Patent Application
20240286015
Embodiments of the present disclosure generally relate to paddles for sports. More specifically, embodiments of the disclosure relate to an apparatus and methods for a sports paddle for pickleball, tennis, smashball, paddle tennis, ping pong, or racquetball.
Pickleball typically is played on a badminton-sized court with a tennis-like net, using a perforated plastic hollow ball. The ball is struck by players using pickleball paddles that resemble large table tennis paddles. Pickleball paddles generally are made of wood, graphite, aluminum, carbon fiber, fiberglass, composite materials, and other suitable materials. They often have a polypropylene or foam core.
Pickleball paddles may be constructed by cutting or machining a large sheet of material into the shape of a paddle or by surrounding the core in a composite material and allowing it to cure in a fixed tool. As shown in
The opposing flat surfaces of the paddle 100 may be covered by a skin or protective layers. The skin is sometimes called a “laminate” or “face sheet.” In embodiments where a core material is bonded to a skin material, the paddle 100 is referred to as a “composite panel” or “sandwich panel.” The skin material may comprise thin, but stiff, skins while the core material may comprise a lightweight, but thick, core. The core material generally is low strength material, but its greater thickness provides the sandwich panel with high bending stiffness and low overall density.
The core material may comprise open-cell-structures and closed-cell-structured foams such as polyvinylchloride, polyurethane, polyethylene or polystyrene foams, balsa wood, syntactic foams, honeycombs, and the like. Open-cell and closed-cell metal foam can also be used as core materials.
Laminates comprising glass or carbon fiber-reinforced thermoplastics or thermoset polymers, such as unsaturated polyesters, epoxies, and the like, may be used as skin materials. Sheet metal may also be used as skin material.
A drawback to conventional paddles is that they tend to develop weak spots or soft spots, known as “dead spots.” Dead spots typically form at locations where wear damage occurs, or where the adhesive fails, resulting in delamination of the skin material from the core material. Dead spots can also occur because edges of conventional paddles are held together only by a flexible rail guard that allows the paddle edges to flex during ball impacts.
Another drawback to conventional paddles comprising sandwich panels, such as the paddle 100, arises due to edge treatments. Some manufacturers apply a U-channel or other type of molding, such as the edge guard 112, to protect the edge of the planar portion 104 and enclose the periphery of the core material disposed between the skin materials. The edge guard 112 forms a lip 132 around the planar portion 104 that creates interference when striking the ball in this area of the paddle 100. Further, some manufacturers finish the edge with a composite material. Unfortunately, the composite material renders the edge of the paddle 100 overly fragile, resulting in damage if the ground or a hard object is struck during play. Moreover, many methods of finishing the edge of the paddle 100 cause reliability issues, such as the edge treatment tending loosen and separate or fall off with age or stress. Additionally, in some instances a flexible rail guard may be used, but such rail guards often cause undesirable ball trajectories when struck by the ball during play.
There is a need, therefore, for a paddle that does not require an edge treatment, such as the edge guard 112 shown in
An apparatus and a method are provided for a sports paddle for pickleball, tennis, or racquetball. The sports paddle comprises a planar portion defining opposing flat surfaces for striking a ball and a handle portion for grasping in a hand. A skin layer encloses the planar portion and the handle portion. Rounded edges are disposed around the planar portion and the handle portion. The planar portion may comprise a core material surrounded by a rigid portion. The rigid portion may comprise 20-24 lb. foam while the core material is a honeycomb structured material. A synthetic or polymeric grip is wrapped around the handle portion to provide stability and firmness for a player. A binding secures the grip to a neck of the planar portion. An end cap placed at an end of the handle provides support and protection of the paddle.
In an exemplary embodiment, a sports paddle comprises: a planar portion defining opposing flat surfaces for striking a ball; and a handle portion for grasping in a hand.
In another exemplary embodiment, the planar portion and the handle portion comprise a single component. In another exemplary embodiment, the planar portion comprises a core material wrapped within a skin layer. In another exemplary embodiment, the core material comprises open-cell-structures and closed-cell-structured foams such as polyvinylchloride, polyurethane, polyethylene or polystyrene foams, balsa wood, syntactic foams, honeycombs, and the like.
In another exemplary embodiment, the core material comprises between 20-lb. and 24-lb. foam. In another exemplary embodiment, the skin layer surrounds an entirety of the core material. In another exemplary embodiment, enclosing the core material within the skin layer enables incorporating rounded edges into the paddle portion and the handle portion. In another exemplary embodiment, the skin layer comprises any of fiberglass, graphite, carbon fiber, or other suitable material that offers a practitioner a sense of control, feel, or power during play.
In another exemplary embodiment, the skin layer includes permanent or removeable film portions that are configured to provide desired performance properties. In another exemplary embodiment, the skin layer includes adhesive stickers comprising carbon fiber sheets configured to provide consistent or enhanced traction. In another exemplary embodiment, the skin layer is configured to provide noise suppression properties. In another exemplary embodiment, the skin layer comprises noise suppressing stickers that can be applied to and removed from the planar portion of the paddle. In another exemplary embodiment, the skin layer comprises fixed foam surfaces that cover the planar portion of the paddle.
In another exemplary embodiment, an edge guard is configured to be coupled with a periphery of the planar portion so as to provide protection to portions of the skin layer that are disposed on the rounded edges. In another exemplary embodiment, the edge guard comprises a polymer portion and a mass strip portion comprising a thin strip of metal, such as lead, that increases the weight of the planar portion. In another exemplary embodiment, the polymer portion includes a recess for receiving the mass strip such that a flat surface of the polymer portion and a back surface of the mass strip form a substantially uniform surface suitable for being adhered to the periphery of the planar portion. In another exemplary embodiment, the polymer portion includes a rounded surface configured to smoothly join with the rounded edges so as to produce a low-profile edge rail for the sports paddle.
In another exemplary embodiment, a synthetic or polymeric grip is wrapped around the handle portion to provide stability and firmness for a player. In another exemplary embodiment, the grip is wrapped around hardwood portions that are coupled with the handle portion. In another exemplary embodiment, a binding secures the grip to a neck of the planar portion. In another exemplary embodiment, an end cap placed at an end of the handle provides support and protection of the paddle.
In another exemplary embodiment, the opposing surfaces of the planar portion are covered by skin layers comprising different materials. In another exemplary embodiment, the planar portion comprises a core surrounded by a rigid portion. In another exemplary embodiment, the rigid portion comprises between 20-lb. and 24-lb. foam while the core comprises a honeycomb structured material.
In another exemplary embodiment, a padded edge guard is bonded to a periphery of the rigid portion before the skin layer is applied to the planar portion. In another exemplary embodiment, one or more weights are incorporated into the planar portion to increase the weight of the paddle. In another exemplary embodiment, the planar portion includes a core comprising a different type or density of foam than the foam comprising the rigid portion. In another exemplary embodiment, the core comprises a number of holes positioned on the rigid portion so as to reduce the weight of the paddle.
In an exemplary embodiment, a method for a sports paddle comprises: forming planar portion that extends to a handle portion; disposing rounded edges around the planar portion and the handle portion; enclosing the planar portion and the handle portion within a skin layer; positioning hardwood portions on opposite sides of the handle portion; wrapping the hardwood portions and the handle portion with a grip; securing the grip to the planar portion by way of a binding; and installing an end cap onto the handle portion.
In another exemplary embodiment, forming includes disposing a core within a rigid portion. In another exemplary embodiment, the rigid portion comprises between 20-lb. and 24-lb. foam while the core comprises a honeycomb structured material. In another exemplary embodiment, forming includes disposing rounded edges around the planar portion and the handle portion.
In another exemplary embodiment, the method further comprises coupling an edge guard to a periphery of the planar portion so as to provide protection to portions of the skin layer that are disposed on the rounded edges. In another exemplary embodiment, coupling includes adhering a mass strip portion between the edge guard and the periphery to increase the weight of the planar portion. In another exemplary embodiment, adhering includes adhering the mass strip within a recess comprising the polymer portion such that a flat surface of the polymer portion and a back surface of the mass strip form a substantially uniform surface suitable for being adhered to the periphery of the planar portion.
In an exemplary embodiment, a sports paddle, comprises: a planar portion defining opposing flat surfaces for striking a ball; a core material having rounded edges; a handle portion for grasping in a hand; and a skin layer surrounding at least a majority of the planar portion.
In another exemplary embodiment, the core material comprises an open-cell-structure. In another exemplary embodiment, the core material comprises a closed-cell-structured foam. In another exemplary embodiment, the foam comprises any one or more of polyvinylchloride, polyurethane, polyethylene or polystyrene foams, balsa wood, syntactic foams, honeycombs, and any combination thereof.
In another exemplary embodiment, the core material comprises an open-cell or closed-cell metal foam. In another exemplary embodiment, the core material comprises a polypropylene honeycomb core that is wrapped in multiple layers of pre-preg carbon fiber. In another exemplary embodiment, the carbon fiber is adhered to the honeycomb core and baked under compression to form a boned surface of the planar portion. In another exemplary embodiment, the core material comprises between 20-lb. and 24-lb. foam.
In another exemplary embodiment, the planar portion includes a rigid portion surrounding the core material. In another exemplary embodiment, the rigid portion comprises between 20- and 24-lb. foam while the core material comprises a honeycomb structured material. In another exemplary embodiment, one or more weights are incorporated into the core material.
In another exemplary embodiment, the polypropylene honeycomb core is dipped into a bath of a liquid material that remains flexible in a dried state. In another exemplary embodiment, the liquid material comprise any one or more of rubber, Urethanes, exotic materials such as liquid diamond dust, liquid carbon fiber, liquid Kevlar, liquid gold dust, liquid ruby dust, and any combination thereof. In another exemplary embodiment, the liquid material is selected so as to affect material properties of the paddle, such as any one or more of weight, construction strength, bounce, and any combination thereof. In another exemplary embodiment, the liquid material is selected to seal off chamber walls comprising the polypropylene honeycomb core so as to prevent small pieces from later coming loose causing rattles. In another exemplary embodiment, the polypropylene honeycomb core comprising dried liquid material is wrapped in multiple layers of pre-preg carbon fiber. In another exemplary embodiment, the carbon fiber is adhered to the honeycomb core and baked under compression to form a boned surface of the planar portion.
In another exemplary embodiment, the skin layer comprises different materials applied to the opposing flat surfaces. In another exemplary embodiment, the skin layer includes film portions that provide desired performance properties. In another exemplary embodiment, the skin layer includes adhesive stickers comprising carbon fiber sheets that provide affect traction.
These and other features of the concepts provided herein may be better understood with reference to the drawings, description, and appended claims.
The drawings refer to embodiments of the present disclosure in which:
While the present disclosure is subject to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. The present disclosure should be understood to not be limited to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one of ordinary skill in the art that the paddle and methods disclosed herein may be practiced without these specific details. In other instances, specific numeric references such as “first core material,” may be made. However, the specific numeric reference should not be interpreted as a literal sequential order but rather interpreted that the “first core material” is different than a “second core material.” Thus, the specific details set forth are merely exemplary. The specific details may be varied from and still be contemplated to be within the spirit and scope of the present disclosure. The term “coupled” is defined as meaning connected either directly to the component or indirectly to the component through another component. Further, as used herein, the terms “about,” “approximately,” or “substantially” for any numerical values or ranges indicate a suitable dimensional tolerance that allows the part or collection of components to function for its intended purpose as described herein.
Pickleball paddles generally are made of wood, graphite, aluminum, fiberglass, carbon fiber, composite materials, and other suitable materials. In many embodiments, a core material is bonded between sheets of a skin material. A drawback to conventional paddles is that they tends to develop dead spots at locations where wear damage occurs, or where the adhesive fails, resulting in delamination of the skin material from the core material. Another drawback arises due to edge treatments, such as an edge guard used to protect the edge of the planar portion and enclose the periphery of the core material disposed between the skin materials. The edge guard forms a lip around the planar portion that creates interference when striking the ball in this area of the paddle. Embodiments presented herein provide a paddle that does not require an edge guard, allowing the paddle to be made out of a solid material that encloses the core material as well as any structures incorporated into the core.
As shown in
The skin layer 168 may comprise fiberglass, graphite, carbon fiber, or other suitable material that offers a practitioner a sense of control, feel, or power during play. In some embodiments, the opposing sides of the planar portion 144 may be covered by skin layers 168 comprising different materials, thereby forming a “hybrid” paddle that offers differing performance on the opposing sides. For example, one side may offer greater power while the other side offers greater precision. Further, in some embodiments, the skin layer 168 may be laminates comprising glass or carbon fiber-reinforced thermoplastics or thermoset polymers, such as unsaturated polyesters, epoxies, and the like, as well as sheet metal, without limitation.
Moreover, in some embodiments, the skin layer 168 may be configured to provide specific performance properties, such as, for example, a consistent traction, noise suppression, and the like. In some embodiments, the skin layer 168 may include permanent or removeable film portions that are configured to provide desired performance properties, such as a consistent traction, without limitation. In some embodiments, adhesive stickers comprising carbon fiber sheets may be configured to provide consistent or enhanced traction. It is contemplated that such adhesive stickers may be applied to and removed from the planar portion 144 of the paddle 140 as desired.
In some embodiments, the skin layer 168 may be configured to provide noise suppression properties. As such, in some embodiments, the skin layer 168 may include adhesive stickers comprising a synthetic rubber compound, such as by way of non-limiting example, neoprene or ethylene propylene diene monomer (EPDM), and the like. It is contemplated that, in some embodiments, the noise suppressing stickers can be applied to and removed from the planar portion 144 of the paddle 140, as desired. In some embodiments, the skin layer 168 may comprise fixed foam surfaces that cover the planar portion 144 of the paddle 140. Further, in some embodiments, the skin layer 168 may comprise a removeable skin that is configured to be pulled onto the planar portion 144 and then closed onto the paddle 140. It is contemplated that the removeable skin includes a zipper or similar device for enclosing the planar portion 144. In some embodiments, the removeable skin may include foam portions configured to dampen the sound of striking a ball with the paddle 140. As will be appreciated, applying noise damping properties to the paddle 140 is particularly useful for playing pickleball or other similar games near residences.
The core material may comprise open-cell-structures and closed-cell-structured foams such as polyvinylchloride, polyurethane, polyethylene or polystyrene foams, balsa wood, syntactic foams, honeycombs, and the like. Open-cell and closed-cell metal foam can also be used as core materials. In one embodiment, the core material comprises a complete polypropylene honeycomb core that is wrapped in 4 layers of pre-preg carbon fiber. The carbon fiber is adhered to the honeycomb and baked under compression to form a “boned surface.” In one embodiment, the core material comprises between 20-lb. and 24-lb. foam. Other suitable materials will be apparent to those skilled in the art.
Moreover, in some embodiments, the polypropylene honeycomb is dipped into a bath of a liquid material that remains flexible in a dried state. The liquid material may comprise any one or more of rubber, Urethanes, as well as exotic materials such as liquid diamond dust, liquid carbon fiber, liquid Kevlar, liquid gold dust, liquid ruby dust, and the like. Once the liquid material is dried onto the honeycomb core, the core is wrapped in 4 layers of pre-preg carbon fiber. The carbon fiber is adhered to the honeycomb and baked under compression to form a boned surface, as mentioned above. It is contemplated that the dried liquid material can be used to change the properties of the paddle 140, such as change weight, construction strength, bounce, and the like. Further, it is contemplated that dipping the honeycomb core seals off the honeycomb chamber walls, preventing small pieces from coming off causing rattles.
It is contemplated that any of various structures may be incorporated into the planar portion before being wrapped in the skin layers 168, as described herein. For example,
Moreover, it is contemplated that an edge guard may be bonded to the periphery of the rigid portion 200 after the skin layer 168 is applied to the planar portion 208.
Turning, now, to
In some embodiments, one or more weights may be incorporated into the planar portion to increase the weight of the paddle. For example,
While the paddle and methods have been described in terms of particular variations and illustrative figures, those of ordinary skill in the art will recognize that the paddle is not limited to the variations or figures described. In addition, where methods and steps described above indicate certain events occurring in certain order, those of ordinary skill in the art will recognize that the ordering of certain steps may be modified and that such modifications are in accordance with the variations of the paddle. Additionally, certain of the steps may be performed concurrently in a parallel process when possible, as well as performed sequentially as described above. To the extent there are variations of the paddle, which are within the spirit of the disclosure or equivalent to the paddle found in the claims, it is the intent that this patent will cover those variations as well. Therefore, the present disclosure is to be understood as not limited by the specific embodiments described herein, but only by scope of the appended claims.
This application is a continuation-in-part of, and claims the benefit of, U.S. patent application, entitled “Sports Paddle,” filed on May 8, 2023, and having application Ser. No. 18/144,770, which claims the benefit of, and priority to, U.S. Provisional application, entitled “Sports Paddle,” filed on May 9, 2022, and having application Ser. No. 63/339,855, and to U.S. Provisional application, entitled “Sports Paddle,” filed on Oct. 15, 2022, having application Ser. No. 63/419,154, the entirety of each of said applications being incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63339855 | May 2022 | US | |
| 63419154 | Oct 2022 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 18144770 | May 2023 | US |
| Child | 18658701 | US |
