a transverse sectional view of the pickleball paddle taken along line 25B-25B of FIG. 25A.

FIG. 25C is a transverse sectional view of the pickleball paddle taken along line 25C-25C of FIG. 25A.

FIG. 26 is a front side perspective view of another example pickleball paddle.

FIGS. 27 through 29 are transverse sectional views of other example pickleball paddles.

FIG. 30 is a side perspective view of an inner core of an example pickleball paddle.

FIG. 31 is a front perspective view of the inner core of FIG. 30.

FIG. 32A is a front view of another example pickleball paddle.

FIG. 32B is a transverse sectional view of the pickleball paddle taken along line 32B-32B of FIG. 32A.

FIG. 33 is a transverse sectional view of another example pickleball paddle.

FIG. 34A is a front view of another example pickleball paddle.

FIG. 34B is a transverse sectional view of the pickleball paddle taken along line 34B-34B of FIG. 34A.

FIG. 35 is a transverse sectional view of another example pickleball paddle.

FIG. 36A is a front view of another example pickleball paddle.

FIG. 36B is a transverse sectional view of the pickleball paddle taken along line 36B-36B of FIG. 36A.

FIG. 37A is a front perspective view of an example pickleball paddle kit with replaceable faceplates.

FIGS. 37B and 37C are front views of pickleball paddles of the pickleball paddle kit of FIG. 37A.

FIG. 38A is a front perspective view of another example pickleball paddle.

FIG. 38B is a transverse view of the pickleball paddle taken along line 38B-38B of FIG. 38A.

FIG.38C is a transverse sectional view of the pickleball paddle taken along line 38C-38C of FIG. 38A.

FIG. 38D is a longitudinal sectional view of the pickleball paddle taken along line 38D-38D of FIG. 38A.

FIG. 39A is a front perspective view of an example pickleball paddle kit with replaceable handles.

FIG. 39B is a front side perspective view of a pickleball paddle of the pickleball paddle kit of FIG. 39A.

FIG. 40A is an exploded front perspective view of another example pickleball paddle.

FIG. 40B is a front perspective view of another example pickleball paddle.

FIG. 40C is an end perspective view of another example pickleball paddle.

FIGS. 41 through 45 are front views of other example pickleball paddles.

FIG. 46 is a plan view of an example pickleball paddle.

FIG. 47 is a plan view of an example pickleball paddle.

FIG. 48 is a perspective view of the example pickleball paddle of FIG. 47, further illustrating example unit cell geometries for different regions of the pickleball paddle.

FIG. 49 is a sectional view of the pickleball paddle of FIG. 47 taken along line 49-49.

FIG. 50 is a sectional view of the pickleball paddle of FIG. 47 taken along line 50-50.

FIG. 51 is a sectional view of the pickleball paddle of FIG. 47 taken along line 51-51.

FIG. 52 is an enlarged sectional view of a portion of the pickleball paddle of FIG. 47 according to another implementation of the present invention.

FIG. 53 is an enlarged perspective view of a portion of an example pickleball paddle of FIG. 47 according to another implementation of the present invention.

FIG. 54 is an exploded perspective view of an example pickleball paddle.

FIG. 55 an exploded perspective view of an example pickleball paddle.

FIG. 55 is a top view of an example inner layer of the pickleball paddle of FIG. 55.

FIG. 56 is a plan view of an example pickleball paddle.

Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements. The figures are not necessarily to scale, and the size of some parts may be exaggerated to more clearly illustrate the example shown. Moreover, the drawings provide examples and/or implementations consistent with the description; however, the description is not limited to the examples and/or implementations provided in the drawings.

DETAILED DESCRIPTION OF EXAMPLES

FIG. 1 illustrates an example pickleball paddle 20, or a paddle for use in the sport of pickleball. Paddle 20 provides the user with desirable sound and feel as well as a large sweet spot for striking a pickleball ball. Paddle 20 comprises handle 30 and head 40. Handle 30 extends from head 40 and is configured for being gripped by a person's hand or hands. In the example illustrated, handle 30 has a polygonal cross-sectional shape. In other implementations, handle 30 may have a circular or oval cross-sectional shape.

The handle 30 is a longitudinal tubular structure having a distal end and proximal end. The distal end of the handle 30 is coupled to the head 40. The handle 30 can include a grip 34 (FIG. 32A) to enhance the ability of a player to grasp, hold and manipulate the paddle 20. The handle 30 can further include a butt cap 36 (FIG. 32A) coupled to the proximal end of the handle 30. In one implementation, the butt cap 36 can be directly adhesively bonded to the proximal end. In an alternative implementation, the butt cap can be thermally bonded, mechanically fastened, or otherwise directly attached to the proximal end.

In one implementation, the handle 30 can be integrally formed with, and connected to, the head 40 to form a one-piece frame. Referring to FIGS. 24C and 24D, in one implementation, a perimeter of the head 40 and the handle 30 can be formed through bladder molding from a fiber composite material. The fiber composite material is molded to form the rim or perimeter of head 40 and a hair pin 2132 of the handle 30. In one implementation, a polyurethane foam, or other foam, can be applied to the hairpin to from a foamed pallet 2134 for receiving the grip 34. In another implementation, the fiber composite material can be molded to form the pallet that receives the grip 34. In another implementation, the handle 30 can be formed separate from and coupled to the head 40. The handle 30 is configured for grasping by one or more hands of a user during play. The handle 30 can be formed of one or more materials such as a carbon-fiber composite material. Alternatively, the handle 30 can be formed of other materials such as other composite materials, aluminum, other metallic alloys, wood, a polyurethane foam, a thermoplastic material, a thermoset material and combinations thereof.

Head 40 is coupled to handle 30 and provides two opposing faces for striking a pickleball ball. Head 40 comprises an inner layer 42 sandwiched between a first outer faceplate 44 and a second opposite outer faceplate 46. In the example illustrated, head 40 additionally comprises an edge strip or bumper 48. For purposes of this disclosure, the term “coupled” means directly or indirectly connected. For example, a handle can be integrally formed to a head, or the handle can be separated from the head by one or more intermediate components. In each example, the handle is coupled to the head. In the context of railroad cars, a caboose of a train can be directly connected to an engine of the train. Alternatively, one or more railroad cars can be positioned between the engine and the caboose. In each case, whether directly connected or separated by one or more railroad cars, the caboose is coupled to the engine.

Inner layer 42 comprises a layer composed of multiple levels of individual cells, a stack of cellular layers, which may be aligned or offset relative to one another. FIG. 1B illustrates various examples of such multi-level cellular material that may be used for inner layer 42. As shown by FIG. 1B, inner layer 42 may be formed from multi levels of rhombic cells 50, multi levels of Kagome cells 52, multi levels of Voronai cells, multi levels of Vorobom cells 54, multi levels of vorofc cells 56, multi levels of a first type of tetra cells 58, multi levels of a second different tetra cells 60, multi levels of Voro-1 cells 62 or multi levels of voro-2 cells 64. Each of the different candidates may be formed using a micro layer-by-micro layer additive manufacturing process. The multi levels of cells provide paddle 20 with enhanced stiffness and coefficient of restitution performance at a lower weight. In some implementations, the cells may form a nonorthogonal lattice, where the cells are not arranged so as to face in directions perpendicular to faceplates 44 and 46.

In one implementation, each of the different multilevel cellular layers may be formed from a material such as polypropylene, polyurethane, polyester, thermoplastic polyurethane (TPU), polyamide, other rigid polymer or glass/carbon filled polymer composite. In other implementations, inner layer 42 may have other layer geometries. For example, as will be described hereafter, inner layer 42 may alternatively have a closed cavity array geometry as shown in FIGS. 6-8. In yet other implementations, inner layer 42 may have variations of the example orthogonal lattice in the form of a single layer of honeycomb cells or multiple such layers of honeycomb cells, single layer of such honeycomb cells being shown in FIGS. 10A and 10B.

In some implementations, the inner layer 42 can be formed of a urethane foam, polypropylene, Nomex® polycarbonamide material, ethylene vinyl acetate (EVA), aluminum, balsa, corrugated cardboard, a rubber, polyethylene, polyvinyl chloride, a polyethylene vinyl acetate, other polymeric foams, other lightweight elastic foams, other types of wood, other metallic alloys, and combinations thereof. In some implementations, the cells of inner layer 42 may be filled or injected with a different material. For example, in one implementation, the cells of inner layer 42 may be injected with a foam material. In some implementations, selected portions of inner layer 42 may have their cells filled or injected with material, such as a foamed material or other selected portions of inner layer 42 have empty or unfilled cells. In one implementation, first selected portions may have cells filled with a first material, such as a first foamed material, second selected portions may have cells filled with a second material such as a second different foamed material and third portions having empty void cells. In such implementations, the selective filling of cells at selected locations may provide different stiffness levels and coefficient of restitution and different portions of the face of the paddle 20 to optimize performance and feel. In some implementations, the selective filling of cells may form a visually attractive design, logo, image or other graphic, which may be viewable in implementations where one or both of faceplates 44, 46 are translucent. In some implementations, different cells may be filled with different colored materials such as different colored foamed materials to provide a unique design, logo, graphic or the like which is viewable through a translucent faceplate 44 and/or 46.

Outer faceplates 44 and 46 extend on opposite sides of inner layer 42. Outer faceplates 44 and 46 comprise panels or plates that extend generally parallel to one another. In one implementation, faceplates 44 and 46 are opaque. In another implementation, one or both of faceplates 44 and 46 is formed from a translucent material. For purposes of disclosure, the term “translucent” encompasses both transparent and semi-transparent structures. Transparent structures allow light to pass through and the details of underlying structure(s) to be seen through such transparent structures. In contrast, semi-transparent structures allow diffused light, but not detailed shapes, to pass through the material without the detailed shapes and edges of structures behind the semi-transparent structure to be discernible. In one implementation, plates 44 and 46 are similar to one another in composition and stiffness. In another implementation, plates 44 and 46 are different in chemical composition, thickness and/or stiffness characteristics.

In one implementation, faceplates 44 and 46 are formed from the same material. In other implementations, faceplates 44 and 46 are formed from different materials having different material properties. In one implementation, faceplates 44 and 46 may be formed from materials such as a fiber-composite material, a braided fiber composite material, a woven material, nonwoven fibers embedded in a polymeric matrix, and combinations thereof. As used herein, the terms “composite material” or “fiber composite material” refer to a matrix or a series of plies (also referred to as sheets or layers) of fiber bundles impregnated (or permeated throughout) with a resin. The fiber bundles can be co-axially bundled and aligned in the plies. A single ply typically includes hundreds or thousands of fiber bundles that are initially arranged to extend coaxially and parallel with each other through the resin that is initially uncured. Each of the fiber bundles includes a plurality of fibers. The fibers are formed of a high tensile strength material such as carbon. Alternatively, the fibers can be formed of other materials such as, for example, glass, graphite, boron, basalt, carrot, Kevlar®, Spectra®, poly-para-phenylene-2, 6-benzobisoxazole (PBO), hemp and combinations thereof. In one set of preferred embodiments, the resin is preferably a thermosetting resin such as epoxy or polyester resins. The resin can be formed of the same material from one ply to another ply. Alternatively, each ply can use a different resin formulation. During heating and curing, the resin can flow between plies and within the fiber bundles. The faceplates 44 and/or 46 can be coated with one or more layers of paint and/or clear coats. Examples of translucent materials which may be used to form faceplate 44 and/or 46 include, but are not limited to, polycarbonate, poly methyl methacrylate, polyamide 11, polyolefins (e.g, polyethylene), or polyurethane.

In one implementation, plates 44 and 46 are adhesively bonded to opposite faces of inner layer 42. In yet another implementation, plates 44 and 46 are welded or fused to inner layer 42. In some implementations, plates 44 and 46 are integrally formed as a single unitary body with inner layer 42, such as where inner layer 42 and layers or faceplates 44 and 46 are formed through additive manufacturing techniques. The term integrally means the components, such as, for example, the inner layer and the faceplates, are formed as one single unitary body, which cannot then be separated into separate components without damaging one or more of the inner layer or the faceplates. As will be described hereafter, in yet other implementations, plates 44 and/or 46 may be removably mounted to paddle 20, over inner layer 42, facilitating exchange of faceplates 44 and/or 46 for customization or modification of paddle 20.

Bumper 48 comprises a strip of material covering the outer peripheral edge of inner layer 42. In one implementation, bumper 48 is opaque, concealing inner layer 42. In other implementations, bumper 48 is translucent, facilitating a view of inner layer 42. In one implementation, bumper 48 may be formed from a thin strip of a polymeric film or tape adhesively bonded to the exterior of inner layer once 42. In yet other implementations, bumper 48 may be a layer that is coated about the peripheral edge of inner layer 42. Examples of materials from which bumper 48 may be formed include, but are not limited to, nylon, rubber, a thermoplastic material, a thermoset material, wood and combinations thereof. In other implementations, the paddle may be formed without a bumper.

FIG. 2 illustrates an example pickleball paddle 120. Pickleball paddle 120 comprises handle 130 and head 140. Paddle 120 is similar to paddle 20 except that paddle 120 is illustrated without bumper 48 to illustrate the example nonorthogonal lattice 150 forming inner layer 142 sandwiched between faceplates 44 and 46. The non-orthogonal lattice 150 comprises a three-dimensional array of lattice segments joining interconnecting nodes and forming a two dimensional array or three-dimensional array of pockets or cells having faces facing in directions or centerlines extending in directions nonparallel (non-orthogonal) to the plane of the outer faceplate 44 and 46. Because the cells face in directions nonorthogonal to the faceplates 44 and 46, the cells may produce generate a lower volume of sound when striking a pickleball ball. In addition, the cells may provide a more desirable stiffness and coefficient of restitution when striking a pickleball.

In one implementation, paddle 120 includes bumper 48 that is opaque. In another implementation, paddle 120 includes a bumper 48 that is translucent. In yet another implementation, paddle 120 may omit bumper 48, reducing the weight of paddle 120 and revealing inner layer 142. As shown by FIG. 2, in addition to forming an interior core of head 140, inner layer 142 extends from head 142 also form an inner core or middle layer of handle 130. A pallet 132 can be applied over the inner core or middle layer of handle 130. As a result, paddle 120 provides enhanced stiffness and enhanced feel.

FIGS. 3A and 3B illustrate inner layer 142 in more detail. FIG. 3B illustrates the orientation and configuration of the individual cells forming nonorthogonal lattice 150. In one implementation, nonorthogonal lattice 150 comprises a polymer such as rigid polyurethane. In other implementations, lattice 50 may be formed from other materials such as thermoplastic polyurethane, polypropylene, Nomex® polycarbonamide material, ethylene vinyl acetate (EVA), polyethylene, polyvinyl chloride, a polyethylene vinyl acetate, polyamide, acrylonitrile butadiene styrene (ABS), poly ether (ether) ketone, polylactic acid, acrylate-based polymeric system mimicking one of the aforementioned polymers, other polymeric materials, other lightweight elastomeric, thermoplastic or thermoset materials, and combinations thereof. In one implementation, the nonorthogonal as 150 comprise a single layer of lattices having a thickness of at least 0.1 mm and no greater than 10 mm. In one implementation, the nonorthogonal lattice 150 is formed by additive manufacturing, wherein the lattice 150 is formed on a continuous or discrete layer-by-layer basis and wherein lattice 150 may be formed from multiple individual and consecutively deposited layers of material.

FIGS. 4A and 4B illustrate an example inner layer 242 which may be used in place of layer 142 of paddle 120. Like inner layer 142, inner layer 242 is formed from a single integral layer of material forming a nonorthogonal lattice 250. Layer 242 has a nonorthogonal lattice 250 different than lattice 150. Lattice 250 provides an alternative feel, stiffness and coefficient of restitution as compared to lattice 150. In one implementation, lattice 250 may be formed by an additive manufacturing process. In one implementation, lattice 250 may be formed from a polymer such as Rigid polyurethane. In other implementations, lattice 250 may be formed from other materials such as thermoplastic polyurethane, polypropylene, Nomex® polycarbonamide material, ethylene vinyl acetate (EVA), polyethylene, polyvinyl chloride, a polyethylene vinyl acetate, polyamide, acrylonitrile butadiene styrene (ABS), poly ether (ether) ketone, polylactic acid, acrylate-based polymeric system mimicking one of the aforementioned polymers, other polymeric materials, thermoplastic polyurethane, polypropylene, Nomex® polycarbonamide material, ethylene vinyl acetate (EVA), polyethylene, polyvinyl chloride, a polyethylene vinyl acetate, polyamide, acrylonitrile butadiene styrene (ABS), poly ether (ether) ketone, polylactic acid, acrylate-based polymeric system mimicking one of the aforementioned polymers, other polymeric materials, other lightweight elastomeric, thermoplastic or thermoset materials, and combinations thereof.

FIG. 5 illustrates an example inner layer 342 which may be used in place of layer 142 of paddle 120. Like inner layer 142, inner layer 342 is formed from a single integral layer of material forming a nonorthogonal lattice 350. Layer 342 has a nonorthogonal lattice 350 different than lattice 150. Lattice 350 provides an alternative feel, stiffness and coefficient of restitution as compared to lattice 150. In one implementation, lattice 350 may be formed by an additive manufacturing process. In one implementation, lattice 350 may be formed from a polymer such as rigid polyurethane. In other implementations, lattice 350 may be formed from other materials such as thermoplastic polyurethane, polypropylene, Nomex® polycarbonamide material, ethylene vinyl acetate (EVA), polyethylene, polyvinyl chloride, a polyethylene vinyl acetate, polyamide, acrylonitrile butadiene styrene (ABS), poly ether (ether) ketone, polylactic acid, acrylate-based polymeric system mimicking one of the aforementioned polymers, other polymeric materials, other lightweight elastomeric, thermoplastic or thermoset materials, and combinations thereof thermoplastic polyurethane, polypropylene, Nomex® polycarbonamide material, ethylene vinyl acetate (EVA), polyethylene, polyvinyl chloride, a polyethylene vinyl acetate, polyamide, acrylonitrile butadiene styrene (ABS), poly ether (ether) ketone, polylactic acid, acrylate-based polymeric system mimicking one of the aforementioned polymers, other polymeric materials, other lightweight elastomeric, thermoplastic or thermoset materials, and combinations thereof.

FIG. 6 illustrates portions of an example inner layer 442. Like inner layer 142, inner layer 442 is formed from a single integral layer of material forming a closed cavity array 450. In the example illustrated, array 450 comprises a closed cavity array in the form of an array of pyramidal voids 452 formed by interconnected triangular facets 454, wherein the pyramidal voids 452 face plates 44 and 46 (shown in FIG. 1) while the triangular facets face in directions nonorthogonal to plates 44 and 46. Array 450 provides an alternative feel, stiffness and coefficient of restitution as compared to lattice 150. In one implementation, array 450 may be formed by an additive manufacturing process. In one implementation, array 450 may be formed from a polymer such as rigid polyurethane. In other implementations, array 450 may be formed from other materials such as thermoplastic polyurethane, polypropylene, Nomex® polycarbonamide material, ethylene vinyl acetate (EVA), polyethylene, polyvinyl chloride, a polyethylene vinyl acetate, polyamide, acrylonitrile butadiene styrene (ABS), poly ether (ether) ketone, polylactic acid, acrylate-based polymeric system mimicking one of the aforementioned polymers, other polymeric materials, other lightweight elastomeric, thermoplastic or thermoset materials, and combinations of thermoplastic polyurethane, polypropylene, Nomex® polycarbonamide material, ethylene vinyl acetate (EVA), polyethylene, polyvinyl chloride, a polyethylene vinyl acetate, polyamide, acrylonitrile butadiene styrene (ABS), poly ether (ether) ketone, polylactic acid, acrylate-based polymeric system mimicking one of the aforementioned polymers, other polymeric materials, other lightweight elastomeric, thermoplastic or thermoset materials, and combinations thereof.

FIGS. 7 and 8 illustrate example inner layers 542 and 642, respectively, which may be used in place of layer 142 of paddle 120. Like inner layer 142, inner layers 542 and 642 are formed from a single integral layer of material forming closed cavity arrays 550 and 650, respectively. Arrays 550 and 650 are each formed from a single panel or plate of material repeatedly folded molded or deformed to provide the individual pockets or cells 552.Cells 652 differ from cells 552 in the cell 652 each include an opposite flats 654, which may facilitate bonding to plates 42 and 44. Arrays 550 and 650 provide alternative feel, stiffness and coefficient of restitution as compared to lattice 150. In one implementation, arrays 550 and 650 may be formed by an additive manufacturing process. In one implementation, arrays 550 and 650 may be formed from a polymer such as rigid polyurethane. In other implementations, arrays 550 and 650 may be formed from other materials such as thermoplastic polyurethane, polypropylene, Nomex® polycarbonamide material, ethylene vinyl acetate (EVA), polyethylene, polyvinyl chloride, a polyethylene vinyl acetate, polyamide, acrylonitrile butadiene styrene (ABS), poly ether (ether) ketone, polylactic acid, acrylate-based polymeric system mimicking one of the aforementioned polymers, other polymeric materials, other lightweight elastomeric, thermoplastic or thermoset materials, and combinations thereof.

FIGS. 9A and 9B illustrate an example inner layer 742 which may be used in place of layer 142 of paddle 120. Inner layer 742 is formed from a single integral layer of material forming multiple levels of cells in the form of a mesh 750. Mesh 750 is formed from an integral mesh of layers of cells which are offset and overlap one another. In the example illustrated, mesh 750 is in the form of a lattice structure. Mesh 750 provides an alternative feel, stiffness and coefficient of restitution as compared to lattice 150. Mesh 750 can comprise cells of varying sizes such that the inner layer 742 can essentially have regions of more compact cells or smaller cells, and other regions of larger or less compacted cells. The integral mesh of layers of cells can be offset, overlapped or sized to form virtually any form of additional structural support. For example, in FIGS. 9A and 9B, mesh region 751 is a longitudinally extended region of higher density, and/or more compacted cells and mesh region 753 is a transversely extended region of higher density and/or more compacted cells. The remaining portions of mesh 750 have larger, lower density and/or less compacted cells. In other implementations, the shape, size and cell configuration of mesh regions 751 and 753 can be varied. The cross pattern of FIG. 9A can be replaced with other patterns and other sizes of patterns. In one implementation, mesh 750 may be formed by an additive manufacturing process. In one implementation, mesh 750 may be formed from carbon or a polymer such as rigid polyurethane. In other implementations, mesh 750 may be formed from other materials such as thermoplastic polyurethane, polypropylene, Nomex® polycarbonamide material, ethylene vinyl acetate (EVA), polyethylene, polyvinyl chloride, a polyethylene vinyl acetate, polyamide, acrylonitrile butadiene styrene (ABS), poly ether (ether) ketone, polylactic acid, acrylate-based polymeric system mimicking one of the aforementioned polymers, other polymeric materials, other lightweight elastomeric, thermoplastic or thermoset materials, and combinations thereof.

Referring to FIG. 9C, in one implementation a paddle 720-1 can be produced through an additive manufacturing process. The pickleball paddle 720-1 is a one-piece structure. In the example illustrated, the one piece structure forms a handle 730-1 and a head 740-1. The handle 730-1 may have an oval or cylindrical shape extending from head 740-1 and terminating at an outwardly flared butt end 731. The handle 730-1 has a core and the head 740-1 has an inner layer 742-1 formed from a mesh in the form of a lattice 750-1. Although the lattice 750-1 has varying thickness, lattice 750-1 continuously extends through the core of the handle 730 in the inner layer 742-1 of head 740-1. In the example illustrated, the lattice 750-1 is encapsulated with a transparent film or layer, which forms the exterior 732 of handle 730-1 and also forms faceplates 744 and 746 on opposite sides of inner layer 742-1 of head 740-1. In the example illustrated, the transparent film or layer is continuous and imperforate. In one implementation, the faceplates 744 and 746 and the exterior 732 can be integrally formed as part of a one-piece paddle 720-1. In another implementation, the faceplates 744 and 746 and/or the exterior 732 of the handle 730 can be applied to the one-piece head 740-1 and handle 730-1. As a result, the paddle 720-1 of FIG. 9C can be used for play as shown.

Alternatively, a grip can be added to the handle 730, decals or other alphanumeric and/or graphical indicia can be applied to the outer faceplates 744 and 746. In other implementations, a bumper may be applied around the perimeter of the head 740. In another implementation, the head or the handle may be formed from a process other than additive manufacturing while the other of two portions of the paddle can be formed from the additive manufacturing process. In another implementation, the bumper can also be formed from the additive manufacturing process.

FIGS. 9D and 9E illustrate another implementation of a pickleball paddle 720-2 from using computer modeling, dynamic modeling and/or impact analysis. Paddle 720-2 comprises a handle. Computer modeling, dynamic modeling and/or impact analysis can be used to select the configuration of a mesh 750 formed through an additive manufacturing process. Through computer modeling, dynamic modeling and/or impact analysis, the size, shape, number, density, and position of the cells or structure of the mesh can be varied to provide the optimal or preferred configuration for a particular application, player, playability feature, league, coach's preference or other factors.

In the implementation of FIGS. 9D and 9E, a computer model simulating the application of a 3 kg load applied to multiple locations about an outer faceplate 744 or 746 of pickleball paddle 720-2 was performed. The load was applied over a half-inch diameter area, and a deflection of 0.005 inch was utilized as the maximum allowable deflection. The computer model can be used to simulate the paddle test plan of USAPA Pickleball. The computer analysis can analyze the deflections for the 3 kg applied loads at the multiple impact locations. The analysis can be performed in numerous iterations in which one or more characteristics of the mesh as described can be varied. For example, the density, size and shape of the cells or other structure forming the mesh 750 were varied.

In another implementation, a dynamic model simulating the impact of a pickleball (not shown) with an outer faceplate 744 or 746 of a pickleball paddle 720-2 can be utilized. The model can simulate the pickleball impacting the outer faceplate 744 of the paddle 720-2 at an incoming velocity at multiple impact positions about the outer faceplate 744 of the paddle 720-2. The dynamic analysis can analyze the pickleball exit velocities for simulated impacts at the multiple impact locations. The analysis can include hundreds of iterations in which several characteristics of the mesh as described above were varied.

The resulting data was then utilized to optimize the selection of each of the characteristics of the mesh 750 including the density, size, shape, number and configuration of the cells or other structure. In the implementation of FIGS. 9D and 9E, the density, size and shape of the structure of the mesh 750 is adjusted about the head 740-2 of the paddle 720-2 to provide the paddle 720-2 with an optimal performance level that satisfies the pickleball paddle requirements of the International Federation of Pickleball and/or the USA Pickleball Association. The head 740 includes a generally higher density structural zone or region 752 and a lower density structural zone or region 754. The shape and specific structure of the higher density structural region 752 may be defined by dynamic modeling and impact analysis. For example, the shape and structure of paddle 720 can be defined from an iterative topology optimization analysis In one implementation, dynamic analysis can be used to adjust the sound emanating from the pickleball paddle 720 upon impact. In other implementations, dynamic modeling and impact analysis can be used to develop paddles that provide alternate desirable performance characteristics and that satisfy the pickleball requirements of at least level of organized pickleball play.

Similar to pickleball paddle 720-1, the pickleball paddle 720-2 of FIGS. 9D and 9E is a one-piece structure produced from additive manufacturing. In the example illustrated, the one-piece structure forms a handle 730-2 and a head 740-2. The handle 730-2 has polygonal cross sectional shape and extends from head 740-2 and terminates at an outwardly flared butt end 731. The handle 730-2 has a core and the head 740-2 has an inner layer 742-2 formed from a mesh in the form of a lattice 750-2. Although the lattice 750-2 has varying thickness, lattice 750-2 continuously extends through the core of the handle 730-2 and the inner layer 742-2 of head 740-2.

In the example illustrated, the lattice 750-2 is surrounded with an outer film or layer which in integrally formed with the lattice 750-2 and forms the exterior 732 of handle 730-1 and also forms faceplates 744 and 746 on opposite sides of inner layer 742-2 of head 740-2. As shown by FIG. 9D, in one implementation, the outer layer 732 forms an exterior comprising a series of spaced ribs or strips 733 longitudinally extending along the handle and encircling the handle. As shown by FIG. 9E, in yet another implementation, outer layer 732 may be continuous and imperforate on opposite sides of handle 730-2, and having open sides so as to expose lattice 750-2 extending within handle 730-2. In the example illustrated, the outer layer 732 is continuous and imperforate across inner layer 742-2 to form faceplates 744 and 746. As shown by FIG. 9D, in some implementations, the outer layer 730 is translucent or transparent to reveal the geometry of inner layer 742-2. As shown by FIG. 9E, in some implementations, the outer layer 732 may be opaque.

As further shown by FIG. 9E, junctures between lattice 750-2 and the integrally formed faceplates 744 and 746 include fillets 751 which are located in the corners between lattice 750-2 and the opposite faceplates 744 and 746. Fillets 751 increase the surface area at the ends of the lattice struts connected to the faceplates 744 and 746 to strengthen the connection between lattice 750-2 and the faceplates 744, 746 extending across faces of inner layer 742.

The paddle 720-2 of FIGS. 9E and 9E may be used for play as shown. Alternatively, a grip can be added to the handle 730-2, decals or other alphanumeric and/or graphical indicia can be applied to the outer faceplates 744 and 746. In other implementations, a bumper may be applied around the perimeter of the head 740-2. In another implementation, the head or the handle may be formed from a process other than additive manufacturing while the other of two portions of the paddle can be formed from the additive manufacturing process. In another implementation, the bumper can also be formed from the additive manufacturing process.

In the example illustrated, head 740-2 may be formed with the use of additive manufacturing and dynamic modeling. The design configurations of the mesh and the pickleball paddle as a whole can be varied in an almost infinite number of variations. A design configuration can be uniformly applied over the mesh, the head portion of the paddle or the entire pickleball paddle. Alternatively, the design configuration can be varied across the mesh, head portion and/or the entire pickleball paddle. Some of the design characteristics of the cells or structure of the mesh, the head portion of the paddle or the paddle as a whole that can be adjusted and produced using additive manufacturing and/or dynamic modeling include, for example, the density, the size, the shape, the thickness, the material, the height, the stiffness gradient, the shear gradient and combinations thereof.

FIGS. 10A and 10B illustrate portions of an example inner layer 842 which may have the same shape and dimensions as that of inner layers 42-742 described above. Inner layer 842 comprises an orthogonal lattice 850 in the form of a two-dimensional array of orthogonal lattices such as honeycomb cells 852. The honeycomb cells 852 may be formed from an additive manufacturing process, may be formed from an extrusion process or other process. FIG. 10A provides dimensions for one example lattice 850. In other implementations, lattice 850 and its individual cells 852 may have other corresponding dimensions. In the example illustrated, cells 852 have centerline 851 that extends between plates 44 and 46 as shown in FIG. 1, or between opposing faces of inner layer 842. In particular, lattice 850 has a first face 856 that abuts or faces plate 44 and a second opposite face 858 that faces or abuts plate 46.

FIG. 11 is a sectional view of an example pickleball paddle 920. Paddle 920 is similar to paddle 20 described above except that paddle 920 comprises an inner layer 942 in place of inner layer 42. Inner layer 942 is similar to inner layer 842 described above except that the individual cells 852 are oriented so as to have centerline that extend parallel to plates 44 and 46 rather than orthogonal to plates 44 and 46. In one implementation, the individual cells 852 are centered along lines that extend perpendicular to the longitudinal axis of handle 30 (shown in FIG. 1), yet parallel to plates 44 and 46. In another implementation, the individual cells 852 are centered along lines that extend parallel to the longitudinal axis of handle 30 shown in FIG. 1 yet parallel to faces 44 and 46. In yet another implementation, the individual cells 852 centered along lines that extend oblique to the longitudinal axis of handle 30, yet parallel to faces 44 and 46.

Lattice 942 can provide an alternative feel, stiffness and/or coefficient of restitution as compared to lattice 150. In one implementation, lattice 942 may be formed by an additive manufacturing process. In yet another implementation, lattice 942 may be formed from an extrusion process. In one implementation, lattice 942 may be formed from a polymer such as rigid polyurethane. In other implementations, lattice 942 may be formed from other materials such as thermoplastic polyurethane, polypropylene, Nomex® polycarbonamide material, ethylene vinyl acetate (EVA), polyethylene, polyvinyl chloride, a polyethylene vinyl acetate, polyamide, acrylonitrile butadiene styrene (ABS), poly ether (ether) ketone, polylactic acid, acrylate-based polymeric system mimicking one of the aforementioned polymers, other polymeric materials, other lightweight elastomeric, thermoplastic or thermoset materials, and combinations thereof.

FIG. 12 illustrates an example inner layer 1042, which may be used in place of layer 142 of paddle 120. Inner layer 1042 is similar to inner layer 842 described above except that inner layer 842 additionally comprises perforated top and bottom panels 1056 which extend over and which are connected to the walls of the individual cells 852. Panels 1056 each include openings or perforations 1058 generally located opposite to the interiors of the individual cells 852. Perforations 1058 reduce the weight of inner layer 1042 and that of the pickleball paddle comprising inner layer 1042. In some implementations, perforations 1058 may be omitted, wherein panels 1056 are imperforate. Panels 1056 provided large surface area for bonding to plates 44 and 46 shown in FIGS. 1 and 2 as well as the pallets 132 completing handle 130. In one implementation, the panels 1056 can be used as the outer surface of the head of paddle without the use of plates 44 and 46. In another implementation, the panels 1056 may be covered with only an outer coating and/or indicia in lieu of plate 44 and 46.

In one implementation, the walls of the individual cells 852 and panels 1056 are integrally formed as a single unitary body. In one implementation, such an inner layer 1042 may be formed from an additive manufacturing process. In yet other implementations, the cells 852 may be formed as a single layer, which is then bonded to layers 1056. In one implementation, lattice 1042 may be formed from a polymer such as rigid polyurethane. In other implementations, lattice 1042 may be formed from other materials such as thermoplastic polyurethane, polypropylene, Nomex® polycarbonamide material, ethylene vinyl acetate (EVA), polyethylene, polyvinyl chloride, a polyethylene vinyl acetate, polyamide, acrylonitrile butadiene styrene (ABS), poly ether (ether) ketone, polylactic acid, acrylate-based polymeric system mimicking one of the aforementioned polymers, other polymeric materials, other lightweight elastomeric, thermoplastic or thermoset materials, and combinations thereof.

FIG. 13 illustrates an example inner layer 1142, which may be used in place of inner layer 142 of paddle 120. Inner layer 1142 comprises a generally hollow container or body having an empty interior bordered by an outer periphery formed by an open-celled wall 1150. Wall 1150 comprises a two dimensional array of irregular, differently shaped cells 1152. Cells 1152 reduce the weight of inner layer 1142 of providing structural strength and stiffness to inner layer 1142 and the pickleball paddle employing inner layer 1142. In other implementations, cells 1152 may have other shapes and densities.

In some implementations, the hollow interior bordered by wall 1150 may be filled with another material having different properties than the material forming wall 1150. For example, in other implementations, the hollow interior may be filled with a material the same as that of wall 150, but formed, containing close cells or pockets of air or gas. In yet other implementations, hollow interior may be filled with a different formed material. In implementations where the interior is filled with a foam material, the foamed material may reduce noise and increase stiffness while providing inner layer 1142 with a lower weight as compared to otherwise solid inner layers. The foam material can a urethane foam, other polymeric foams, other lightweight elastic foams and combinations thereof.

FIG. 14 illustrates an example inner layer 1242, which may be used in place of inner layer 142. Inner layer 1242 comprises a single continuous layer of cells/cavities 1250. Cells/cavities 1250 may comprise a honeycomb cells 852 (as shown in FIG. 10), openings within a nonorthogonal lattice structure (as shown in FIGS. 2-7), cells of a mesh (such as shown in FIGS. 9 and 10) or closed depressions or cavities of an array (such as shown in FIGS. 8-9). In contrast to the previously described inner layers, inner layer 1242 has selected portions that are filled with a material or multiple materials. For example, in implementations where inner layer 1242 is formed from a honeycomb pattern of cells 852 (as described above with respect to FIGS. 10 and 11), selected cells 85 to have interiors that are selectively filled. In implementations where inner layer 1242 is formed from a nonorthogonal lattice such as shown and described above with respect to FIGS. 2-7, selected cells 150, 250 and 1250 have interiors that are filled or injected with a material. In implementations where inner layer 1242 is formed from a closed cavity array (such as shown in FIGS. 8 and 9) where the floors are bottoms of the depressions forming the array are solid or closed, selected cavity interiors may be filled with a material.

In one implementation, the cells/cavities 1250 may be filled with a polymeric material. In some implementations, cells/cavities 1250 may be filled with a colored polymeric material. In some implementations, the cells/cavities 1250 may be filled with a foamed material. By selectively filling certain cells/cavities 1250 with different materials, different portions of inner layer 1242 may provide the paddle with different stiffnesses, coefficients of restitution, feel, weight distribution and performance parameters customized to a player's skill level or preferences. In addition, by selectively filling certain cells/cavities 1250 with different materials and by using a plate 44 and/or 46 having translucent properties in at least selected regions, ball striking cues, designs and logos may be provided. FIG. 14 illustrates various examples of such features incorporated into a single inner layer 1242. As should be appreciated, in some implementations, various combinations of the multiple features illustrated may be employed.

As shown by FIG. 14, inner layer 1242 comprises filled regions 1260, 1262, 1264 and 1266. Those remaining portions of inner layer 1242 comprise unfilled or empty cells or cavities. Filled region 1260 extends along the perimeter edge of inner layer 1242, generally adjacent to bumper 48 (when provided). In the example illustrated, filled region 1260 has a shape corresponding to or following the outer edge perimeter of inner layer 1242. Filled region 1260 comprise a material filling the cells/cavities 1250 that reduces noise and increases stiffness along the perimeter edge of inner layer 1242. In some implementations where bumper 48 is translucent or omitted, filled region 1260 may be formed from material having a desired color for providing the edge with a desired appearance. In one implementation, the material filling the cells or cavities comprise a foamed material such as a foamed polymer.

Filled region 1262 and 1264 comprise regions of the cells/cavities 1250 filled with different materials having different physical properties and/or different colors. The different physical properties provide different degrees of stiffness, coefficient of restitution and ball striking performance characteristics. For example, filled region 1264 may be filled with a stiffer material as compared to region 1262. In addition, regions 1262 and 1264 can be filled with different colors of material to provide a ball striking or hitting cue to the user, indicating a sweet spot of the paddle (where at least portions of plate 44 or 46 (shown in FIG. 1) are translucent). In some implementations, regions 1262 and 1264 are filled with the same foam material, but where the densities of the foamed material forming regions 1262 and 1264 are different (different density of internal closed cells or pockets in the material filling the larger cells/cavities 1250).

Filled region 1266 comprise regions of the cells/cavities 1250 filled with a material different than that of regions 1260, 1262 and 1264. The material forming filled region 1266 may have a selected color. Those individual cells/cavities 1250 filled in region 1266 may form a design, graphic or logo (such as the letter “L” shown). The material forming filled region processes may comprise a solid material or a foamed material. In one implementation, the foamed material may comprise a foamed polymer. In addition to providing a unique aesthetic appearance, which may be potentially viewed through plate 44 and/or plate 46, filled region can also provide a desired stiffness or other physical properties for the portion of inner layer 1242.

In one implementation, the entire surface area of 44 and/or 46 may be translucent in some implementations transparent. In other implementations, selected portions of plates 44 and 46 may be translucent or transparent while other portions remain opaque. For example, in one implementation, as shown by broken lines, plate 44 or plate 46 may be provided with a window 1269, wherein portions inside the window 1269 are translucent or transparent to allow viewing of filled regions 1262, 1264 and 1266 portions. The portions 1250 and 1260 outside of window 1269 are opaque, concealing filled region 1260. As shown by FIG. 14, unfilled cavities/cells 1250 may also be viewed through the translucent or transparent portions of the plate 44 and/or 46.

FIGS. 15 and 16 illustrate an example pickleball paddle 1320. Pickleball paddle 1320 comprises handle 30 and head 1340. As shown by FIG. 16, head 1340 comprises outer plates 44 and 46 sandwiching an inner layer 1342 therebetween. Head 1340 further comprises bumper 48 extending about the perimeter of inner layer 1342. As described above, plates 44, 46 and bumper 48 may be opaque in some implementations or may be translucent in other implementations.

Inner layer 1342 comprises sub layers 1370-1 and 1370-2 (collectively referred to as sub layers 1370). Sub layers 1370 comprise layers of different open celled material. In one implementation, each layer 1370 comprises a different layer of a nonorthogonal lattice. For example, in one implementation, layer 1370-1 may comprise a nonorthogonal lattice similar to that shown in FIGS. 3 and 4 while layer 1370-2 comprises a nonorthogonal lattice similar to that shown in FIGS. 5-6 or that are shown in FIG. 7. In other implementations, layers 1370 may comprise different closed cavity arrays such as shown in FIGS. 6-8. In yet other implementations, layers 1370 may comprise a first layer selected from a group of layers consisting of a nonorthogonal lattice, a closed cell cavity array, a mesh or a honeycomb array, and a second layer, different than the first layer, also selected from a group of layers consisting of a nonorthogonal lattice, a closed cell cavity array, a mesh or a honeycomb array. By providing inner layer 1342 with two different sub layers 1370-1 and 1370-2, paddle 1320 comprises two different striking performance capabilities: a first striking performance for balls struck by faceplate 44 and a second striking performance for ball struck by faceplate 46. As a result, a player may, depending upon the game circumstances, select which face, 44 or 46, to use to strike the ball depending upon the desires result.

In one implementation, layers 1370 are adhesively bonded to one another. In yet another implementation, layers 1370 are integrally formed from a single unitary body of material formed by an additive manufacturing process. In yet other implementations, layers 1370 simply rests alongside one another without intervening adhesive. In such an embodiment, the layers 1370 may be able to move independently with respect with each upon impact with a pickleball. In one implementation, layers 1370 have similar thicknesses. In yet other implementations, layers 1370 may have differing thicknesses.

In some implementations, layers 1370-1 and 1372 may be formed from different colored materials, while layers 44 and 46 are translucent, to visibly differentiate the layers and their different hitting characteristics. In certain implementations, selected portions of layer 1370-1 and/or layer 1370-2 may be filled with material. For example, such portion layer 1370-1 and/or 1370-2 may be selectively filled with material as described above with respect to FIG. 14. In such an implementation, plates 44 and 46 may be opaque, may be translucent are may be selectively opaque and selectively translucent in different portions. In one implementation, each of layers 1370-1 and 1370-2 are filled with different materials similar to the filling of layer 1242 described above with respect to FIG. 14. In such an implementation, both of plates 44 and 46 may have the above-described window 1269.

FIG. 17 is a sectional view illustrating head 1440 which may be used in place of head 1340 described above. Head 1440 is similar to head 1340 except that head 1440 omits bumper 48. As a result, the peripheral edges of layers 1370 are viewable.

FIG. 18 is a sectional view illustrating head 1540 which may be used in place of head 1340 described above. Head 1540 is similar to head 1340 except that head 1540 comprises an inner layer 1542. Inner layer 1542 is similar to inner layer 1342 except that inner layer 1542 additionally comprises release layer 1572. Release layer 1572 is sandwiched between layers 1370. Release layer 1572 facilitates transverse, sliding or independent movement of layer 1370-1 relative to layer 1370-2 upon the impact of the head 1540 of the paddle 1320 with a pickleball. In one implementation, release layer 1572 is bonded to, fused to or coated upon layer 1370-1 so as to move with layer 1370-1, yet slide relative to layer 1370-2 or move independently with respect to layer 1370-2. In yet other implementations, release layer 1572 can be bonded to, fused to or coated upon layer 1370-2 so as to move with layer 1370-2, yet slide or move independently relative to layer 1370-1. In yet other implementations, release layer 1572 is not secured to either of layers 1370, being movable relative to each of layers 1370. In one implementation, release layer 1572 may be formed from a layer of low friction material such as polytetrafluoroethylene. In yet other implementations, release layer 1572 may be formed from other materials such as polydimethylsiloxane (PDMS) or other low surface energy and/or lubricating polymers.

FIG. 19 is a sectional view illustrating head 1640 which may be used in place of head 1340 described above. Head 1640 is similar to head 1340 except that head 1640 comprises an inner layer 1642. Inner layer 1642 comprises sub layers 1370-2 (described above), 1670-1 and 1670-2. Sublayer 1670-1 is sandwiched between sub layers 1370-2 and 1670-2. Sublayer 1670-1 comprises a solid layer of material disposed between such layers. In implementations where faceplates 44 and 46 are translucent, sublayer 1670-1 separates layers 1370-2 and 1670-2 such that closed cavities or cells of the different layers 1370-2 and 1670-2 are not simultaneously viewable through a single one of faceplates 44, 46, providing a clear differentiation of such layers. In one implementation, sublayer 1670-1 may comprise a reflective material such as a white colored material or a metallic mirror -like layer of material. In some implementations, layer 1670-1 may be omitted, where an empty void is provided between layers 1370-2 and 1670-2 or where the thickness of one of layers 1370-2 and/or 1670-2 is increased to fill the void formed by the omission of layer 1670-1.

Sublayer 1670-2 can comprise a nonorthogonal lattice, similar to that described above with respect to FIGS. 2-4B. As schematically shown by the different depicted gradient, sublayer 1670-2 has a varying density of cells in a direction perpendicular to the plane of faceplates 44 and 46. In one implementation, the density of the individual cells of sublayer 1670-2 is greatest near sublayer 1670-1 and gradually decreases as layer 1670-2 approaches faceplates 44. In other implementations, this transition may be reversed where sublayer 1670-2 has a greatest density of cells near faceplates 44 and wherein the density gradually decreases as sublayer 1670-2 approaches faceplates 46. In still other implementations, instead of gradually transitioning between the highest density to the lowest density of cells, layer 1670-2 may provide one or more transitions in a stepwise fashion. Such a density variation may provide a selected stiffness and coefficient of restitution for the ball-striking surface of faceplates 44 four enhanced ball striking performance.

In one implementation, layer 1670-2 is formed on a micro layer by micro layer basis with an additive manufacturing process, facilitating the variation of the density of the individual cells, yet providing layer 1670-2 as a single integral unitary body of material. In one implementation, layer 1670-1 and 1370-2 are bonded, fused, or laid (without bonding or fusing) next to layer 1670-2. In yet other implementations, each of layers 1370-2, 1670-1 and 1670-2 are formed as a single integral unitary body of material such as with a micro layer by law micro layer additive manufacturing process. In some implementations, faceplates 44 and/or 46 as well as bumper 48 may also be formed as a single integral unitary body of material with layers 1670-2, 1670-1 and 1370-2 using a micro layer by micro layer additive manufacturing process. In some implementations, layer 1670 may be originally formed as a single unitary body with faceplates 44 while layers 1670-1 and/or 1370-2 are integrally formed as a single unitary body with faceplates 46 using an additive manufacturing (3D printing) process, wherein the two integral bodies are then subsequently fused, bonded or retained adjacent to one another to form head 1640.

FIG. 20 is a sectional view illustrating head 1740 which may be used in place of head 1340 described above. Head 1740 is similar to head 1340 except that head 1740 comprises an inner layer 1742. Inner layer 1742 comprise a single integral unitary body of open celled material such as a nonorthogonal lattice as illustrated in FIGS. 2-4B. Inner layer 1742 sandwiched between faceplates 44 and 46, contacting or directly bonded to each of faceplates 44 and 46. Inner layer 1742 is itself similar to sublayer 1670-2 in that inner layer 1742 has a varying density in a direction perpendicular to the plane of faceplates 44 and 46. In the example illustrated, inner layer 1742 has a central or middle region 1745 having a greater density of cells and to opposite outer regions 1747 and 1749 having a lesser density of cells. In one implementation, the change in density of cells is gradual with no abrupt transition. In yet another implementation, the change in the density of the cells is stepped with sharp or abrupt transitions. In one implementation, layer 1742 may be formed as an single integral unitary body using a micro layer by micro layer additive manufacturing process. In some implementations, inner layer 1742 may be integrally formed as a single unitary body with one or both of faceplates 44 and 46 (and in some implementations bumper 48) using a micro layer by micro layer additive manufacturing process. The varying density of cells across the thickness of layer 1742 provides a customized ball stiffness and ball striking performance for the paddle 1320 including head 1740.

Although layer 1742 is illustrated as being more dense in a central region and changing to a lower density of cells approaching faceplates 44 and 46, in other implementations, the central portion or core of layer 1742 may have a lesser density of cells, or the density of cells increases when approaching faceplates 44 and 46. Although region 1745 is illustrated as being symmetrically located, equidistantly spaced from, faceplates 44 and 46, in some implementations, region 1745 may be asymmetrically positioned between faceplates 44 and 46, being closer to one of faceplates 44, 46 as compared to the other of faceplates 44 and 46. In still other implementations, inner layer 1742 may have a first region adjacent to one of faceplates 44, 46 with a greater density, wherein the density of cells decreases as layer 1742 approaches the other of faceplates 44, 46. In such an implementation, the two different faces of head 1740 may offer distinct feel coefficient of restitution and other hitting performance qualities.

As described above, in some implementations, one or both of faceplates 44, 46 may be translucent to allow a player to visibly discern between the two opposite faces or to visibly see the layer 1742. In some implementations, the cells of layer 1742 may be selectively filled with material. For example, in one implementation, layer 1742 may be selectively filled with different materials in a manner similar to that described above with respect to the selected filling of inner layer 1242. Layer 1742 may include unfilled portions 1250 and filled portions 1260, 1262, 1264 and 1266. In such implementations, selected portions of faceplates 44 and 46 may be opaque while the portions may be translucent to facilitate viewing of the selectively field regions.

FIGS. 21A and 21B illustrate an example pickleball paddle 1820. Paddle 1820 is similar to paddle 1320 except that paddle 1820 comprises head 1840 having inner layer 1842. Inner layer 1842 comprises sublayers 1870-1 and 1870-2 (collectively referred to as sublayer's 1870). In the example illustrated, sublayers 1870 comprise two different layers having the same layout or arrangement of cells (also referred to as lattices). In one implementation, sublayers 1870 comprise honeycomb cells. In another implementation, sublayers 1870 each comprise orthogonal lattices having the same geometries. In another implementation, sublayers 1870 can comprise nonorthogonal lattices. In other implementations, one layer may be orthogonal and the other nonorthogonal.

As indicated by arrow 1875 (shown in FIG. 21B), sublayers 1870 are offset or shifted from, and/or rotated with respect to, one another in that the corresponding cells/lattices of the two sublayers 1870 can be shifted so as to be not directly aligned with one another. In one implementation, the corresponding cells/lattices are rotated relative to one another. In another implementation, the corresponding cells/lattices are vertically, horizontally or diagonally offset from one another. The offset patterning of cells/lattices can provide paddle 1820 with a Moire effect, enhancing the appearance of paddle 1820. One example of the more effective shown in FIG. 21A. In the illustrated example, at least one of panels 44, 46 is translucent to facilitate viewing of the Moire effect. Although paddle 1820 is illustrated as having an inner layer 1842 having to two sublayers 1870, in other implementations, paddle 1820 may include three or more layers having corresponding cells/lattices that are offset from one another to form other more complex Moire effects.

FIG. 22 is a sectional view illustrating portions of head 1940 which may be used in place of head 1340 or head 1840 of paddles 1320 and 1820, respectively, as described above. Head 1940 comprises an inner layer 1942 sandwiched between faceplates 44, 46 and bordered by bumper 48. Inner layer 1942 comprises an open celled layer body of material such as a layer of honeycomb cells, an orthogonal lattice layer, a nonorthogonal lattice layer or a mesh layer as described above. As schematically illustrated by the depicted shading gradient, layer 1942 has a varying density of cells that varies in a direction parallel to the plane of faceplates 44 and 46. Such a varying density may provide different portions of head 1940 with different stiffnesses, coefficients of restitution and ball hitting performance.

In the example illustrated, inner layer 1942 comprises a central region 1945 and outer regions 1947. Regions 1945 and 1947 have differing densities of cells. Region 1945 has an increased are larger density of cells while outer region 1947 have a lower or lesser density of cells. In yet other implementations, this varying of cell density may be reversed where region 1945 has a lower density of cells while regions 1947 have a greater density of cells in the example illustrated, the density changes in a gradual fashion. In other implementations, the density may change with more abrupt transitions such as in a stepwise fashion.

Although head 1940 is illustrated as having a bell-shaped distribution of different densities (a single high/low density region surrounded by a low/high density region), in other implementations, head 1940 may include a stepwise or wavy distribution of different densities. For example, inner layer 1942 may include multiple regions of higher cell densities, which transition to multiple distinct regions of lower cell densities. Inner layer 1942 may include multiple distinct and spaced regions of low cell densities surrounded by regions of high cell densities. In such an implementation, different selected regions of head 1940 may be provided with customized stiffness characteristics and ball striking performance qualities.

Inner layer 1942 may be formed as a single integral unitary body out of a single material using a micro layer by micro layer additive manufacturing process. In some implementations, layer 1942 may be integrally formed faceplates 44 and/or faceplates 46 (and in some implementations bumper 48) using such an additive manufacturing process. In some implementations, faceplates 44, faceplates 46 and/or bumper 48 may be formed from a separate translucent material, rather than opaque material to facilitate viewing of the inner layer 1942 to facilitate user identification of the different regions with the different pickleball striking qualities.

FIGS. 23A and 23B illustrate an example pickleball paddle 2020. Pickleball paddle 2020 comprises handle 30 and head portion 2040. Head portion 2040 comprises inner layer 2042. Inner layer 2042 is sandwiched between faceplates 44 and 46 and bordered by bumper 48. In the example illustrated, bumper 48 is opaque while faceplates 44 and 46 are translucent. In some implementations, bumper 48 may also be translucent or may be omitted.

Inner layer 2042 comprises sublayers 2072-1 and 2072-2 (collectively referred to as sublayers 2072). Sublayers 2072 extend side-by-side within a single plane between faceplates 44 and 46. Sublayers 2072 are each formed from a different material having a different chemical composition and/or a different architecture or geometry. As a result, sublayers 2072 provide distinct portions of head 2040 with distinct and customized coefficient of restitution, stiffness and other ball striking qualities.

In the example illustrated, sublayer 2072-2 extends along the peripheral edge of head 2040, adjacent to bumper 48 and from handle 30. Sublayer 2072-1 is surrounded or enclosed by sublayer 2072-2 within the plane between faceplates 44, 46. In other implementations, sublayers 2072 may have different shapes and relative sizes. In still other implementations, inner layer 2042 may include greater than two distinct sublayers form from different materials or geometries.

In the example illustrated, sublayers 2072 are each formed from a same material having a same chemical composition, with different geometries. In the example illustrated, sublayers 2072 are each formed from a same material having honeycomb cells, wherein sublayers 2072 have differing densities of honeycomb cells. In other implementations, sublayers 2072 are formed from a same material having a single nonorthogonal lattice geometry/architecture, wherein sublayers 2072 have different densities of the lattice, different densities of cells. In other implementations, sublayers 2072 may be formed with different densities of cells, one or more orthogonal lattices, and/or out of different materials. In another implementation, such sublayers may be integrally formed as a single unitary body using a micro layer by micro layer additive manufacturing process.

In still other implementations, sublayers 2072 may be formed from different cell/lattice geometries. For example, one of sublayers 2072 may have a nonorthogonal lattice while the other of sublayers 2072 is a honeycomb cell layout. One of sublayers 2072 may have a first nonorthogonal lattice geometry while the other of sublayers 2072 has a second different nonorthogonal lattice geometry. In some implementations, the differing sublayers 2072 may have different cell/lattice geometries and be formed from different materials. In each of the above described example implementations, the cells/lattices of sublayers 2072 may be differently filled with a filling material as described above with respect to inner layer 1242. In each of such implementations, the cells/lattices of each individual sublayer 2070-1, 2070-2 may have the same or differing cell density variations, extending perpendicular to the plane of faceplates 44, 46 as described above with respect to sublayer 1670-2 or inner layer 1742, or extending parallel to the plane of faceplates 44, 46 as described above with respect to inner layer 1942.

In each of the implementations, sublayers 2072 may be formed from material having the same color or may be formed from the same material different material having different colors. The differing colors, when in combination with a translucent faceplate 44, 46 may further assist in the user identifying the boundaries of the different sublayers 2070-2 to assist in determining how to position a paddle when striking a pickleball such that the ball is struck with a desired result in a given game circumstance. For example, in a first circumstance, the player may decide to strike the pickleball with a first one of sublayers 2072-1 and in a different circumstance may decide to strike the ball with sublayer 2072-2 to produce a different result. In one implementation, a top half of head 2040 may include a first sublayer while the bottom half of head 2040 includes a second different sublayer to provide distinct ball striking qualities. In yet another implementation, a left side of head 2040 may include a first sublayer of the right side of head 2040 as a second different sublayer to provide distinct ball striking qualities. During particular circumstances in a game, a player may choose to use the top/bottom or left side/right side to attain different ball striking results.

FIGS. 24A and 24B illustrate an example pickleball paddle 2120. Paddle 2120 is similar to paddle 2020 described above except that paddle 2120 comprises a head portion 2140 having inner layer 2142. Inner layer 2142 is similar to inner layer 2042 except the inner layer 2142 replaces sublayer 2072-2 with sublayer 2172-2. Sublayer 2072-1 forms the central region or portion of the head portion 2140. Sublayer 2172-2 comprises a layer of material omitting open cells or lattices. In one implementation, sublayer 2172 comprise a closed cell foam material. In another implementation, sublayer 2172-2 comprises a solid polymer. Sublayer 2172-2, may provide enhanced stiffness or weight distribution. In other implementations, sublayers 2172-2 and/or 2072-1 can be formed of a wood, a plastic, a closed cellular material, a composite material, an alloy, and combinations thereof.

FIGS. 24A, 24C and 24D illustrate another example of pickleball paddle 2120. Paddle 2120 includes head portion 2140 that includes the inner layer 2142. In the implementation of FIG. 24C sublayer 2172-2 is a tubular body formed of fiber composite material, similar to a composite tennis racquet frame. In one implementation, the sublayer 2172-2 is one elongate tube of fiber composite material that is molded into the shape of the perimeter of the head portion 2140. In another implementation, the two ends of the tubular body of fiber composite material of sublayer 2172-2 can be drawn together and positioned side by side through the handle 30 to form a hairpin 2132 beneath the handle 30. The handle 30 can also include a pallet 2134 positioned over the hairpin 2132 of sublayer 2172-2 within the handle 30. The pallet 2134 provides the polygonal cross-sectional shape to the handle 30. The pallet 2134 is preferably formed of a lightweight durable material such as, for example, wood, a rigid polyurethane foam, a plastic, other foams, or lattice structures similar to sublayer 2072-1. Faceplates 44 and 46 can be positioned over each side of the head portion 2140. In one implementation, the paddle 2120 can be formed without a bumper 48. In such an implementation, the tubular body of the sublayer 2172-2 provides the outer peripheral edge surface. In another implementation, a bumper can be positioned over the outer peripheral edge surface of the tubular body of sublayer 2072-2. Sublayer 2072-1 can be positioned within the closed curved opening defined by the tubular body of sublayer 2072-2. Sublayer 2072-1 can be a single orthogonal layer of cells. In other implementations, sublayer 2072 can be two or more layers of cells, and each layer can be an orthogonal and/or a nonorthogonal cell layer.

FIGS. 25A, 25B and 25C illustrate an example pickleball paddle 2220. Pickleball paddle 2220 is similar to paddle 2020 or paddle 2120 described above except that paddle 2220 additionally comprises crossbeams 2274-1 and 2274-2 (collectively referred to as crossbeams 2274). Crossbeams 2274 extend through and across sublayers 2072-1 and 2072-2 to divide such sublayers 2072 into distinct portions. In other implementations, the crossbeams can extend through, over or under sublayer 2072-1 and/or 2072-2, such that the crossbeams 2274 do not fully divide sublayers 2072 into distinct portions. In one implementation, each of crossbeams 2274 comprises a solid rail or wall providing enhanced stiffness where crossbeams 2274 extend. In the example illustrated, crossbeam 2274-1 extends parallel to the longitudinal axis 31 of handle 30 substantially from handle 30 to the opposite end of head 2240. Crossbeam 2274-2 extends across head 2240 in a direction perpendicular to axis 31 through a center of head 2240. Crossbeams 2274 intersect one another at a center point of head 2240. In another implementation, at least one of the crossbeams 2274 can be formed of a fiber composite material and take an elongate tubular shape. The crossbeams can be molded in conjunction with the fiber composite sublayer 2072-2 of FIG. 24C. In other implementations, the crossbeams can be formed of other rigid durable materials, such as, for example, wood, aluminum, other alloys, a plastic, a thermoset material, a rigid thermoplastic material, and combinations thereof.

Although crossbeams 2274 are illustrated as extending perpendicular to one another in intersecting one another at a center point of head 2240, in other implementations, crossbeams 2274 may extend through and across head portion 2240 in other locations and may extend at other angles relative to one another. Although head 2240 is illustrated as comprising two intersecting cross rails 2274, in other implementations, head 2240 may include a single cross beam 2274 or may include greater than two crossbeams 2274, wherein the multiple crossbeams 2274 intersect at multiple points or wherein the crossbeams 2274 do not intersect one another when extending across head 2240.

Although each of the portions of head 2240 separated from other portions by crossbeams 2274 is illustrating as having the same combination of cells/lattices (the cells of layer 2072-1 and the cells of layer 2072-2), in other implementations, each of the four quadrants formed by crossbeams 2274 may be filled with different sublayers or different cells/lattices. For example, in one implementation, each of the different quadrants may include a different arrangement or array of cells/lattices. One quadrant may include a nonorthogonal lattices one another quadrant may include a honeycomb cell array. One quadrant may include nonorthogonal lattices of a first lattice density will another quadrant may include nonorthogonal lattices of a second greater lattice density. Different quadrants may be provided with different customized pickleball striking characteristics.

As described above, in some implementations, selected portions of sublayers 2072-1 and 2072-2, or different quadrants formed by cross beams 2274 may be filled to further alter the sound or stiffness characteristics of selected portions of head 2240. For example, selected portion may be filled with materials as described above with respect to inner layer 1242. In some implementations, one or both of the faceplates 44, 46 may be opaque, may be translucent or may have selected portions that are translucent to facilitate viewing. In some implementations, the cells/lattice densities within the different quadrants may vary in direction perpendicular to faceplates 44, 46, and/or in directions parallel to faceplates 44, 46. For example, in some implementations, sublayer 2072-1 may gradually or stepwise increase in density as such sublayers approach the intersection of crossbeams 2274. In other implementations, inner layer 2072 may gradually or stepwise decrease in density as the sublayer distances itself from the intersection of crossbeams 2274. This varying density may provide for more uniform density given the increased density at the intersection of crossbeams 2274.

FIG. 26 is a perspective view of an example pickleball paddle 2320. Paddle 2330 is similar to paddle 2120 except that pickleball paddle 2320 comprises crossbeams 2374-1, 2374-2 and 2374-3 (collectively referred to as crossbeams 2374 are similar to crossbeams 2274 except that crossbeams 2374 radially spread out our fan out from proximate handle 30 towards the distal end of head 2340. Crossbeams 2374 provide enhanced stiffness is selected portions of head 2340 for customized pickleball striking performance. In other implementations, additional crossbeams may extend across crossbeams 2374. As shown by FIG. 26, each of faceplates 44 and 46 are translucent, similar to faceplates 44 and 46 of paddle 2220. In other implementations, one or both of faceplates 44 and 46 may be opaque or may be partially opaque. The crossbeams 2374 can be formed in a manner similar to crossbeams 2274 in that the crossbeams may be solid rigid bars, ribs or walls, or the crossbeams can be formed of fiber composite material resulting in an elongate tubular fiber composite section. Similarly, crossbeams 2374 may be configured to divide inner layer 2072-1 in separate spaced apart sections or regions. In other implementations, the crossbeams 2374 may extend over, under or through a portion of the inner layer 2072-1 in a manner that does not fully space apart or separate the inner layer 2072-1 into separate portions or sections.

FIG. 27 is a sectional view of an example head 2440, which may be used in place of any of the heads of the above described pickleball paddles which extend from handle 30. The sectional view may be taken along a line such as line 23B-23B of FIG. 23A. In the example illustrated, head 2440 comprises inner layer 2442 sandwiched between faceplates 44 and 46 and bordered by bumper 48. In one implementation, faceplates 44 and 46 are translucent. In other implementations, faceplates 44 and 46 are opaque. In yet other implementations, faceplates 44 and 46 have windows of translucency and regions that are opaque. Bumper 48 may be translucent or opaque.

Inner layer 2442 comprises sublayers 2470-1, 2470-2, 2470-3 and 2470-4 (collectively referred to as sublayers 2470). Sublayer 2470-1 can have a density of cells/lattices that varies in a direction parallel to the plane of faceplates 44 and 46. Sublayer 2470-1 is similar to inner layer 1942 described above except that sublayer 2470-1 has a central region 2445 having a region of low density cells/lattices. The outer regions 2447 would surround region 2445 in a single plane and can have a greater density of cells/lattices. The change in density is gradual between such regions, wherein the density gradually increases from the center point of sublayer 2470-1 to the edges of layer 2470-1, adjacent bumper 48. In other implementations, the transition between the varying densities may be in a stepwise manner.

Sublayer 2470-2 is similar to inner layer 1742. Sublayer 2470-2 comprises a layer of material having an open cell geometry (orthogonal lattice, nonorthogonal lattice architecture) different than that of sublayers 2470-1 and 2470-3. For example, sublayer 2470-1 may comprise a first nonorthogonal lattice having a first lattice geometry, sublayer 2470-2 may comprise a second nonorthogonal lattice having a second lattice geometry different than the first lattice geometry and sublayer 2470-3 may comprise a third nonorthogonal lattice having a third lattice geometry different than the first geometry and different than the second geometry. In yet other implementations, one of sublayers 2470 may have a first nonorthogonal lattice having a first geometry, a second one of sublayers 2470 may have a second nonorthogonal lattice having a second geometry different than the first geometry and a third one of sublayers 2470 may have an orthogonal lattice, such as a honeycomb arrangement of cells oriented perpendicular to faceplates 44 and 46. In other implementations, other combinations of cells or lattices are contemplated including combinations of orthogonal and non-orthogonal cells/lattices.

Sublayer 2470-2 can have a density that varies in a direction perpendicular to faceplates 44 and 46. Sublayer 2470-2 can have a greater density of cells/lattices in a central middle region, wherein the density of cells/lattices gradually decreases as sublayer 2470-2 approaches faceplates 44 and 46. In other implementations, a transition between different densities may occur in a stepwise fashion.

Sublayer 2470-3 surrounds sublayer 2470-2. Sublayer 2470-3 comprises a layer or layers of material have an open cell geometry, such as a nonorthogonal lattices or an orthogonal lattice such as a honeycomb cell array. Like sublayer 2470-2, sublayer 2470-3 has a different lattice geometry as compared to each of the other sublayers 2470. In one implementation, sublayer 2470-3 has a higher degree of stiffness given its geometry. In yet other implementations, sublayer 2470-2 has a lower degree of stiffness. Such stiffness may be chosen to provide customized pickleball striking characteristics.

Sublayer 2470-4 is similar to sublayer 1572 described above. Sublayer 2470-4 comprises a release layer facilitating sliding relative movement between sublayers 2470-1 in each of sublayers 2470-2 and 2470-3. In some implementations, sublayer 2470-4 may be omitted. In some implementations, sublayer 2470-1 may be adhesively bonded, fused or integrally formed as a single unitary body with sublayers 2470-2 and 2470-3.

In one implementation, sublayers 2470-1, 2470-2 and 2470-3 are formed from the same material having the same chemical composition. In other implementations, two or more of such sublayers 2470 may be formed from different materials having different chemical compositions. In some implementations, such as where sublayer 2470-4 is omitted, sublayers 2470-1, 2470-2 and 247-3 may be integrally formed as a single unitary body. In one implementation, such sublayers may be integrally formed as a single unitary body using a micro layer by micro layer additive manufacturing process. In one implementation, sublayers 2470-2 and 2470-3 or integrally formed as a single unitary body using an additive manufacturing process, wherein the single unitary body is then joined to sublayers 2470-4 and 2470-1. In one implementation, sublayers 247-1, 2470-2 and 2470-3 are formed from a polymer material. Sublayer 2470-4 may be formed from a layer of low friction material such as polytetrafluoroethylene.

FIG. 28 is a sectional view of an example head 2540 of an example pickleball paddle. Head portion 2540 may be using any of the above described pickleball paddles, wherein head 2540 extends from handle 30. The sectional view may be taken along a line such as line 23B-23B of FIG. 23A. Head 2540 comprises inner layer 2542 sandwiched between faceplates 44 and 46 and bordered by bumper 48. In one implementation, faceplates 44 and 46 are translucent. In other implementations, faceplates 44 and 46 are opaque. In yet other implementations, faceplates 44 and 46 can have windows of translucency and regions that are opaque. Bumper 48 may be translucent or opaque.

Inner layer 2542 is similar to inner layer 2442 except that inner layer 2542 comprises sublayer 2570 in place of sublayer 2470-1. The cells of sublayer 2570 have a uniform density throughout and are filled with the material 2571 to reduce noise and enhance stiffness. In one implementation, the cells/lattices are filled with a foam material. In one implementation, the cell such as a filled with a foamed polymer material.

FIG. 29 is a sectional view of an example head 2640 of an example pickleball paddle. Head portion 2640 may be using any of the above described pickleball paddles, wherein head 2640 extends from handle 30. The sectional view may be taken along a line such as line 23B-23B of FIG. 23A. Head 2640 comprises inner layer 2642 sandwiched between faceplates 44 and 46 and bordered by bumper 48. In one implementation, faceplates 44 and 46 are translucent. In other implementations, faceplates 44 and 46 are opaque. In yet other implementations, faceplates 44 and 46 have windows that are translucent and regions that are opaque. Bumper 48 may be translucent or opaque.

Inner layer 2642 is similar to inner layer 2442 except that the cells of sublayer 2470-1 are filled with the material 2571 to reduce noise and enhance stiffness. In one implementation, the cells/lattices are filled with a foam material. In one implementation, the cell such as a filled with a foamed polymer material.

FIGS. 30 and 31 are side views illustrating one example inner layer or sublayer 2700 having a varying density of cells. As shown by FIG. 30, layer 2700 has a central region 2702 having a first density of cells 2704 while the outer regions 2704 above and below region 2702 can have a lower density of cells 2706. In the example illustrated, the individual cells 2706 have a different geometry or shape as compared to the shape or geometry of the individual cells 2704. In other implementations, cells 2704 and 2706 may have the same shape or geometry, but simply different proportional sizes so as to result in different densities.

As shown by FIG. 31, layer 2700 has a central region 2712 having a first density of cells 2714 while the outer regions 2714 to the left and right of region 2714 have a lower density of cells 2716. In the example illustrated, the individual cells 2716 have a different geometry or shape as compared to the shape or geometry of the individual cells 2714. In other implementations, cells 2714 and 2716 may have the same shape or geometry, but simply different proportional sizes so as to result in different densities.

FIGS. 32A and 32B illustrate an example pickleball paddle 2820. Pickleball paddle 2820 comprises handle 30 and head 2840. As shown by FIG. 32B, head 2840 comprises inner layer 2842 sandwiched between faceplates 2844 and 46 and bordered by bumper 28. Inner layer 2842 comprises sublayers 2870-1, 2870-2 and 2870-3 (collectively referred to as sublayers 2870). Sublayer 2870-1 is similar to sublayer 1370-2 described above.

Sublayer 2870-2 comprises a layer of material having a lattice or open cell geometry that is different from the open cell geometry of layer 2870-1. In one implementation, sublayer 2870-2 comprises a nonorthogonal lattice. In other implementations, sublayer 2870-2 comprises an orthogonal lattice, such as a honeycomb cell array, a closed cavity array, a mesh or other configuration. As shown by FIG. 32A, sublayer 2870-2 is patterned so as to have a shape corresponding to an image, design or logo 2880. Although the cells/lattices (or closed cavities) of sublayer 2870-2 are illustrated as being void or empty of material, in some implementations, the cells/lattices or close cavities may be filled or injected with a material, such as a foamed polymer.

Sublayer 2870-3 comprises a layer of material having an open cell geometry, such as an orthogonal lattice (such as shown in FIGS. 10A and 10B) or nonorthogonal lattice (examples of which are shown in FIGS. 2-5), a closed floor array (examples of which are shown in FIGS. 6-8) or a mesh (an example of which is shown in FIGS. 9A and 9B). In the example illustrated, sublayer 2870-3 has a geometry similar to that of layer 2870-1, but can be formed of a different colored material. In other implementations, sublayer 2870-3 may be formed from the same material having the same color as that of sublayer 2870-1. In some implementations, sublayer 2870-3 may be filled or injected with the material, such as a foamed polymer. In yet other implementations, sublayer 2870-3 may have a layer with a different geometry as compared to layer 2870-1. Sublayer 2870-3 surrounds sublayer 2870-2, extending between sublayer 2870-2 and bumper 28.

Faceplates 2844 is similar to faceplates 44 described above except that faceplates 2844 has selected translucent portions 2869 and selected opaque portions 2871. Translucent portions 2869 have shapes, sizes and locations corresponding to the shape, sizes and locations of sublayer 2870-2, facilitating viewing of the underlying sublayer 2870-2 through faceplates 2844. Opaque portions 2871 have shapes, sizes and locations corresponding to the shape size and locations of sublayer 2870-3, blocking the view of the underlying sublayer 2870-3. As shown by FIG. 32A, in some implementations, opaque portions 2871 may themselves include designs, logo, alphanumeric characters or other information printed thereon or formed therein.

Faceplate 46 is described above. Faceplate 46 may be opaque or may be translucent. In one implementation, inner layer 2842 is formed as a single integral unitary body. In one implementation, inner layer 2842 is formed on a micro layer by micro layer basis using additive manufacturing. In yet other implementations, sublayers 2870-1, 2870-2 and 2870-3 may be separately formed and bonded are fused to one another to form inner layer 2842. In some implementations, sublayers 2870-1 may be inner the formed as a single unitary body with faceplate 46 using an additive manufacturing process. In other implementations, the paddle 2820 can be formed without opaque portion 2871. In other words, the structure of sublayers 2870-1, 2870-2 and 2870-3 can extend through the entire inner layer 2842, and plate 46 can have a similar structure to plate 2844.

FIG. 33 is a sectional view illustrating an example head portion 2940 taken along line 32B-32B of FIG. 32A. Head 2940 comprises inner layer 2942 sandwiched between faceplates 2844 and 46 and bordered by bumper 28. Inner layer 2942 comprises sublayers 2870-1 (described above) and sublayer 2970. Faceplate 2844 is described above and has a shape, size and location corresponding to the design, logo, image or other depiction presented on the face of head 2840.

Sublayer 2970 is similar to sublayer 2870-2 except that sublayer 2970 continuously extends across head 2940, beneath both opaque portions 2871 and translucent portions 2869 of faceplates 2844. Those portions of sublayer 2970 exposed to translucent portion 2869 form the image, graphic, logo or design 2880 shown in FIG. 32A. In some implementations, the cells/lattices, mesh or closed cavities of the array of one or both of sublayer 2870-1 or 2970 may be filled with or injected with a material, such as a foamed polymer. In one implementation, the material used to inject or fill such cells/lattices, mesh or close cavities may have different colors of the same material, different colors of different materials or different materials with the same color. In some implementations, rather than having different geometries (different orthogonal or nonorthogonal lattice geometries, different orthogonal lattice geometries, or different types of geometries (lattice/cell versus closed cavity array versus mesh), sublayer 2870-1 and 2970 may have similar geometries. Some implementations, inner layer 2942 may comprise a single layer of material having a single geometry of cell/lattices, or cavities.

In one implementation, inner layer 2942 is formed as a single integral unitary body. In one implementation, inner layer 2942 is formed on a micro layer by micro layer basis using additive manufacturing. In yet other implementations, sublayers 2870-1 and 2970 may be separately formed and bonded are fused to one another to form inner layer 2942.

In the example illustrated, sublayer 2970 forms the graphic 2880 shown in FIG. 32A, wherein the opaque portions 2871 formed the surrounding background area about the graphic 2880. In other implementations, this relationship may be reversed. In particular, opaque portions 2871 may form the logo, design, image or graphic, wherein those portions of sublayer 2970 exposed through translucent portions 2869 form the surrounding area are background for the graphic 2880.

FIGS. 34A and 34B illustrate an example pickleball paddle 3020. Paddle 3020 comprises handle 30 (described above) and head 3040. FIG. 34B is a sectional view of head 3040 taken along line 34B-34B. Head 3040 comprises an inner layer 3042 sandwiched between faceplates 44, 46 and bordered by bumper 28. Inner layer 3042 comprises sublayers 3070-1 and 3070-2 (collectively referred to as sublayers 3070). Sublayer 3070-1 comprises a layer having a mesh, orthogonal lattice or nonorthogonal lattice geometry. Sublayer 3070-1 comprises recesses 3073 which have shapes, sizes and locations corresponding to the shapes, size and locations of the at least one logo, image, design or other graphic 3080 presented on the face of head 3040.

Sublayer 3070-2 comprise a layer of material having the same geometry as that of sublayer 3070-1, but provided with a different, arrangement of colors or patterns. Sublayer 3070-2 occupies recesses 3073. Faceplate 44 is translucent, facilitating viewing of both of sublayer 3070-1 and 3070-2 through faceplates 44. In one implementation, faceplate 46 is translucent. In another implementation, faceplate 46 is opaque.

In other implementations, sublayers 3070-1 and 37-2 may be formed from layers of materials having different lattice/cell geometries or other different geometries. In other implementations, sublayers 3070 may have the same geometry, but be formed from different materials having different chemical compositions. In some implementations, one or both of sublayer 3070 may be filled or injected with a material, such as a foamed polymer, within the individual cells/lattices. In some implementations, one or both of sublayer 3070 may have varying cell/lattice densities extending in a direction perpendicular to faceplates 44 and 46 or parallel to faceplates 44 and 46.

In one implementation, sublayers 3070 may be integrally formed as a single unitary body using an additive manufacturing process. In other implementations, sublayers 3070 may be separately formed and bonded or fused one another. In one implementation, layer 3070 may first be formed, wherein a material removal process used to form recesses 3073 and wherein the separately formed sublayer 3070-2 is inserted into the thus formed recesses 3073. It should be appreciated that the exact configuration of the graphic 3080 may vary.

FIG. 35 is a sectional view of an example head 3140 taken along the lines 34B-34B of FIG. 34A. Head 3140 extends from handle 30 (described above). Head 3140 comprises an inner layer 3142 sandwiched between faceplates 3144 and 3146 while being edgewise bordered by bumper 28. Inner layer 3142 comprise a single layer of material having a non-solid thickness such as an orthogonal lattice geometry, a nonorthogonal lattice geometry, a closed cavity array, a mesh or the like. In one implementation, inner layer 3142 comprises a layer similar to layer 1370-2 described above. In one implementation, inner layer 3142 comprise a series of open cell/lattice such that layer 3142 is partially transparent, permitting one to see through layer 3142.

Faceplates 3144 and 3146 each comprise translucent face plates similar to faceplates 44 and 46 described above except that faceplates 3144 and 3146 each include opaque regions 3171 on their inner or outer faces. Opaque regions 3171 may be painted or printed upon faceplates 3144. In other implementations, faceplates 3144 and 3146 may be co-molded with translucent and opaque polymers or the like. Opaque regions 3171 form a graphic such as a logo, image, design of the like on each of the faces of head 3140. In the example illustrated, opaque portions 3171 are substantially aligned with one another such that a person viewing one of faces of head 3140 directly perpendicular may see a single graphic and such that a person viewing one of faces of head 3140 at an oblique angle may see portions of the opaque regions 3171 through inner layer 3142, providing a depth to the graphic, such as graphic 3080. In other implementations, opaque regions 3171 on faceplates 3144 and 3146 may be offset to facilitate a design. In some implementations, inner layer 3142 may be filled with an opaque filling material, such as an opaque polymer foam, wherein the opaque regions 3171 on faceplates 3144 and 3146 are not necessarily aligned with one another and provide different images on the opposite faces of head 3140.

FIGS. 36A and 36B illustrate an example pickleball paddle 3220. FIG. 36B is a sectional view of the paddle taken along line 36B-36B of FIG. 36A. Paddle 3220 comprises a head 3240 extending from handle 30. Head 3240 comprises an inner layer 3242 sandwiched between faceplates 44, 46 and bordered by bumper 28. In the example illustrated, faceplates 44 and 46 are each translucent, facilitating viewing of inner layer 3242 through such faceplates.

Inner layer 3242 comprises sublayers 3270-1, 3270-2, 3270-3, 3270-4 and 3270-5 (collectively referred to as sublayers 3270). Sublayers 3270-1 and 3270-2 extend on one side of sublayer 3270-5, between sublayer 3270-5 and faceplates 44. Sublayers 3270-1 and 3270-2 are each formed from a nonsolid layer of material having a nonorthogonal lattice geometry, and orthogonal lattice geometry, a mesh, or a closed cavity array geometry. Sublayers 3270-1 and 3270-2 may have the same geometry and form from the same material, but where sublayers 3270-1 and 3270-2 have different colors so as to provide the graphic 3080 shown in FIG. 34. In other implementations, sublayers 3270-13270-2 may also have different geometries and/or may be formed from different materials.

Sublayers 3270-3 and 3270-4 can extend on an opposite side of sublayer 3270-5 and form the graphic 3280 shown in FIG. 36A. The graphic 3280 serves as a hitting cue, helping a player to hit the pickleball at the sweet spot of head 3240. In one such implementation, sublayers 3270-3 and 3270-4 may be formed from the same material having the same geometries, but by with different colors.

In some implementations, sublayers 3270-3 and 3270-4 may have different material geometries such as different densities of cells/lattices providing different degrees of stiffness. As a result, the sublayers 3270-2 and 3270-3, forming inner layer 3242, provide different regions of different coefficients of restitution to enhance the ball striking performance of the face of head 3240 adjacent faceplates 46. In the example illustrated, sublayers 3270-3 and 3270-4 form a series of concentric rings forming a target and providing different annular regions of stiffness.

Sublayer 3270-5 separates sublayers 3270-1 and 3270-2 from sublayers 3270-3 and 3270-4. Sublayer 3270-5 comprises a solid opaque layer such that the patterned regions of layers on opposite sides of sublayer 3270-5 do not interfere with one another. In one implementation, sublayer 3270-5 comprises a layer having a color that does not absorb light, such as the color white. In another implementation, sublayer 32-5 comprises a spectral reflective layer. Although each of sublayers 3270-1, 3270-2, 3270-3 and 3270-4 are illustrated as having empty cells/lattices or cavities, in other implementations, the cells/lattices or cavities may be filled with the material, such as a polymeric foam. In some implementations, selected portions of the graphic 3280 may be filled while other regions have cells that remain empty. For example, in one implementation, the innermost ring in graphic 3280 formed by sublayer 3270-4 may be empty while the outermost ring formed by sublayer 3270-4 may be filled with a polymeric foam.

FIGS. 37A, 37B and 37C illustrate an example pickleball paddle customization kit 3300. Kit 3300 provides a player with the option of customizing his or her pickleball paddle with different faceplates having different qualities. Kit 3300 comprises base paddle 3310 and interchangeable faceplates 3344-1, 3344-2 (collectively referred to as faceplates 3344). Base paddle 3310 comprises a pickleball paddle to which faceplates 3344 may be removably and interchangeably mounted to form a complete pickleball paddle 3320-1 as shown in FIG. 37B or a complete pickleball paddle 3320-2 as shown in FIG. 37C.

Base paddle 3310 comprises handle 30 (described above and head 3340. Head 3340 extends from handle 30 and may comprise any of the above illustrated and described pickleball paddle heads. In contrast to such heads, pickleball paddle 3340 additionally comprises faceplates retainers 3343 (schematically illustrated). Retainers 3343 releasably retain and secure one of faceplates 3344 over the inner layer 3342. In one implementation, retainers 3343 releasably retain one of faceplates 3344 directly over and in contact with inner layer 3342. Inner layer 3342 may comprise any of the above-described inner layers. In other implementations, retainers 3343 releasably retain one of faceplates 3344 directly over and in contact with an existing non-removal faceplate 44 as indicated in broken lines.

Retainers 3343 may include various structures or mechanisms for releasably retaining one of faceplates 3344 to base paddle 3310. In one implementation, retainers 3343 comprise a hook and loop fastener arrangement with one of a hook and loop structure on head 3340 of base panel 32310 and the other of the hook and loop structure on the backside of faceplates 3344. In yet other implementations, retainers 3343 comprise clips, latches, overhangs, snap-fit connections or other fasteners. As we described hereafter, in some implementations, retainers 3343 may comprise grooves or channels into which faceplates 3344 may be removably slid and positioned.

Faceplates 3344 have different characteristics as compared to one another. In one implementation, faceplates 3344 are formed from different materials having different coefficients of restitution to provide different hitting performance characteristics. In some implementations, faceplates 3344 may include different graphics or images. For example, in some implementations, faceplates 3344 may have different promotional or advertising printing thereon. By removing one of faceplates 3344 and replacing it with another of faceplates 3344, either of pickleball paddles 3320 may be formed for a given match or play session. Although not illustrated, in other implementations, the reverse side of head 3340 may also include retainers 3343 four removably mounting one of a plurality of available different faceplates thereto. In yet other implementations, the other side of head 3340 may have a stationary or fixed faceplate 3346.

FIGS. 38A-38D illustrate an example pickleball paddle customization kit 3400. Like kit 3300, kit 3400 facilitates the interchange of different faceplates to a base paddle to customize pickleball paddle for different opponents, different weather conditions, different court conditions or different player preferences. Kit 3400 comprises base paddle 3410 and interchangeable faceplates 3344-1, 3344-2 (shown in FIG. 37A) and 3344-3. Base paddle 3410 is similar to base paddle 3310 except that base paddle 3410 is specifically illustrated as comprising retainers 3443-1.

As shown by FIG. 38B and 38C, retainers 3443-1 comprise overhangs on opposite sides of head 3440. Retainers 3443-1 Extend opposite to inner layer 3342 and are spaced from inner layer 3342 to form mutually facing channels 3445, which slidably receive edge portions of face plates 3344. To replace a faceplate, the faceplate is simply withdrawn from channels 3445 and a new faceplate is split into channels 3445.

To secure the received faceplate in place relative to base paddle 3410, each faceplate 3344 is additionally provided with a retainer 3443-2. Retainer 3443-2 comprises a flexible flap extending from the main edge of faceplate and bendable so as to overlie the top edge of base paddle 3410. In the example illustrated, each retainer 3443-2 comprises one of a hook and loop fastener arrangement, wherein the other of the hook and loop fastener arrangement is provided on the top edge of inner layer 3342 as shown in FIG. 38D. In other implementations, retainers 3443-2 may comprise other releasable mounting or securing mechanism such as latches, hooks, snaps and the like. In some implementations, retainers 3443-2 may be omitted where retainers 3443-1 adequately retain faceplates 3344 in place.

FIGS. 39A and 39B illustrate an example pickleball paddle customization kit 3500. Customization kit 3500 is similar to kit 3400 except that kit 3400 comprises head 3540 in place of head 3440 and comprises a set of interchangeable handles 3530-1, 3530-2, 3530-3, 3530-4 (collectively referred to as handles 3530). Head 3540 is similar to head 3440 described above except that head 3540 comprises an inner layer 3542. Inner layer 3542 may comprise any of the above-described inner layers except that inner layer 3542 additionally comprises an internal cavity 3550 for receiving a portion of each of handles 3530. Internal cavity 3550 comprises an external mouth 3552 into which portions of handles 3530 may be slid are positioned.

Interchangeable handles 3530 comprise structures that are configured to be manually grasped by a player. Each of handles 3530 comprises a grip portion 3554, a transition region 3560 and a tongue 3562. Grip portion 3554 comprises a generally elongate bar or cylinder for being gripped. In some implementations, grip portion 3554 may have a polygonal cross-sectional shape. In other implementations, grip portion 3554 may have a circular or oval cross-sectional shape.

In some implementations, each of handles 3530 may have a grip portion 3554 of a different length. In one implementation, handle 3530-1 and handle 3530-2 each a length of 4 inches extending from transition region 3560 to the end of grip portion 3554. Handle 3530-2 has a length of 3 inches extending from transition region 3560 to the end of grip portion 3554. Handle 3530-4 has a length of 2 inches extending from transition region 3560 to the axial end or end cap of grip portion 3554. In other implementations, the grip portion 3554 can be formed of other lengths. The shorter length of the grip portion 3554 of handle 3530-4 may facilitate a larger head 3540, head 3540 may be longer and/or wider as compared to those paddles that utilize the other handles 3530 having longer grip portions 3554. In one implementation, paddle 3520, or any of the prior described paddles, can be formed with a handle that is approximately 2 inches in length. The handle can be permanently affixed to the head, or removably attached to the head. In other implementations, the handle of paddle 3520, or any of the prior described paddles, can be approximately 3 inches in length, and handle may be permanently or removably attached to the head of the paddle. In other implementations, the handle of paddle 3520, or any of the prior described paddles, can be approximately 4 inches in length, and handle may be permanently or removably attached to the head of the paddle.

Transition region 3560 extends from grip portion 3554 and includes an end slot or channel 3563 for receiving an end of head 3540 and for extending over, across the edges of mouth 3552. Transition region 3560 can overlap and gradually slope down to and over each of faceplates currently mounted to head 3540. As a result, each transition region 3560 can provide surfaces that are flush with the exterior faceplates 3344. Transition region 3560 provides a smooth transition to facilitate various grip portions of the completed paddle 3520 (shown in FIG. 39B) and less interference with striking by paddle 3520.

In other implementations, the tongue 3562 can project from grip portion 3554 and transition region 3560 so as to be insertable into cavity 3550 within head 3540. In the example illustrated, each of handles 3530 can have a different tongue 3562. The different tongues can facilitate the customization of paddle 3520 to provide paddle 3520 with a different sweet spot, different sound qualities, different ball striking qualities and the like. In the example illustrated, the tongues 3562 of the different handles 3530 have different lengths so as to project into cavity 3550 by different extents, altering repositioning the sweet spot of the completed paddle 3520.

In the example illustrated, tongues 3562 of handles 3530-1 and 3530-3 can be formed from different materials. In one implementation, tongue 3562 of handle 3530-1 comprises a bar or rod formed from cells or a lattice of a first material, wherein tongue 3562 of handles 3530-3 comprises a bar or rod formed from cells or a lattice of a second different material. In some implementations, the materials of tongues 3562 of handles 3530-1 and 3530-3, but the density of the cells of the tongues may be different. In some implementations, tongue 3552 of handle 3530-1 may be solid or may be formed from a foam material while tongue 3562 of handle 3530-2 is formed from an open celled lattice such as a nonorthogonal lattice or an orthogonal lattice (as described above with respect to the inner layers). Although system 3500 is illustrated as providing both interchangeable faceplates and interchangeable handles, in other implementations, system 3500 may be employed in heads that have fixed or permanent faceplates, wherein only handles 3530 are interchangeable with respect to head 3540.

As shown by FIGS. 39A and 39B, in some implementations, kit 3500 additionally includes retainer 3570 to assist in maintaining a selected handle 3530 within and releasably mounted to head 3540. In one implementation, retainers 3570 comprises a pair of opposite detents 3572 formed along the interior sides of cavity 3550 in inner layer 3542. At the same time, each of tongues 3562 carries a spring loaded or biased projection or pin 3574. Upon insertion of tongue 3562 into cavity 3550, retainer 3570 compresses the compression spring while being pushed into an interior cavity of tongue 3562. When positioned adjacent to detents 3572, retainer 3570 is resiliently biased so as to project into detents 3572, releasably locking tongue 3562 within cavity 3550. With a sufficient amount of force, retainer 3570 may be withdrawn from cavity 3550, during which retainer 3570 (shown as a pin) compresses the associated compression spring. Removal of tongue 3562 permits withdrawal of the associated handle 3530, facilitating insertion of a new or different handle 3530. In other implementations, other retainers may be used. In still other implementations, each tongue 3562 has sides and top surfaces, which frictionally engage interior surfaces of cavity 3550 to assist in retaining tongue 3562 within cavity 3550.

FIGS. 40A, 40B and 40C illustrate an example pickleball paddle customization kit 3600, an example of customization kit 3500. As with kit 3500, kit 3600 comprises a set of interchangeable handles 3630 (one of which is shown), each of handles 3630 can have different tongues. Each of the interchangeable handles 3630 is identical to the illustrated handle 3630 except that each of handles 3630 may include a different one of tongues 3562 described above with respect kit 3500. Head 3640 is similar to head 3540 described above except that head 3640 comprises an inner layer 3642. Inner layer 3642 is similar to inner layer 3342 except that inner layer 3642 additionally comprises an internal cavity 3550 for receiving a portion of each of handles 3530. Internal cavity 3550 comprises an external mouth 3552 into which portions of handles 3530 may be slid or positioned. FIG. 40B illustrates tongue 3562 of handle 3630 inserted into cavity 3550 through mouth 3552. In the example illustrated, each of tongues 3562 can include a spring biased pin 3574, which snaps or pops into corresponding detents 3572 as described above to releasably retain tongue 3562 within cavity 3550 to form the completed paddle 3620.

As shown by FIG. 40A, each handle portion comprises a hollow octagonal shaft 3680 having openings there through to reduce weight. An outer grip covering may be wrapped about shaft 3680 to form grip portion 3554 and the end of shaft 3680 may be capped with an end cap construct. Although not shown, bumper 48 may further be wrapped around the periphery of inner layer 3642. The shaft 3680 can be formed of different durable lightweight materials such as for example, an aluminum, titanium, other alloy, a fiber composite material, a polymeric material and combinations thereof. The hollow structure with openings reduces the weight of the handle, which can be used for adjusting the swing weight and/or moment of inertia of the paddle 3620. In other implementations, handle 3630 can be formed without a tongue.

The handle 3630 may include a pair of throat flanges 3660 to further secure the handle 3630 to the head 3640. In one implementation, the throat flanges 3660 can be used in conjunction with the tongue 3562 to secure handle 3630 to the head 3640. In another implementation, handle 3630 can be formed without tongue 3562 and the head 3640 can be formed without the internal cavity 3550 and the mouth 3552. In this implementation, as shown in FIG. 40C, the pair of throat flanges 3660 are secured to the proximal region of the head 3640. In one implementation, the throat flanges 3660 can be removably secured to the head 3640 through fasteners, clips, latches, hooks, snaps and the like. In another implementation, the throat flanges 3660 can be non-removably secured to the head 3640 through bonding, adhesives, fasteners, and combinations thereof. In another implementation, the proximal region of the head 3640 can include recesses for receiving the throat flanges 3660 in a manner that does not result in a raised edge or a raised surface between the head 3640 and the throat flanges 3660 resulting in a smooth transition at the connection of the head 3640 and the throat flanges 3660.

Although each of the above described heads of the disclosed pickleball paddle have the depicted shape, in other implementations, each of the pickleball paddles may have other shapes. FIGS. 41-44 illustrate various alternative pickleball paddle other profiles are shapes having alternative had shapes and corresponding inner layers. As shown by FIG. 41, each of the above described pickleball paddles may have a head 3740 having a more tapered region 3741 extending from handle 30. As shown by FIG. 42, each of the above disclosed pickleball paddle heads may alternatively comprise a head 3840 having a more rounded end portion 3842. As shown by FIG. 43, each of the above-disclosed Pickleball heads may be in the shape of head 3940 having a fan-shape 3942. As shown by FIG. 44, each of the above-disclosed heads may alternatively have a head in the shape of head 4040 having a fatter and less tapered region 4042 proximate to handle 30 and a more rounded end portion 4044 distant handle 30.

FIG. 45 illustrates yet another configuration for an example head 4140. Any of the pickleball paddles in the disclosure may alternatively have the outer perimeter or shape of head 4140. As shown by FIG. 45, head 4140 comprises a yoke 4142 that transitions between handle 30 and the remainder of head 4140. Yoke 4142 may enhance the stiffness of head 4140 and reduce its weight. The yoke 4142 may also be desirable to some players as an alternate gripping location.

FIG. 46 illustrates an example pickleball paddle 4220. FIG. 46 illustrates how the head of a pickleball paddle may be provided with different zones or regions (its topology) for enhanced performance. FIG. 46 illustrates an example of how the inner layer of a head of a pickleball paddle may be provided with different zones or regions. Each of the different zones or regions may have a different geometry, a different density or thickness of lattice segments or struts and/or may be formed from a different material or combination of materials. In some implementations, the inner layer may be formed from a lattice, such as an orthogonal lattice or honeycomb structure or a nonorthogonal lattice. The inner layer may be formed from any of the construction described above, such as those constructions described above with respect to FIGS. 1B, 3B, 4B, and 5-10.

In some implementations, the inner layer providing the different regions may be separate from the outer faceplates and bonded, fastened, fused, welded or otherwise joined to the outer faceplates. In some implementations, the inner layer providing the different regions may be integrally formed as a single unitary body with the faceplates. In some implementations, the inner layer providing the different regions may additionally extend into the handle of the pickleball paddle. In some implementations, the inner layer may widen to form the entirety of the handle but for an optional grip. In some implementations, the inner layer may extend into the handle, wherein additional structures, such as a pallet or a sleeve can be positioned about the inner layer to complete the handle. In some implementations, the peripheral edge of the inner layer may be further covered with a bumper.

In the example illustrated in FIG. 46, paddle 4220 comprises handle 4230 and head 4240. Handle 4230 may have a configuration similar to handle 130 described above with respect to FIG. 2 or may have an outer configuration similar to handle 730-1 or 730-2 described above with respect to FIGS. 9C-9E. Handle 4230 has a core, which is integrally formed as a single unitary body with the inner layer of head 4240. In some implementations, handle 4230 may be formed from the same material as head 4240. In some implementations, the faceplates of head 4240 are also formed from the same material as inner layer 4242 and handle 4230.

The material chosen for inner layer 4242 and handle 4230 (and the faceplates in implementations where the faceplates are formed with the inner layer as a single unitary body) provides paddle 4220 with satisfactory elongation properties and durability. Such materials may be chosen to facilitate three-dimensional printing of paddle 4220. In some implementations, paddle 4220 is printed using a powder bed system. In other implementations, paddle 4220 is printed using a resin-based system, such as where the resin is cured through UV light or is thermally cured. In one implementation, inner layer 4242 is formed from a thermoplastic elastomer such as a thermoplastic urethane, a thermoplastic vulcanite (TPV), a thermoplastic amide (TPA), or combinations thereof. In one implementation, inner layer 4242 is formed from TPE-300. In some implementations, inner layer 4242 may be formed from a nylon material or a polyamide. As should be appreciated, handle 4230 may have a separately attached outer grip in the form of an outer wrap or sleeve of a gripping material such as leather, synthetic leather, rubber, synthetic rubber, an elastomeric material or other material.

Head 4240 extends from handle 4230 and includes an inner layer 4242, which includes various zones or regions with many of the zones or regions having a different deflection or performance characteristic. As noted above, in some implementations, inner layer 4242 may be integrally formed as a single unitary body with opposite faceplates (described above). Alternatively, inner layer 4242 may be covered by separate faceplates which are bonded, welded, adhered, fused or otherwise joined to inner layer 4242. In the example illustrated, inner layer 4242 further extends into and through handle 4230. Inner layer 4242 comprises regions 4250-1, 4250-2, 4250-3, 4250-4, 4250-5, 4250-6, 4250-7, 4250-8, 4250-9, 4250-10 and 4250-11 (collectively referred to as regions 4250). Regions 4250 enhance player feel and performance. Regions 4250 are based at least partially upon balance point and center of gravity locations for pickleball paddle 4220. Regions 1450 are further configured to satisfy official pickleball paddle regulations promulgated by the International Federation of Pickleball and/or the USA Pickleball Association.

Region 4250-1 continually extends through handle 4230 and passes a midpoint of head 4240. Region 4250-1 forms a core of handle 4230 and serves as a spine along a longitudinal centerline of handle 4230 and head 4240. Region 4250-1 has a construction that provides a first deflection or stiffness response for vertical compressive loads (loads applied in a direction that is perpendicular to the plane of the faceplates). Region 4250-1 provides stiffness to the handle 4230 and to the central hitting area of head 4240. The enhanced stiffness extending from the center portion of the head 4240 through the handle 4230 provides enhanced feel for the person or player using paddle 4220.

Regions 4250-2 and 4250-3 may have the same general construction as region 4250-1. Region 4250-2 contains a vertical and longitudinal center point 4251 of head 4240. Regions 4250-1, 4250-2 and 4250-3 have the same general degree of stiffness or response to vertical compressive loads. In some implementations, these regions may have different lattices, lattices with different unit cell geometries, different unit cell sizes and/or different unit cell strut diameters.

Regions 4250-4, 4250-5 and 4250-6 have the same general geometry and generally have two surfboard shapes on opposite sides of regions 4250-2 and 4250-3 while being joined to opposite sides of region 4250-1. Each of such regions can have a construction that provides a greater degree of stiffness in response to vertical compression loads as compared to the degree of stiffness found in region 4250-1. In the example illustrated, regions 4250-5 have a degree of stiffness in response to vertical compression loads that is greater than the degree of stiffness in response to vertical compression loads of regions 4250-4 and 4250-6. In the example illustrated, regions 4250-5 contain points 4251-5 which are horizontally aligned with center point 4251 and which are transversely spaced from the axial centerline 4255 (which intersects center point 4251) of head 4240 by distance D of at least 0.75 inch and no greater than 1.25 inches.

Region 4250-7 extends about an outer periphery of head portion 4240. Region 4250-8 extends along the outer corners of head 4240. Region 4250-7 can have a density that provides enhanced impact resistance and durability for the perimeter of head 4240. Regions 4250-8 can have a higher degree of impact resistance as compared to region 4250-7 so as to provide increased durability in the corners of head 4240.

Regions 4250-9 and 4250-10 extends between region 4250-7 and the regions 4250-1 through 4250-6. Regions 4250-94050-10 fill in those volumes between region 4250-7 and the generally more stiffer regions 4250-1-4250-6. Regions 4250-9 and 4250-10 may have the lowest density or mass and are also the softest as such regions have the lowest degree of stiffness in response vertical compression loads.

Region 4250-11 extends about a portion of region 4250-1. Region 4250-11 may have the lowest density of the different regions for weight reduction. Region 4250-11 may form an exterior for being gripped, wherein region 4250-11 may provide handle 4230 with a circular, polygonal (such as hexagonal or octagonal) or oval cross-sectional shape. In some implementations, region 4250-11 may additionally provide an outwardly flared butt end 4231.

FIGS. 47-53 illustrate an example pickleball paddle 4320. As with pickle ball paddle 4220, pickleball paddle 4320 may be formed as a single integral unitary body out of a single material, wherein the handle, the opposite faceplates and the head are all formed as a single unitary body out of a single material. In some implementations, pickleball paddle 4320 may have an inner layer forming both a core of head 4240 and handle 4230, wherein separate faceplates are then joined to head 4240 and/or wherein a separate pallet can be added to complete the handle 4230. As described above, the material chosen for inner layer 4242 and handle 4230 (and the faceplates in implementations where the faceplates are formed with the inner layer as a single integral unitary body) provides paddle 4320 with satisfactory elongation properties and durability. Such materials may be chosen to facilitate three-dimensional printing of paddle 4320. In some implementations, paddle 4320 is printed using a powder bed system. In other implementations, paddle 4320 is printed using a resin-based system, such as where the resin is cured through UV light or is thermally cured. In one implementation, inner layer 4242 is formed from a thermoplastic elastomer such as a thermoplastic urethane, a thermoplastic vulcanite (TPV), a thermoplastic amide (TPA), or combinations thereof. In one implementation, inner layer 4242 is formed from TPE-300, a thermoplastic urethane having a 92 Shore A hardness. In some implementations, inner layer 4242 may be formed from a nylon material or a polyamide.

The head 4240, or the previously disclosed heads, can have a thickness of at least 0.25 inch, and a density of no greater than 1 g/cc. In other implementations, the thickness of a head having a lattice or honeycomb structure, which is the ratio of the equivalent effective density of the lattice or honeycomb structure, divided by the density of the material forming the lattice or honeycomb structure, can be at least 0.5 inch, and can have a density no greater than 0.5 g/cc.

FIG. 47 illustrates pickleball paddle 4320, a specific example of pickleball paddle 4220, wherein the different regions are formed by different lattices formed by arrangements of cubic unit cells produced from an iterative topology optimization analysis. FIG. 48 is a perspective view of paddle 4320 and further identifies the particular unit cell geometry in the different regions. FIG. 48 does not illustrate the variations in size and strut diameters for the different unit cells found in the different regions. FIGS. 49-51 are sectional views illustrating the variations in size and strut diameters for the different unit cells in the different regions. FIGS. 49-51 additionally illustrate the outer skin of paddle 4320 provided by faceplates 4344 and 4346 as well as the outer skin 4347 forming the exterior of handle 4230. In the example illustrated, outer skin 4347 integrally formed as part of a single unitary body with the unit cells of handle 4230. As described above, in some implementations, faceplates 4344 and 4346 are also integrally formed as part of a single unitary body with the unit cells of head 4240. In other implementations, faceplates 4344 and 4346 or separately form is absently joined to head 4240. In the example illustrated, the unit cells are in a single layer, having a single unit thickness in a direction perpendicular to the faceplates. In other implementations, such unit cells may be stacked in a direction perpendicular to the faceplates.

In the example illustrated, the individual cubic unit cells are formed by connections or struts extending between various combinations of 27 nodal points for such unit cells. In other implementations, the cells may have a greater or fewer of such nodal points and different connection structures. Although the unit cells are illustrated as being generally cubic in shape, in some implementations, the unit cells may have other shapes. To provide zones having a nonrectangular shape, to provide zones having an acute or obtuse corner or to provide a zone with a rounded perimeter, individual unit cells may be stretched or compressed, deforming the initial cubic shape of the unit cells.

The lattices in the different regions may differ from one another in their geometry (the arrangement of connections or struts between the nodal points of the unit cells), the thickness or diameter of the individual connections or struts of each unit cell, the size of the individual unit cells forming the lattice and/or the density of the unit cells (the number of unit cells for a given volume or the mass of material for a given volume). In the example illustrated, the different regions are formed by different nonorthogonal lattices, lattices having struts or walls that are not orthogonal to the faceplates of pickleball paddle 4320. FIG. 48 further illustrates the individual lattice geometries and the different unit cells found in the different regions.

As shown by FIG. 48, regions 4250-1, 4250-2 and 4250-3 are formed from unit cells 4350-1, 4350-2 and 4350-3, respectively, that have connections or struts that pass through the face centers and that also have vertical out of plane connections. This geometry provides each of the unit cells 4350-1, 4350-2 and 4350-3 as well as the regions 4250-1, 4250-2 and 4250-3 with a degree of stiffness with respect to vertical compression loads that is greater than the remaining regions but for regions 4250-4, 4250-5 and 4250-6.

Regions 4250-4, 4250-5 and 4250-6 are formed from unit cells 4350-4, 4350-5 and 4350-6, respectively. Each of unit cells 4350-4, 4350-5 and 4350-6 has a larger number of in-plane connections or struts as compared to unit cells 4250-1, 4250-2 and 4250-3. The large number of in-plane connections or struts provides enhanced in-plane mechanical stiffness while also reducing deflection in response to a vertical compression load. As shown by FIG. 50, the connections or struts of unit cells 4350-5 have a strut diameter that is greater than the strut diameter of unit cells 4350-4 and 4350-6 so as to be stiffer in response to vertical compression loads. In the example illustrated, the struts of unit cells 4350-5 have a diameter of at least 2.5 mm and no greater than 3.5 mm. in contrast, the struts of unit cells 4350-4 and 4350-6 have a diameter of at least 2 mmno greater than 3 mm. In other implementations, such unit cells may have other strut diameters.

Regions 4250-7 and 4250-8 are formed from a tetrahedral base mesh or what is sometimes referred to as a Voronai lattice. The tetrahedral base mesh provides an aesthetically pleasing outer edge for head 4240, appearing as a random lattice, without being random for uniform strength and impact resistance. Regions 4250-7 and 4250-8 are formed with a minimal strut diameter. In the example illustrated, region 4250-8 has a greater density as compared to the other regions of pickleball paddle 4320. The enhanced densities due to the mass of material per unit volume. In the example shown in FIGS. 46-48 and 51, region 4250-7 has an end portion 4253, extending between regions 4250-11. End portion 4253 has a less dense tetrahedral base mesh or Voronai lattice as compared to the remaining portions of regions 4250-7. The lower density of end portion 4253 reduces weight in those regions where impact is less likely and where such impact would be resisted by regions 4250-8.

Regions 4250-9 and 4250-10 are formed from unit cells 4350-9 and 4350-10, respectively. In the example illustrated, unit cells 4350-9 and 4350-10 are similar to one another. In other implementations, such cells may be varied with respect to density or strut diameter. For example, in some implementations, unit cells 4350-9 may be denser or may be provided with larger strut diameters for enhanced stiffness to provide greater strength proximate to the junction of head 4240 and handle 4230. Unit cells 4350-9 and 4350-10 have a minimal strut diameter. In the example illustrated, the minimal strut diameter is at least 0.8 mm and no greater than 1.2 mm. Reducing the strut diameter reduces weight; however, in other implementations, strut diameter may be larger.

Unit cells 4350-9 and 4350-10 having connections or struts passing through face centers with vertical out of plane connections. As compared to the unit cells of the other regions, this geometry of unit cells 4350-9 and 4350-10 is less stiff. In the example illustrated, unit cells 4350-9 and 4350-10 have a stiffness in directions perpendicular to the faceplates that is lower than the stiffness of unit cells 4250-1, 4250-2 and 4250-3. Addtionally, unit cell 4250-5 has the highest stiffness followed by unit cells 4250-4 and 4350-6.

As shown by FIGS. 52-53, the axial ends of the struts of unit cells 4350-9 and 4350-10, that extend perpendicular to the faceplates, form corners with faceplates 4344 and 4346, wherein such corners are filled with fillets 4355. As with fillets 755 of paddle 720-2 described above in FIGS. 9E and 9F, fillets 4355 increase the surface area at the ends of the lattice struts connected to the faceplates 4344 and 4346 to strengthen the connection between inner layer 4242 and the faceplates 4344, 4346 extending across faces of inner layer 4242, reducing delamination issues. In some implementations, the junctures between the other unit cells and faceplates 4344, 4346 may likewise be provided with fillets to enhance the structural connection between inner layer 4242 and faceplates 4344, 4346. As shown by FIG. 52, in some implementations, fillets 4355 are formed during 3D printing of inner layer 4242 and the faceplates 4344, 4346 as a single unitary body. As shown by FIG. 53, in other implementation where separate faceplates are subsequently joined to the prior formed inner layer 4244, such fillets 4355 provide additional surface area 4357 for applying an adhesive, weld or the like to secure the faceplates to the inner layer 4242.

Region 4250-11 has a similar lattice construction is that of regions 4250-7 and 4250-8. Region 4250-11 is formed from a tetrahedral base mesh or Voronai lattice. In contrast to regions 4250-7 and 4250-8, region 4250-11 has a lower density (mass per unit volume) due to a less compact mesh density. Region 4250 surrounds a core of handle 4230 formed by unit cells 4350-1 to provide the outer structural surface of handle 4230 for being directly gripped or for being wrapped by an exterior gripping surface. In the example illustrated, region 4250 forms outwardly flared butt end 4231.

FIG. 54 is an exploded perspective view of an example pickleball paddle 4420. Paddle 4420 is similar to paddle 4320 except that paddle 4420 additionally comprises lattice filler 4453, crossbeams 4474-1, 4474-2, 4474-3 (collectively referred to as crossbeams 4474), faceplates 4444, 4446 and edging or bumper 4448. The remaining components of paddle 4420, which correspond to components of paddle 4320 are numbered similarly. For example, paddle 4420 may include each of the regions and unit cells described above with respect to paddle 4320.

Lattice filler 4453-1 and 4353-2 (collectively referred to as lattice fillers 4453 and represented by stippling) comprises a material or materials filling the interstitial voids or spaces of individual unit cells forming the lattice. In some implementations, lattice fillers 4453 are injected into such voids or spaces following a three-dimensional printing of the unit cells that make up the lattice. The material may add cushioning, durability, sound dampening or other characteristics to those regions in which lattice filler 4453 is used. In the example illustrated, lattice filler 4453-1 may be used to fill the interstitial voids or spaces of unit cells 4350-7 and/or 4350-8 to enhance the strength and durability along the edge of head portion 4240. In such an implementation, lattice filler 4453 may comprise a filler selected from a group of fillers consisting of open cell foams, closed cell foams, urethane, polypropylene, other thermoplastic materials, other thermoset and combinations thereof. In the example illustrated, lattice filler 4453-2 may be used to fill the unit cells 4350-11 of handle 4230. In such an implementation, lattice filler may be selected from a group of lattice fillers consisting of a thermoplastic polyurethane, polypropylene, Nomex® polycarbonamide material, ethylene vinyl acetate (EVA), polyethylene, polyvinyl chloride, a polyethylene vinyl acetate, polyamide, acrylonitrile butadiene styrene (ABS), poly ether (ether) ketone, polylactic acid, acrylate-based polymeric system mimicking one of the aforementioned polymers, other polymeric materials, other lightweight elastomeric, thermoplastic or thermoset materials, and combinations thereof. In yet other implementations, a lattice filler 4453 may be used to fill the unit cells 4350-1 and/or unit cells 4350-5 to increase the stiffness of such regions. In some implementations, one or both of lattice fillers 4453 may be omitted.

Crossbeams 4474 extend from proximate handle 4230, through inner layer 4242 towards the axial end of paddle 4420. Crossbeams 4474 comprise rigid bars or rods that extends from handle 4230 and provide stiffness to head 4240. Crossbeams 4474 may be integrally formed as part of a single unitary body with inner layer 4242, wherein crossbeams 4474 may be solid masses of material or may be formed from unit cells having densities greater than those of the remaining unit cells forming inner layer 4242. In some implementations, the unit cells may be formed or 3D printed around pre-existing crossbeams 4474. In the example illustrated, crossbeam 4474-1 extends along a longitudinal centerline of paddle 4420, intersecting center point 4251. Crossbeam 4474-1 extends through region 4250-1 of handle 4230. Crossbeams 4474-2 and 4474-3 extend from opposite lateral sides of handle 4230, through inner layer 4242 of head 4240. In other implementations, paddle 4420 may include additional crossbeams. In some implementations, such crossbeams may extend transversely across head 4240. In some implementations, the crossbeams may be provided at other locations within head 4240. In some implementations, some or all of the crossbeams 4474 may be omitted.

Faceplates 4444 and 4446 provide smooth imperforate faces for head 4440 of paddle 4420 and can be similar to faceplates 44 and 46 as well as faceplates 4344 and 4346 described above. Faceplates 4444 and 4446 may be integrally formed as part of a single unitary body with inner layer 4242. In other implementations, faceplates 4444 and 4446 may be separately formed and joined to the prior formed inner layer 4242. In the example illustrated, faceplates 4444 and 4446 are substantially similar to one another. Each of faceplates 4444 and 4446 can have a varying thickness across its face to provide different stiffness and performance characteristics. Each of faceplates 4444 and 4446 has an inner face 4242 that has a thinner central region 4445 and a thicker outer region 4447. In the example illustrated, the thicker outer region 4447 encircles the thinner region 4445 and generally corresponds to or overlaps the peripheral outer rim of head 4240 formed by unit cells 4350-7 (and in some implementations 4350-8). As a result, the thicker outer region 4447 provides enhance rigidity and durability to those outer peripheral portions of head 4240. The thinner inner region 4445 facilitates stiffness control based upon the underlying characteristics of inner layer 4242. In other implementations, faceplates 4444 and 4446 may have the same thickness or may be formed from different materials (such as where faceplates are formed separately and subsequently joined to inner layer 4242). In some implementations, different portions of the same faceplate 4444 and/or 4446 may have different thicknesses, wherein a thickness of the underlying adjacent unit cells may be adjusted such that head 4240 has a uniform thickness across its face. In some implementations, other regions of faceplates 4444 and/or 4446 may have greater thicknesses. In the example illustrated, faceplate 4446 has different portions 4447-1 and 4447-2 with different thicknesses to provide different stiffness characteristics for different pickle impact characteristics.

Bumper 4448 extends along and covers the peripheral edge of head 4240 and the opposite side edges of handle 4230. In the example illustrated, bumper 4448 extends to the butt end 4231 of handle 4230. Bumper 4448 increases the strength of head 4240 and increases the durability of the connection between handle 4230 and head 4240. In some implementations, bumper 4448 is integrally formed as part of a single unitary body with inner layer 4242. In some implementations, bumper 4448 is integrally formed as part of a single unitary body with inner layer 4242, faceplates 4444, 4446 and handle 4230. In yet other implementations, bumper 4448 may be separately formed and subsequently joined to head 4240 and handle 4230 such as with fusing, welds, fasteners, adhesives, and the like. In some implementations, bumper 4448 may be omitted. As described above, in some limitations, an outer skin 4347 may be formed about the outer surface of handle 4230. In some implementations, an additional wrap, or sleeve providing a grip may be positioned about the outer skin or direct contact with the unit cells of inner layer 4242 forming handle 4230.

FIGS. 55 and 56 illustrate an example pickleball paddle 4520. FIG. 55 is an exploded perspective view of paddle 4520. FIG. 56 is a plan view schematically illustrating an inner layer 4542 of paddle 4520. As shown by FIG. 55, paddle 4520 comprises handle 4530 and head 4540. FIG. 56 illustrates the inner layer 4542, which is integrally formed as a single unitary body and extends through both head 4540 and handle 4530. Inner layer 4542 comprises a non-orthogonal lattice having multiple different zones or regions. 4420, Handle 4530 extends from head 4540. The inner layer 4542 may be similar to any of the above-described handles, and can be integrally formed as part of a single unitary body with faceplates 4344 and 4346 (shown in FIGS. 49 and 50). In some implementations, handle 4530 may be composed entirely of inner layer 4542, wherein layer 4542 has a generally circular, oval or polygonal outer shape. In yet other implementations, layer 4542 may form a core of handle 4530, wherein additional pallets (such as pallets 132 of FIG. 2, which are secured to inner layer 4542 to complete the outer profile of handle 4530.

Head 4540 has two opposite faceplates 4344 and 4346 formed on opposite sides of inner layer 4542. As described above, in some implementations, the faceplates 4344 and 4346 may be integrally formed as a single unitary body with the inner layer 4542. In some implementations, the faceplates 4344 and 4346 may be separately formed in subsequent need joined to the previously formed inner layer 4542.

As further shown by FIG. 55, inner layer 4542 comprises two annular non-circular regions extending about a central region and an extension that forms handle 4530. Similar to paddles 4320 and 4420, inner layer 4542 is formed from a nonorthogonal lattice comprising of unit cells. In the example illustrated, handle 4530 is formed from a dense arrangement of unit cells similar to unit cells 4350-1 described above.

Head 4540 comprises regions 4550-2, 4550-10, 4550-5 and 4550-7 (collectively referred to as regions 4550). Regions 4550 form a single layer of unit cells. In the example illustrated, regions 4550 are generally concentric rectangles. Regions 4550 provide head 4540 with enhanced player feel and performance. Regions 4550 are based at least partially upon balance point and center of gravity locations for pickleball paddle 4520. Regions 4550 are further configured to satisfy official pickleball paddle regulations promulgated by the International Federation of Pickleball and/or the USA Pickleball Association.

In the example illustrated, region 4550-2 is located at a center point 4551 of head 4540. Region 4550-2 formed from unit cells 4350-2 described above, providing region 4550-2 with a medium level of stiffness greater than that of regions 4550-7 and 4550-10, but less than that of region 4550-5. Region 4550-10 is formed from unit cells 4350-10 described above. Region 4550-10 is a softest or least stiff portion of head 4540.

Region 4550-5 is formed from unit cells 4350-5 described above and has strut diameter similar to the largest strut diameters found in region 4250-5. Similar to regions 4250-5, region 4550-5 contains points 4551-5 which are horizontally aligned with center point 4551 and which are transversely spaced from the axial centerline 4553 (which intersects center point 4551) of head 4540 by distance D of at least 0.75 inch and no greater than 1.25 inches. Region 4550-5 is the stiffest amongst the regions in directions perpendicular to the face of faceplates 4344 and 4346.

Region 4550-7 surrounds the rectangular ring of region 4550-5 and forms the peripheral outer edge of head 4540. Region 4550-7 is formed from a less dense tetrahedral base mesh or Voronai lattice, similar to the last geometry of region 4250-7. In other implementations, head 4540 may have other arrangements of regions form from other types of unit cells or nonorthogonal lattices. In some implementations, head 4540 may be formed from orthogonal lattices or other measures described above.

As further shown by FIG. 56, paddle 4520 additionally comprises an elongate crossbeam 4574 which serves as a spine, extending through handle 4530 to the opposite end of head 4540. Crossbeam 4574 may extend along the centerline of handle 4530 and may intersect center point 4551. Similar to crossbeam 4474-1 described above, crossbeam 4574 may be integrally formed as part of a single unitary body with inner layer 4542, wherein crossbeam 4574 may be solid masses of material or may be formed from unit cells having densities greater than those of the remaining unit cells forming inner layer 4542.

Each of the above-described unit cells and arrangements of unit cells represents just one example for illustrative purposes. In other implementations, the example pickleball paddles may include a wide variety of different cell configurations, shapes and sizes to address particular needs of a player, an application, a league or other objective. Each of the above disclosed pickleball paddles satisfies the official pickleball paddle regulations promulgated by the International Federation of Pickleball and/or the USA Pickleball Association. For example, each of the disclosed pickleball paddles has a total length of no greater than 17 inches and a combined length plus with of no greater than 24 inches. Each of the faces provided by the various faceplates is devoid of any surface or texture that causes spin.

Throughout the disclosure, the various inner layer insert described as comprising an array of cells/lattices or closed depressions or cavities. Such cells/lattices or closed depressions or cavities may have a density of individual cells/lattices or a density of closed depressions or cavities of at least 1/mm³. In each of the examples, the cell/lattices are closed depressions or cavities may be filled with a material, so as solid material or a foamed material. In each of the examples, the cell/lattices or closed depressions or cavities may be left empty void of material. As should be appreciated, those examples illustrating a layer sublayer having a uniform density of cells may alternatively have a nonuniform density of cells, wherein the nonuniformity extends parallel to and/or perpendicular to the plane of the faceplates. In each of the examples, the continuous or discrete layers or combination of multiple sublayers may be adhesively bonded to one another, fused or welded to one another, interlocked with one another or integrally formed as a single unitary body using a micro layer by micro layer additive manufacturing process such as a powder bed an inkjet or dropped on powder printing additive manufacturing process, a stereolithography process, fused deposition modeling process, a selective laser sintering process, an additive manufacturing process polymerizing via ultraviolet radiation or a laminated object manufacturing process.

The above-described implementations are examples only of how a pickleball paddle can be produced. A significant number of other lattice, unit cell and/or crossbeam configurations can be produced under the inventive concepts described above, and are contemplated under the present inventive concepts.

The above examples illustrate a multitude of features for pIckleball paddles. Such features include the provision of an inner layer having (1) multi-levels of cellular layers aligned or misaligned relative to one another, (2) nonorthogonal lattices, (3) meshes, (4) close cavity arrays, (5) cells oriented parallel to the faceplates, (6) orthogonal lattices having top and/or bottom films (see FIG. 12), outer cellular walls about a hollow or filled interior (see FIG. 13), (7) selectively filled cells, (8) cellular layers having density gradients or variations in directions perpendicular to the faceplates or parallel to the faceplates, (9) multiple sublayers stacked in a direction perpendicular to the faceplates with or without an intervening release layer, (10) multiple sublayers forming a stack and offset are rotated relative to one another to form a Moire effect, (11) multiple sublayers of cellular layers (single level cellular layers or multi levels cellular layers) in a single plane, (12) the additional provision of crossbeams through the cellular layers. The above examples illustrate the provision of different faceplates having selective opaque and translucent portions to selectively facilitate viewing of one or more than one cellular layer below the faceplates, were in the selective translucent portions may form a graphic. The above examples illustrate the forming of images upon opposite faceplates to provide a dimensionality to the images (see FIG. 35). The above examples illustrate the use of cellular layers and faceplates to provide an indication of a sweet spot for the paddle as well as providing customized sweet spot for the paddle. The above examples illustrate interchangeable faceplates provide a customized pickleball paddles system. The above examples illustrate interchangeable handle portions to alter the length of the handle, allowing a greater area head, or to alter the sweet spot of the head. Although each particular combination of features may not be specifically illustrated, Ii should be appreciated that each of the above described features may be utilized in various combinations with other described features.

Although the claims of the present disclosure are generally directed to an example pickleball paddle, the present disclosure is additionally directed to the features set forth in the following definitions.

Non-Orthogonal Lattice Head Inner layer

1. A pickleball paddle comprising:

• • a handle; and
  • a head coupled to the handle, the head comprising an inner layer sandwiched between a first outer faceplate and a second outer faceplate, the inner layer comprising a non-orthogonal lattice.

2. The pickleball paddle of definition 1, wherein the non-orthogonal lattice is homogenous across the first outer faceplate and the second outer faceplate.

3. The pickleball paddle of definition 2 further comprising a second inner layer sandwiched between the inner layer and the second outer faceplate.

4. The pickleball paddle of definition 3, wherein the second inner layer comprises a second non-orthogonal lattice.

5. The pickleball paddle of definition 4, wherein the non-orthogonal lattice has a first lattice geometry and wherein the second non-orthogonal lattice has a second lattice geometry different than the first lattice geometry.

6. The pickleball paddle of definition 5, wherein the inner layer is formed from a first material and wherein the second inner layer is formed from a second material different than the first material.

7. The pickleball paddle of definition 4, wherein the non-orthogonal lattice and the second non-orthogonal lattice have a same lattice geometry, wherein the inner layer is formed from a first material and wherein the second inner layer is formed from a second material different than the first material.

8. The pickleball paddle of definition 4, wherein the non-orthogonal lattice and the second non-orthogonal lattice have a same lattice geometry and wherein the second inner layer is rotated relative to the inner layer.

9. The pickleball paddle of definition 8, wherein the first outer faceplate is translucent.

10. The pickleball paddle of definition 3, wherein the second inner layer comprises an orthogonal lattice.

11. The pickleball paddle of definition 1, wherein the first outer faceplate is translucent.

12. The pickleball paddle of definition 1, wherein the non-orthogonal lattice has varying characteristics across the first outer face and the second outer face.

13. The pickleball paddle of definition 1, wherein the non-orthogonal lattice has a varying density of unit cells in a direction across the first outer faceplate and the second outer faceplate.

14. The pickleball paddle of definition 13, wherein the non-orthogonal lattice comprises a first sublayer of unit cells and a second sublayer of unit cells adjacent the first sublayer.

15. The pickleball paddle of definition 13, wherein the non-orthogonal lattice has a varying density of unit cells in a direction perpendicular to the first outer faceplate.

16. The pickleball paddle of definition 15, wherein the non-orthogonal lattice has a first density of unit cells inward a perimeter edge of the inner layer and a second density of unit cells adjacent the outer perimeter of the inner layer, the second density of unit cells being greater than the first density of unit cells.

17. The pickleball paddle of definition 1, wherein the non-orthogonal lattice has a varying density of unit cells in a direction perpendicular to the first outer faceplate.

18. The pickleball paddle of definition 1, wherein the inner layer has an outer edge forming an outer edge surface of the head.

19. The pickleball paddle of definition 1 further comprising a translucent rim over an outer edge of the inner layer.

20. The pickleball paddle of definition 1, wherein the non-orthogonal lattice forms unit cells, wherein a first portion of the unit cells have empty interiors and a second portion of the unit cells are filled.

21. The pickleball paddle of definition 20, wherein the second portion of the unit cells comprise unit cells extending an outer perimeter of the head.

22. The pickleball paddle of definition 1, wherein the first outer faceplate is removably mounted to the head.

23. The pickleball paddle of definition 22, wherein the head comprises at least one groove removably receiving the first outer faceplate.

24. The pickleball paddle of definition 22, wherein the handle is removably mounted to the head.

25. The pickleball paddle of definition 1, the handle is removably mounted to the head.

26. The pickleball paddle of definition 1, wherein the first outer faceplate is formed from a first material and wherein the second outer faceplate is formed from a second material different than the first material.

27. The pickleball paddle of definition 1 further comprising a slit extending into the inner layer in a plane perpendicular to the first outer faceplate.

28. The pickleball paddle of definition 1, wherein the inner layer of the head projects beyond the head to form a portion of the handle.

29. The pickleball paddle of definition 28, wherein portions of the inner layer forming a portion of the handle have filled unit cells.

30. The pickleball paddle of definition 28, wherein the first outer faceplate and the second outer faceplate projects beyond the head to form a portion of the handle.

31. The pickleball paddle of definition 1, wherein the non-orthogonal lattice has a wave pattern.

32. The pickleball paddle of definition 1, wherein an edge of the inner layer is uncovered.

33. The pickleball paddle of definition 1, wherein the inner layer, the first outer faceplate and the second outer faceplate are integrally formed as a single unitary body.

34. The pickleball paddle of definition 1, wherein the first outer faceplate has a first stiffness at a center of the first outer faceplate and wherein the second outer faceplate has a second stiffness, different than the first stiffness, at a center of the second outer faceplate.

35. The pickleball paddle of definition 1, wherein a first portion of the inner layer comprises the nonorthogonal lattice having a first geometry and wherein a second portion of the inner layer comprises a second nonorthogonal lattice having a second geometry different than the first geometry.

36. The pickleball paddle of definition 1, wherein a central region of the inner layer comprises the nonorthogonal lattice and wherein an outer region of the inner layer surrounding the central region comprises a second nonorthogonal lattice.

37. The pickleball paddle of definition 36, wherein the nonorthogonal lattice has a first stiffness and wherein the second nonorthogonal lattice has a second stiffness less than the first stiffness.

38. The pickleball paddle of any of the above definitions, were in the pickleball paddle satisfies official pickleball paddle regulations promulgated by the USA Pickleball Association and/or the International Federation of Pickleball.

Pickleball Paddle Frame

1. A pickleball paddle comprising:

• • a handle extending along a longitudinal axis;
  • a head coupled to the handle, the head comprising:
  • an outer frame forming an outer perimeter of the head;
  • a first outer faceplate coupled to a first face of the outer frame; and
  • a second outer faceplate coupled to a second face of the outer frame.

2. The pickleball paddle of definition 1 further comprising an inner layer within an interior of the outer frame.

3. The pickleball paddle of definition 2, wherein the inner layer comprises a lattice.

4. The pickleball paddle of definition 3, wherein the lattice comprises a nonorthogonal lattice.

5. The pickleball paddle of definition 3, where the lattice comprises an orthogonal lattice.

6. The pickleball paddle of definition 1 further comprising a crossbeam extending across an interior of the outer frame.

7. The pickleball paddle of definition 6, wherein the crossbeam partitions the interior of the outer frame into a first cavity and a second cavity, wherein the pickleball paddle further comprises a first inner layer in the first cavity and a second inner layer in the second cavity.

8. The pickleball paddle of definition 7, wherein the first inner layer comprises a first material and wherein the second inner layer comprises a second material different than the first material.

9. The pickleball paddle of definition 8, wherein the first inner layer has a first lattice geometry and wherein the second inner layer has a second lattice geometry different than the first lattice geometry.

10. The pickleball paddle of definition 9, wherein the first inner layer has a first density of unit cells and wherein the second inner layer has a second density of unit cells different than the first density.

11. The pickleball paddle of definition 10, wherein the first inner layer has a varying density of unit cells.

12. The pickleball paddle of definition 6, wherein the crossbeam partitions the interior of the outer frame into three cavities.

13. The pickleball paddle of definition 6, wherein the crossbeam is imperforate.

14. The pickleball paddle of definition 6, wherein the crossbeam is hollow.

15. The pickleball paddle of definition 6, when the crossbeam is perforate.

16. The pickleball paddle of definition 1, wherein the outer frame comprises a peripheral groove.

17. The pickleball paddle of definition 1 comprising:

• • a first crossbeam extending across an interior of the outer frame; and
  • a second crossbeam extending across the interior of the outer frame.

18. The pickleball paddle of definition 17 further comprising a third crossbeam extending across the interior of the outer frame.

19. The pickleball paddle of definition 17, wherein the first crossbeam extends transverse to the longitudinal axis.

20. The pickleball paddle of definition 17, wherein the first crossbeam extends parallel to the longitudinal axis.

21. The pickleball paddle of definition 17, wherein the first crossbeam and the second crossbeam fan out from the handle.

22. The pickleball paddle of any of the above definitions, wherein the pickleball paddle satisfies official pickleball paddle regulations promulgated by the USA Pickleball Association and/or the International Federation of Pickleball.

Paddle Construction

1. A pickleball paddle comprising:

• • a continuous tubular body looping around to form a perimeter of a head portion and converging to form a handle extending along a longitudinal axis.

2. The pickleball paddle of definition 1 further comprising pallets mounted over the handle.

3. The pickleball paddle of definition 1, wherein the continuous tubular body comprises a fiber composite material.

4. The pickleball paddle of definition 1 further comprising an inner layer within an interior of the head portion.

5. The pickleball paddle of definition 4, wherein the inner layer comprises a lattice.

6. The pickleball paddle of definition 5, wherein the lattice comprises a nonorthogonal lattice.

7. The pickleball paddle of definition 5, where the lattice comprises an orthogonal lattice.

8. The pickleball paddle of definition 1 further comprising a crossbeam extending across an interior of the head portion.

9. The pickleball paddle of definition 6, wherein the crossbeam partitions the interior of the head portion into a first cavity and a second cavity, wherein the pickleball paddle further comprises a first inner layer in the first cavity and a second inner layer in the second cavity.

10. The pickleball paddle of definition 7, wherein the first inner layer comprises a first material and wherein the second inner layer comprises a second material different than the first material.

11. The pickleball paddle of definition 8, wherein the first inner layer has a first lattice geometry and wherein the second inner layer has a second lattice geometry different than the first lattice geometry.

12. The pickleball paddle of definition 9, wherein the first inner layer has a first density of unit cells and wherein the second inner layer has a second density of unit cells different than the first density.

13. The pickleball paddle of definition 10, wherein the first inner layer has a varying density of unit cells.

14. The pickleball paddle of definition 6, wherein the crossbeam partitions the interior of the head portion into three cavities.

15. The pickleball paddle of definition 6, wherein the crossbeam is imperforate.

16. The pickleball paddle of definition 6, wherein the crossbeam is hollow.

17. The pickleball paddle of definition 6, when the crossbeam is perforate.

18. The pickleball paddle of definition 1, wherein the head portion comprises a peripheral groove.

19. The pickleball paddle of definition 1 comprising:

• • a first crossbeam extending across an interior of the head portion; and
  • a second crossbeam extending across the interior of the head portion.

20. The pickleball paddle of definition 17 further comprising a third crossbeam extending across the interior of the head portion.

21. The pickleball paddle of definition 17, wherein the first crossbeam extends transverse to the longitudinal axis.

22. The pickleball paddle of definition 17, wherein the first crossbeam extends parallel to the longitudinal axis.

23. The pickleball paddle of definition 17, wherein the first crossbeam and the second crossbeam fan out from the handle.

24. The pickleball paddle of any of the above definitions, wherein the pickleball paddle satisfies official pickleball paddle regulations promulgated by the USA Pickleball Association and/or the International Federation of Pickleball.

Honeycomb Paddle

1. A pickleball paddle comprising:

• • a handle extending along a longitudinal axis; and
  • a head portion coupled to the handle and comprising a honeycomb arrangement of unit cells, each of the unit cells extending along an axis parallel to the longitudinal axis.

2. The pickleball paddle of definition 1, wherein a portion of the unit cells omit a wall.

3. The pickleball paddle of definition 1 further comprising slits in walls of the unit cells.

4. A pickleball paddle comprising:

• • a handle extending along a longitudinal axis;
  • a head portion coupled to the handle and comprising:
  • a first faceplate;
  • a second faceplate opposite the first faceplate;
  • a first layer adjacent the first face place and comprising a first honeycomb arrangement of unit cells; and
  • a second layer adjacent the second faceplate and comprising a second honeycomb arrangement of unit cells.

5. The pickleball paddle of definition 4 further comprising a release layer between the first layer and the second layer such that the first layer is movable relative to the second layer.

6. The pickleball paddle of definition 5 further comprising:

• • a third layer between the first layer and the second layer, the third layer comprising a third honeycomb arrangement of unit cells.

7. The pickleball paddle of definition 6 further comprising a second release layer between the first layer and the third layer such that the first layer is movable relative to the third layer.

8. The pickleball paddle of definition 4, wherein the first layer is rotated relative to the second layer to form a Moire pattern.

9. The pickleball paddle of definition 1 further comprising a third layer between the first layer and the second layer, the third layer comprising a third honeycomb arrangement of unit cells.

10. The pickleball paddle of definition 1, wherein the unit cells of the first honeycomb arrangement and the unit cells of the second honeycomb arrangement are centered about axes perpendicular to the first faceplate and the second faceplate.

11. The pickleball paddle of definition 1, wherein the unit cells of the first honeycomb arrangement have a different geometry than the unit cells of the second honeycomb arrangement.

12. The pickleball paddle of definition 1, wherein the first honeycomb arrangement has a first stiffness as measured in a direction perpendicular to the first faceplate and wherein the second honeycomb arrangement has a second stiffness, as measured in a direction perpendicular to the first faceplate, second stiffness being different than the first stiffness.

13. The pickleball paddle of definition 1, wherein the first honeycomb arrangement of unit cells is formed from a first material and wherein the second honeycomb arrangement of unit cells form from a second material, different than the first material.

A pickleball paddle comprising:

• • a handle extending along a longitudinal axis; and
  • a head portion comprising:
    • a first faceplate;
    • a second faceplate opposite the first faceplate; and
    • a layer comprising a honeycomb arrangement of unit cells, the honey comb arrangement having a first portion comprising unit cells of a first characteristic and a second portion comprising unit cells of a second characteristic, the second characteristic being different than the first characteristic.

14. The pickleball paddle of definition 14, wherein the first characteristic is a first cross-sectional shape and wherein the second characteristic is a second cross-sectional shape different than the first cross-sectional shape.

15. The pickleball paddle of definition 14, the first characteristic comprises walls formed from a first material and wherein the second characteristic comprises walls formed from a second material different than the first material.

16. The pickleball paddle of definition 14, wherein the first characteristic comprises a first wall thickness and the second characteristic comprises a second wall thickness different than the first wall thickness.

17. The pickleball paddle of definition 14, wherein the first characteristic comprises a first stiffness as measured in a perpendicular to the first faceplate and wherein the second characteristic comprises a second stiffness, as measured in a direction perpendicular to the first faceplate, wherein the second stiffness is different than the first stiffness.

18. The pickleball paddle of definition 14, wherein the first portion of the honeycomb arrangement extends across a center of the first faceplate end and the second faceplate and wherein the second portion of the honeycomb arrangement surrounds the first portion.

Customizable Head

1. A pickleball paddle comprising:

• • a handle having a head transition region;
  • a head comprising:
  • a first face facing in a first direction;
  • a second face facing in a second direction opposite the first direction; and
  • a handle transition region, wherein the head is removably mounted to the handle such that the handle transition region and the head transition region have flush surfaces facing in the first direction and facing in the second direction.

2. The pickleball paddle of definition 1, wherein the handle is removably mounted to the head with a portion of the handle projecting into the head by one of a plurality of selectable extents.

3. The pickleball paddle of definition 1 further comprising a second handle interchangeably and removably mountable to the head in place of the handle, wherein the second handle has a physical characteristic different than the first handle.

4. The pickleball paddle of definition 1 further comprising a second head interchangeably and removably mountable to the handle in place of the head, wherein the second head has a physical characteristic different than the first head.

Handle Length

1. A pickleball paddle comprising:

• • a handle extending along a longitudinal axis;
  • a head extending from the handle and having a width transverse to the longitudinal axis, wherein the paddle a sum of a length of the paddle along the longitudinal axis and the width is no greater than 24 inches, and
  • wherein handle has a length along the longitudinal axis of no greater than 4 inches.

2. The pickleball paddle of definition 1, wherein the handle has a length along the longitudinal axis of no greater than 3 inches.

3. The pickleball paddle of definition 1, wherein the handle has a length along the longitudinal axis of no greater than 2 inches.

Multiple Different Face Plates

1. A pickleball paddle comprising:

• • a handle; and
  • a head coupled to the handle, the head comprising a first outer faceplate and a second outer faceplate having a different characteristic than the first outer faceplate.

2. The pickleball paddle of definition 1, wherein the first outer faceplate is translucent and wherein the second outer faceplate is opaque.

3. The pickleball paddle of definition 2 further comprising an inner layer between the first outer faceplate and the second outer faceplate.

4. The pickleball paddle definition 3, wherein the first translucent outer faceplate has a first facial area and wherein the inner layer has a second facial area less than the first facial area.

5. The pickleball paddle of definition 3, wherein the inner layer comprises a plurality of different colors facing the first outer faceplate.

6. The pickleball paddle of definition 5, wherein the different colors form a number or letter.

7. The pickleball paddle of definition 5, wherein the different colors form a symmetrical design.

8. The pickleball paddle definition 5, wherein the different colors form a logo.

9. The pickleball paddle of definition 2, wherein the second outer faceplate has a face facing a first outer faceplate and wherein the face comprises a plurality of colors visible through the first outer faceplate.

10. The pickleball paddle of definition 9, wherein the different colors form a number or letter.

11. The pickleball paddle of definition 9, wherein the different colors form a symmetrical design.

12. The pickleball paddle definition 9, wherein the different colors form a logo.

13. The pickleball paddle of definition 1, wherein the first outer faceplate is formed from a first material and wherein the second outer faceplate is formed from a second material different than the first material.

14. The pickleball paddle of definition 1, wherein the first outer faceplate has a first shape and wherein the second outer faceplate has a second shape different than the first shape.

15. The pickleball paddle of definition 1, wherein the first outer faceplate has a first stiffness and wherein the second outer faceplate has a second stiffness different than the first stiffness.

Translucent Face Plates

1. A pickleball paddle comprising:

• • a handle; and
  • a head coupled to the handle, the head comprising a first translucent outer faceplate and a second translucent outer faceplate.

2. The pickleball paddle of definition 1 further comprising an inner layer between the first outer faceplate and the second outer faceplate.

3. The pickleball paddle definition 2, wherein the first translucent outer faceplate has a first facial area and wherein the inner layer has a second facial area less than the first facial area.

4. The pickleball paddle of definition 2, wherein the inner layer comprises a plurality of different colors.

5. The pickleball paddle of definition 4, wherein the different colors form a number or letter.

6. The pickleball paddle of definition 4, wherein the different colors form a symmetrical design.

7. The pickleball paddle definition 4, wherein the different colors form a logo.

Miscellaneous Features

1. A pickleball paddle comprising:

• • a handle extending along an axis; and
  • a head coupled to the handle, the head comprising:
    • an inner layer having tubular unit cells, each tubular unit cell extending along a cell axis parallel to the handle axis;
  • a first outer faceplate coupled to a first face of the inner layer; and
  • a second outer faceplate coupled to a second face of the inner layer.

2. A pickleball paddle comprising:

• • a handle;
  • a head coupled to the handle, the head comprising:
    • an inner layer comprising:
  • a first portion having a first two-dimensional array of unit cells having a first density of unit cells; and
  • a second portion having a second two-dimensional array of unit cells having a second density of unit cells different than the first density;
  • a first outer faceplate coupled to a first face of the inner layer; and
  • a second outer faceplate coupled to a second face of the inner layer.

3. The pickleball paddle of definition 2, wherein the two-dimensional array of unit cells comprises a honeycomb arrangement of unit cells, each of the unit cells extending along an axis perpendicular to the first outer faceplate.

4. The pickleball paddle of definition 2 comprising a non-orthogonal lattice forming the two-dimensional array of unit cells.

5. The pickleball paddle of definition 1, wherein the first outer faceplate is translucent.

6. The pickleball paddle of definition 2, wherein the second portion surrounds the first portion in a plane parallel to the first outer faceplate.

7. The pickleball paddle of definition 2, wherein the second two-dimensional array of unit cells projects beyond the head to form a portion of the handle.

8. A pickleball paddle comprising:

• • a handle; and
  • a head coupled to the handle, the head comprising:
  • the first inner layer comprising a first two-dimensional array of unit cells;
  • a second inner layer comprising a second two-dimensional array of unit cells;
  • a first outer faceplate coupled to the first inner layer; and
  • a second outer faceplate coupled to the second inner layer.

9. The pickleball paddle of definition 8, wherein the first inner layer and the second inner layer each have a same unit cell geometry, unit cell size and unit cell density and wherein the second two-dimensional array of unit cells is offset relative to the second two-dimensional array of unit cells.

10. The pickleball paddle of definition 9, wherein the second two-dimensional array of unit cells is rotationally offset relative to the second two-dimensional array of unit cells.

11. The pickleball paddle of definition 10, wherein the first outer faceplate is translucent.

12. The pickleball paddle of definition 8, wherein the first two-dimensional array of unit cells comprises a honeycomb arrangement of unit cells, each of the unit cells extending along an axis perpendicular to the first outer faceplate.

13. The pickleball paddle of definition 8 comprising a non-orthogonal lattice forming the first two-dimensional array of unit cells.

14. The pickleball paddle of definition 8, wherein the first outer faceplate is translucent.

15. A pickleball paddle comprising:

a handle; and

a head coupled to the handle, the head comprising a support portion and at least one removable faceplate removably connected to support portion.

16. The pickleball paddle of definition 15, wherein the support portion comprises an outer frame.

17. The pickleball paddle of definition 15, wherein the support portion comprises an inner layer.

18. The pickleball paddle of definition 15 further comprising a set of different interchangeable faceplates, each of the interchangeable faceplates of the set being removably mountable to the support portion of the head.

19. A pickleball paddle comprising:

• • a handle;
  • a head; and
  • a yoke connecting the handle from the head.

20. The pickleball paddle of definition 19, wherein the handle has a length of less than 4 inches.

21. The pickleball paddle of definition 19, the handle has a length of less than 3 inches.

22. The pickleball paddle of definition 19, wherein the handle has a length less than 2 inches.

23. The pickleball paddle of definition 19, where the yoke has a Y-shape.

24. The pickleball paddle of definition 19, wherein the yoke defines an opening.

25. A pickleball paddle comprising:

• • a handle; and
  • a head, wherein the handle is removably mounted to the head.

26. The pickleball paddle of definition 25, wherein the pickleball paddle is part of a kit, the kit further comprising a second handle that is removably mountable to the head.

27. The pickleball paddle of definition 25, wherein the pickleball paddle is part of the kit, the kit further comprising a second handle that is removably mountable to the head.

28. A pickleball paddle comprising:

• • a handle; and
  • a head coupled to the handle, the head comprising:
    • an inner layer comprising a two-dimensional array of panel folds;
    • a first outer faceplate coupled to a first face of the inner layer; and
    • a second outer faceplate coupled to a second side of the inner layer.

29. A pickleball paddle comprising:

• • a handle; and
  • a head coupled to the handle, wherein the handle comprises a hollow interior and a plurality of outer facets, each of the outer facets comprise at least one elongate aperture.

30. A pickleball paddle comprising:

• • a handle; and
  • a head coupled to the handle, the head comprising:
    • an inner mesh layer;
    • a front outer face plate coupled to a first side of the inner mesh layer; and
    • a second outer face plate coupled to a second side of the inner mesh layer.

31. A pickleball paddle comprising:

• • a handle; and
  • a head coupled to the handle, the head comprising:
  • an inner layer having a peripheral edge;
  • a peripheral rim at least partially covering the peripheral edge;
  • a first outer faceplate coupled to the inner layer; and
  • a second outer faceplate coupled to the inner layer, wherein at least a portion of at least one of the peripheral rim, the first outer faceplate and the second outer faceplate are translucent.

32. The pickleball paddle of definition 31, wherein the inner layer comprises a two-dimensional array of unit cells.

33. The pickleball paddle of definition 32, wherein the inner layer comprises a non-orthogonal lattice forming the two-dimensional array of unit cells.

Although the present disclosure has been described with reference to example implementations, workers skilled in the art will recognize that changes may be made in form and detail without departing from disclosure. For example, although different example implementations may have been described as including features providing various benefits, it is contemplated that the described features may be interchanged with one another or alternatively be combined with one another in the described example implementations or in other alternative implementations. Because the technology of the present disclosure is relatively complex, not all changes in the technology are foreseeable. The present disclosure described with reference to the example implementations and set forth in the following claims is manifestly intended to be as broad as possible. For example, unless specifically otherwise noted, the claims reciting a single particular element also encompass a plurality of such particular elements. The terms “first”, “second”, “third” and so on in the claims merely distinguish different elements and, unless otherwise stated, are not to be specifically associated with a particular order or particular numbering of elements in the disclosure.

Claims

1. A pickleball paddle comprising: a handle; anda head coupled to the handle, the head comprising an inner layer sandwiched between a first outer faceplate and a second outer faceplate, the inner layer comprising a lattice, wherein at least portions of the handle, the inner layer, the first outer faceplate, and the second outer faceplate are integrally formed as a single unitary body.

2. The pickleball paddle of claim 1, wherein inner layer, the first outer face plate and the second outer faceplate are entirely formed as a single unitary body from a single material.

3. The pickleball paddle of claim 2 further comprising at least one layer adhered to the first outer faceplate and the second outer faceplate.

4. The pickleball paddle of claim 1, wherein the handle comprises an outwardly flared butt end, wherein the outwardly flared butt end is integrally formed with the inner layer, the first outer faceplate and the second outer faceplate as part of the single unitary body.

5. The pickleball paddle of claim 1, wherein the handle comprises a handle core and a grip joined to the handle core, the handle core being integrally formed with the inner layer, the first outer faceplate and the second outer faceplate as part of the single unitary body.

6. The pickleball paddle of claim 1, wherein the lattice comprises first fillets at first corners formed between the lattice and the first outer faceplate and second fillets at second corners formed between the lattice and the second outer faceplate.

7. The pickleball paddle of claim 1, wherein the first outer faceplate has a first thickness and the second outer faceplate has a second thickness different than the first thickness.

8. The pickleball paddle of claim 1, wherein the head has a thickness of at least 0.25 inch and a density no greater than 0.5 g/cc.

9. The pickleball paddle of claim 1, wherein the lattice has a varying density in a direction parallel to a face of the first outer faceplate.

10. The pickleball paddle of claim 9, wherein the lattice comprises a non-orthogonal lattice.

11. The pickleball paddle of claim 9, wherein the lattice comprises a honeycomb arrangement of unit cells.

12. The pickleball paddle of claim 1, wherein the head has a varying deflection characteristic across a face of the head.

13. The pickleball paddle of claim 1, wherein the lattice forms cells and wherein a portion of the cells are filled.

14. The pickleball paddle of claim 1 further comprising a crossbeam continuously extending through the handle and through the inner layer of the head, wherein the crossbeam is integrally formed as part of the single unitary body.

15. The pickleball paddle of claim 1 further comprising: a first crossbeam extending from a first side edge of the handle through the inner layer of the head; anda second crossbeam extending from a second side edge of the handle through the inner layer of the head.

16. The pickleball paddle of claim 1 further comprising a bumper continuously extending along an edge of the head and along opposite side edges of the handle.

17. The pickleball paddle of claim 16, wherein the bumper is integrally formed as part of the single unitary body.

18. The pickleball paddle of claim 1, wherein the handle comprises a second lattice, the second lattice being integrally formed as part of the single unitary body.

19. The pickleball paddle of claim 1, wherein the lattice comprises a first portion having a first lattice geometry and a second portion having a second last geometry different than the first lattice geometry.

20. The pickleball paddle of claim 1, wherein the head comprises a first portion having a first lattice and a second portion having a second lattice different than the first lattice.