U.S. patent application number 17/177899 was filed with the patent office on 2021-08-19 for pickleball paddle.
This patent application is currently assigned to Wilson Sporting Goods Co.. The applicant listed for this patent is Wilson Sporting Goods Co.. Invention is credited to Eloisa M. Compostizo, Scott M. Doyle, Sean P. Griffin, Robert T. Kapheim, Wayne C. Klinger, Nadine Lippa, William D. Severa, Robert T. Thurman, Ninad Trifale, Hudson R. Vantrease, David A. Vogel, Dale J. Zwack.
Application Number | 20210252356 17/177899 |
Document ID | / |
Family ID | 1000005461766 |
Filed Date | 2021-08-19 |
United States Patent
Application |
20210252356 |
Kind Code |
A1 |
Thurman; Robert T. ; et
al. |
August 19, 2021 |
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.
Inventors: |
Thurman; Robert T.; (Glenn
Ellyn, IL) ; Vogel; David A.; (Island Lake, IL)
; Trifale; Ninad; (Chicago, IL) ; Severa; William
D.; (Lombard, IL) ; Lippa; Nadine; (Arlington
Heights, IL) ; Doyle; Scott M.; (Palatine, IL)
; Kapheim; Robert T.; (Chicago, IL) ; Zwack; Dale
J.; (Bartlett, IL) ; Compostizo; Eloisa M.;
(Chicago, IL) ; Griffin; Sean P.; (Chicago,
IL) ; Vantrease; Hudson R.; (Chicago, IL) ;
Klinger; Wayne C.; (Hoffman Estates, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Wilson Sporting Goods Co. |
Chicago |
IL |
US |
|
|
Assignee: |
Wilson Sporting Goods Co.
Chicago
IL
|
Family ID: |
1000005461766 |
Appl. No.: |
17/177899 |
Filed: |
February 17, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62978101 |
Feb 18, 2020 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A63B 59/42 20151001;
A63B 60/08 20151001; A63B 60/14 20151001; A63B 2209/02 20130101;
A63B 60/16 20151001 |
International
Class: |
A63B 59/42 20060101
A63B059/42; A63B 60/14 20060101 A63B060/14; A63B 60/08 20060101
A63B060/08 |
Claims
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 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; and a 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.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a non-provisional patent
application claiming priority from U.S. Provisional Patent
Application Ser. No. 62/978,101 filed on Feb. 18, 2020 entitled
PICKLEBALL PADDLE, the full disclosure which is hereby incorporated
by reference.
BACKGROUND
[0002] 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
[0003] FIG. 1A is a front perspective view of an example pickleball
paddle.
[0004] FIG. 1B is a top, side perspective view of set of example
lattice structures for a pickleball paddle
[0005] FIG. 2 is a front, side perspective view of another example
pickleball paddle.
[0006] FIG. 3A is a front, side perspective view of an example
inner core of a pickleball paddle.
[0007] FIG. 3B is an enlarged side perspective view of the inner
core of FIG. 3A.
[0008] FIG. 4A is a front, side perspective view of another example
inner core of a pickleball paddle.
[0009] FIG. 4B is an enlarged side perspective view of the inner
core of FIG. 4A.
[0010] FIG. 5 is a front, side perspective view of another example
inner core of a pickleball paddle.
[0011] FIG. 6 is an enlarged side perspective view of another
example inner core of a pickleball paddle.
[0012] FIG. 7 is a front, side perspective view of another example
inner core of a pickleball paddle.
[0013] FIG. 8 is a front, side perspective view of another example
inner core of a pickleball paddle.
[0014] FIG. 9A is a front, side perspective view of another example
inner core of a pickleball paddle.
[0015] FIG. 9B is an enlarged front, side perspective view of the
example inner core of a pickleball paddle of FIG. 9A.
[0016] FIGS. 9C is a front view of another example pickleball
paddle produced from an additive manufacturing process.
[0017] FIGS. 9D is a front perspective view of another example
pickleball paddle produced from an additive manufacturing process
utilizing dynamic modeling and impact analysis.
[0018] FIGS. 9E is a side front perspective view of the pickleball
paddle of FIG. 9D.
[0019] FIG. 9F is an enlarged view of a portion of the head of the
pickle ball paddle of FIG. 9E.
[0020] FIG. 10A is a front view of a portion of another example
inner core of a pickleball paddle.
[0021] FIG. 10B is a side view of the portion of the example inner
core of a pickleball paddle of FIG. 10A.
[0022] FIG. 11 is a transverse sectional view of another example
pickleball paddle.
[0023] FIG. 12 is a front, side perspective view of another example
pickleball paddle.
[0024] FIG. 13 is an end perspective view of an inner core of
another example pickleball paddle.
[0025] FIG. 14 is a front view of another example pickleball
paddle.
[0026] FIG. 15 is a front, side perspective view of another example
pickleball paddle.
[0027] FIGS. 16 through 20 are transverse sectional views of other
example pickleball paddles taken alone line 16-16 of FIG. 15.
[0028] FIG. 21A is a front view of another example pickleball
paddle.
[0029] FIG. 21B is a transverse sectional view of the pickleball
paddle taken along line 21B-21B of FIG. 21A.
[0030] FIG. 22 is a transverse sectional view of another example
pickleball paddle.
[0031] FIG. 23A is a front view of another example pickleball
paddle.
[0032] FIG. 23B is a transverse sectional view of the pickleball
paddle taken along line 23B-23B of FIG. 23A.
[0033] FIG. 24A is a front side perspective view of another example
pickleball paddle.
[0034] FIG. 24B is a transverse sectional view of the pickleball
paddle taken along line 24B-24B of FIG. 24A.
[0035] FIG. 24C is a transverse sectional view of the pickleball
paddle taken along line 24C-24C of FIG. 24A.
[0036] FIG. 24D is a transverse sectional view of the pickleball
paddle taken along line 24D-24D of FIG. 24A.
[0037] FIG. 25A is a front side perspective view of another example
pickleball paddle.
[0038] FIG. 25B is a transverse sectional view of the pickleball
paddle taken along line 25B-25B of FIG. 25A.
[0039] FIG. 25C is a transverse sectional view of the pickleball
paddle taken along line 25C-25C of FIG. 25A.
[0040] FIG. 26 is a front side perspective view of another example
pickleball paddle.
[0041] FIGS. 27 through 29 are transverse sectional views of other
example pickleball paddles.
[0042] FIG. 30 is a side perspective view of an inner core of an
example pickleball paddle.
[0043] FIG. 31 is a front perspective view of the inner core of
FIG. 30.
[0044] FIG. 32A is a front view of another example pickleball
paddle.
[0045] FIG. 32B is a transverse sectional view of the pickleball
paddle taken along line 32B-32B of FIG. 32A.
[0046] FIG. 33 is a transverse sectional view of another example
pickleball paddle.
[0047] FIG. 34A is a front view of another example pickleball
paddle.
[0048] FIG. 34B is a transverse sectional view of the pickleball
paddle taken along line 34B-34B of FIG. 34A.
[0049] FIG. 35 is a transverse sectional view of another example
pickleball paddle.
[0050] FIG. 36A is a front view of another example pickleball
paddle.
[0051] FIG. 36B is a transverse sectional view of the pickleball
paddle taken along line 36B-36B of FIG. 36A.
[0052] FIG. 37A is a front perspective view of an example
pickleball paddle kit with replaceable faceplates.
[0053] FIGS. 37B and 37C are front views of pickleball paddles of
the pickleball paddle kit of FIG. 37A.
[0054] FIG. 38A is a front perspective view of another example
pickleball paddle.
[0055] FIG. 38B is a transverse view of the pickleball paddle taken
along line 38B-38B of FIG. 38A.
[0056] FIG.38C is a transverse sectional view of the pickleball
paddle taken along line 38C-38C of FIG. 38A.
[0057] FIG. 38D is a longitudinal sectional view of the pickleball
paddle taken along line 38D-38D of FIG. 38A.
[0058] FIG. 39A is a front perspective view of an example
pickleball paddle kit with replaceable handles.
[0059] FIG. 39B is a front side perspective view of a pickleball
paddle of the pickleball paddle kit of FIG. 39A.
[0060] FIG. 40A is an exploded front perspective view of another
example pickleball paddle.
[0061] FIG. 40B is a front perspective view of another example
pickleball paddle.
[0062] FIG. 40C is an end perspective view of another example
pickleball paddle.
[0063] FIGS. 41 through 45 are front views of other example
pickleball paddles.
[0064] FIG. 46 is a plan view of an example pickleball paddle.
[0065] FIG. 47 is a plan view of an example pickleball paddle.
[0066] 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.
[0067] FIG. 49 is a sectional view of the pickleball paddle of FIG.
47 taken along line 49-49.
[0068] FIG. 50 is a sectional view of the pickleball paddle of FIG.
47 taken along line 50-50.
[0069] FIG. 51 is a sectional view of the pickleball paddle of FIG.
47 taken along line 51-51.
[0070] 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.
[0071] 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.
[0072] FIG. 54 is an exploded perspective view of an example
pickleball paddle.
[0073] FIG. 55 an exploded perspective view of an example
pickleball paddle.
[0074] FIG. 55 is a top view of an example inner layer of the
pickleball paddle of FIG. 55.
[0075] FIG. 56 is a plan view of an example pickleball paddle.
[0076] 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
[0077] 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.
[0078] 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.
[0079] 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.
[0080] 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.
[0081] 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.
[0082] 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.
[0083] In some implementations, the inner layer 42 can be formed of
a urethane foam, polypropylene, Nomex.RTM. 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.
[0084] 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.
[0085] 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.RTM., Spectra.RTM.,
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.
[0086] 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.
[0087] 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.
[0088] 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.
[0089] 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.
[0090] 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.RTM. 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.
[0091] 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.RTM. 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.RTM. 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.
[0092] 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.RTM. 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.RTM.
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.
[0093] 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.RTM. 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.RTM.
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.
[0094] 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.RTM. 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.
[0095] 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.RTM. 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.
[0096] 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.
[0097] 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.
[0098] 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.
[0099] 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.
[0100] 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.
[0101] 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.
[0102] 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.
[0103] 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.
[0104] 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.
[0105] 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.
[0106] 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.
[0107] 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.
[0108] 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.
[0109] 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.RTM. 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.
[0110] 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.
[0111] 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.RTM.
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.
[0112] 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.
[0113] 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.
[0114] 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.
[0115] 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.
[0116] 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.
[0117] 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).
[0118] 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.
[0119] 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.
[0120] 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.
[0121] 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.
[0122] 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.
[0123] 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.
[0124] 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.
[0125] 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.
[0126] 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.
[0127] 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.
[0128] 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.
[0129] 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.
[0130] 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.
[0131] 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.
[0132] 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.
[0133] 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.
[0134] 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.
[0135] 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.
[0136] 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.
[0137] 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.
[0138] 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.
[0139] 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.
[0140] 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.
[0141] 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.
[0142] 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.
[0143] 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.
[0144] 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.
[0145] 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.
[0146] 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.
[0147] 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.
[0148] 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.
[0149] 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.
[0150] 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.
[0151] 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.
[0152] 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.
[0153] 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.
[0154] 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.
[0155] 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.
[0156] 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.
[0157] 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 24
7-3 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 24 7-1, 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.
[0158] 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.
[0159] 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.
[0160] 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.
[0161] 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.
[0162] 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.
[0163] 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.
[0164] 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.
[0165] 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.
[0166] 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.
[0167] 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.
[0168] 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.
[0169] 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.
[0170] 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.
[0171] 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.
[0172] 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.
[0173] 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.
[0174] 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.
[0175] 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.
[0176] 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.
[0177] 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.
[0178] 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.
[0179] 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.
[0180] 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 3270-1 3270-2 may also have different
geometries and/or may be formed from different materials.
[0181] 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.
[0182] 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.
[0183] 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.
[0184] 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.
[0185] 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.
[0186] 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 323 10 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.
[0187] 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.
[0188] 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.
[0189] 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.
[0190] 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.
[0191] 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.
[0192] 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.
[0193] 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.
[0194] 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.
[0195] 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.
[0196] 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.
[0197] 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.
[0198] 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.
[0199] 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.
[0200] 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.
[0201] 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.
[0202] 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.
[0203] 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.
[0204] 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.
[0205] 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.
[0206] 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.
[0207] 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.
[0208] 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.
[0209] 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.
[0210] 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.
[0211] 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.
[0212] Regions 4250-9 and 4250-10 extends between region 4250-7 and
the regions 4250-1 through 4250-6. Regions 4250-9 4050-10 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.
[0213] 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.
[0214] 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.
[0215] 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.
[0216] 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.
[0217] 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.
[0218] 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.
[0219] 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.
[0220] 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.
[0221] 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.
[0222] 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.
[0223] 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.
[0224] 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.
[0225] 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.
[0226] 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.
[0227] 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.RTM.
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.
[0228] 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.
[0229] 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.
[0230] 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.
[0231] 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.
[0232] 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.
[0233] 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.
[0234] 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.
[0235] 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.
[0236] 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.
[0237] 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.
[0238] 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.
[0239] 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.
[0240] 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/mm.sup.3.
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.
[0241] 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.
[0242] 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.
[0243] 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.
[0244] Non-Orthogonal Lattice Head Inner layer
[0245] 1. A pickleball paddle comprising: [0246] a handle; and
[0247] 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.
[0248] 2. The pickleball paddle of definition 1, wherein the
non-orthogonal lattice is homogenous across the first outer
faceplate and the second outer faceplate.
[0249] 3. The pickleball paddle of definition 2 further comprising
a second inner layer sandwiched between the inner layer and the
second outer faceplate.
[0250] 4. The pickleball paddle of definition 3, wherein the second
inner layer comprises a second non-orthogonal lattice.
[0251] 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.
[0252] 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.
[0253] 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.
[0254] 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.
[0255] 9. The pickleball paddle of definition 8, wherein the first
outer faceplate is translucent.
[0256] 10. The pickleball paddle of definition 3, wherein the
second inner layer comprises an orthogonal lattice.
[0257] 11. The pickleball paddle of definition 1, wherein the first
outer faceplate is translucent.
[0258] 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.
[0259] 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.
[0260] 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.
[0261] 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.
[0262] 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.
[0263] 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.
[0264] 18. The pickleball paddle of definition 1, wherein the inner
layer has an outer edge forming an outer edge surface of the
head.
[0265] 19. The pickleball paddle of definition 1 further comprising
a translucent rim over an outer edge of the inner layer.
[0266] 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.
[0267] 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.
[0268] 22. The pickleball paddle of definition 1, wherein the first
outer faceplate is removably mounted to the head.
[0269] 23. The pickleball paddle of definition 22, wherein the head
comprises at least one groove removably receiving the first outer
faceplate.
[0270] 24. The pickleball paddle of definition 22, wherein the
handle is removably mounted to the head.
[0271] 25. The pickleball paddle of definition 1, the handle is
removably mounted to the head.
[0272] 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.
[0273] 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.
[0274] 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.
[0275] 29. The pickleball paddle of definition 28, wherein portions
of the inner layer forming a portion of the handle have filled unit
cells.
[0276] 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.
[0277] 31. The pickleball paddle of definition 1, wherein the
non-orthogonal lattice has a wave pattern.
[0278] 32. The pickleball paddle of definition 1, wherein an edge
of the inner layer is uncovered.
[0279] 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.
[0280] 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.
[0281] 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.
[0282] 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.
[0283] 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.
[0284] 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.
[0285] Pickleball Paddle Frame
[0286] 1. A pickleball paddle comprising: [0287] a handle extending
along a longitudinal axis; [0288] a head coupled to the handle, the
head comprising: [0289] an outer frame forming an outer perimeter
of the head; [0290] a first outer faceplate coupled to a first face
of the outer frame; and [0291] a second outer faceplate coupled to
a second face of the outer frame.
[0292] 2. The pickleball paddle of definition 1 further comprising
an inner layer within an interior of the outer frame.
[0293] 3. The pickleball paddle of definition 2, wherein the inner
layer comprises a lattice.
[0294] 4. The pickleball paddle of definition 3, wherein the
lattice comprises a nonorthogonal lattice.
[0295] 5. The pickleball paddle of definition 3, where the lattice
comprises an orthogonal lattice.
[0296] 6. The pickleball paddle of definition 1 further comprising
a crossbeam extending across an interior of the outer frame.
[0297] 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.
[0298] 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.
[0299] 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.
[0300] 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.
[0301] 11. The pickleball paddle of definition 10, wherein the
first inner layer has a varying density of unit cells.
[0302] 12. The pickleball paddle of definition 6, wherein the
crossbeam partitions the interior of the outer frame into three
cavities.
[0303] 13. The pickleball paddle of definition 6, wherein the
crossbeam is imperforate.
[0304] 14. The pickleball paddle of definition 6, wherein the
crossbeam is hollow.
[0305] 15. The pickleball paddle of definition 6, when the
crossbeam is perforate.
[0306] 16. The pickleball paddle of definition 1, wherein the outer
frame comprises a peripheral groove.
[0307] 17. The pickleball paddle of definition 1 comprising: [0308]
a first crossbeam extending across an interior of the outer frame;
and [0309] a second crossbeam extending across the interior of the
outer frame.
[0310] 18. The pickleball paddle of definition 17 further
comprising a third crossbeam extending across the interior of the
outer frame.
[0311] 19. The pickleball paddle of definition 17, wherein the
first crossbeam extends transverse to the longitudinal axis.
[0312] 20. The pickleball paddle of definition 17, wherein the
first crossbeam extends parallel to the longitudinal axis.
[0313] 21. The pickleball paddle of definition 17, wherein the
first crossbeam and the second crossbeam fan out from the
handle.
[0314] 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.
[0315] Paddle Construction
[0316] 1. A pickleball paddle comprising: [0317] 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.
[0318] 2. The pickleball paddle of definition 1 further comprising
pallets mounted over the handle.
[0319] 3. The pickleball paddle of definition 1, wherein the
continuous tubular body comprises a fiber composite material.
[0320] 4. The pickleball paddle of definition 1 further comprising
an inner layer within an interior of the head portion.
[0321] 5. The pickleball paddle of definition 4, wherein the inner
layer comprises a lattice.
[0322] 6. The pickleball paddle of definition 5, wherein the
lattice comprises a nonorthogonal lattice.
[0323] 7. The pickleball paddle of definition 5, where the lattice
comprises an orthogonal lattice.
[0324] 8. The pickleball paddle of definition 1 further comprising
a crossbeam extending across an interior of the head portion.
[0325] 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.
[0326] 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.
[0327] 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.
[0328] 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.
[0329] 13. The pickleball paddle of definition 10, wherein the
first inner layer has a varying density of unit cells.
[0330] 14. The pickleball paddle of definition 6, wherein the
crossbeam partitions the interior of the head portion into three
cavities.
[0331] 15. The pickleball paddle of definition 6, wherein the
crossbeam is imperforate.
[0332] 16. The pickleball paddle of definition 6, wherein the
crossbeam is hollow.
[0333] 17. The pickleball paddle of definition 6, when the
crossbeam is perforate.
[0334] 18. The pickleball paddle of definition 1, wherein the head
portion comprises a peripheral groove.
[0335] 19. The pickleball paddle of definition 1 comprising: [0336]
a first crossbeam extending across an interior of the head portion;
and [0337] a second crossbeam extending across the interior of the
head portion.
[0338] 20. The pickleball paddle of definition 17 further
comprising a third crossbeam extending across the interior of the
head portion.
[0339] 21. The pickleball paddle of definition 17, wherein the
first crossbeam extends transverse to the longitudinal axis.
[0340] 22. The pickleball paddle of definition 17, wherein the
first crossbeam extends parallel to the longitudinal axis.
[0341] 23. The pickleball paddle of definition 17, wherein the
first crossbeam and the second crossbeam fan out from the
handle.
[0342] 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.
[0343] Honeycomb Paddle
[0344] 1. A pickleball paddle comprising: [0345] a handle extending
along a longitudinal axis; and [0346] 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.
[0347] 2. The pickleball paddle of definition 1, wherein a portion
of the unit cells omit a wall.
[0348] 3. The pickleball paddle of definition 1 further comprising
slits in walls of the unit cells.
[0349] 4. A pickleball paddle comprising: [0350] a handle extending
along a longitudinal axis; [0351] a head portion coupled to the
handle and comprising: [0352] a first faceplate; [0353] a second
faceplate opposite the first faceplate; [0354] a first layer
adjacent the first face place and comprising a first honeycomb
arrangement of unit cells; and [0355] a second layer adjacent the
second faceplate and comprising a second honeycomb arrangement of
unit cells.
[0356] 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.
[0357] 6. The pickleball paddle of definition 5 further comprising:
[0358] a third layer between the first layer and the second layer,
the third layer comprising a third honeycomb arrangement of unit
cells.
[0359] 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.
[0360] 8. The pickleball paddle of definition 4, wherein the first
layer is rotated relative to the second layer to form a Moire
pattern.
[0361] 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.
[0362] 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.
[0363] 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.
[0364] 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.
[0365] 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.
[0366] A pickleball paddle comprising: [0367] a handle extending
along a longitudinal axis; and [0368] a head portion comprising:
[0369] a first faceplate; [0370] a second faceplate opposite the
first faceplate; and [0371] 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.
[0372] 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.
[0373] 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.
[0374] 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.
[0375] 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.
[0376] 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.
[0377] Customizable Head
[0378] 1. A pickleball paddle comprising: [0379] a handle having a
head transition region; [0380] a head comprising: [0381] a first
face facing in a first direction; [0382] a second face facing in a
second direction opposite the first direction; and [0383] 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.
[0384] 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.
[0385] 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.
[0386] 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.
[0387] Handle Length
[0388] 1. A pickleball paddle comprising: [0389] a handle extending
along a longitudinal axis; [0390] 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 [0391] wherein
handle has a length along the longitudinal axis of no greater than
4 inches.
[0392] 2. The pickleball paddle of definition 1, wherein the handle
has a length along the longitudinal axis of no greater than 3
inches.
[0393] 3. The pickleball paddle of definition 1, wherein the handle
has a length along the longitudinal axis of no greater than 2
inches.
[0394] Multiple Different Face Plates
[0395] 1. A pickleball paddle comprising: [0396] a handle; and
[0397] 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.
[0398] 2. The pickleball paddle of definition 1, wherein the first
outer faceplate is translucent and wherein the second outer
faceplate is opaque.
[0399] 3. The pickleball paddle of definition 2 further comprising
an inner layer between the first outer faceplate and the second
outer faceplate.
[0400] 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.
[0401] 5. The pickleball paddle of definition 3, wherein the inner
layer comprises a plurality of different colors facing the first
outer faceplate.
[0402] 6. The pickleball paddle of definition 5, wherein the
different colors form a number or letter.
[0403] 7. The pickleball paddle of definition 5, wherein the
different colors form a symmetrical design.
[0404] 8. The pickleball paddle definition 5, wherein the different
colors form a logo.
[0405] 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.
[0406] 10. The pickleball paddle of definition 9, wherein the
different colors form a number or letter.
[0407] 11. The pickleball paddle of definition 9, wherein the
different colors form a symmetrical design.
[0408] 12. The pickleball paddle definition 9, wherein the
different colors form a logo.
[0409] 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.
[0410] 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.
[0411] 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.
[0412] Translucent Face Plates
[0413] 1. A pickleball paddle comprising: [0414] a handle; and
[0415] a head coupled to the handle, the head comprising a first
translucent outer faceplate and a second translucent outer
faceplate.
[0416] 2. The pickleball paddle of definition 1 further comprising
an inner layer between the first outer faceplate and the second
outer faceplate.
[0417] 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.
[0418] 4. The pickleball paddle of definition 2, wherein the inner
layer comprises a plurality of different colors.
[0419] 5. The pickleball paddle of definition 4, wherein the
different colors form a number or letter.
[0420] 6. The pickleball paddle of definition 4, wherein the
different colors form a symmetrical design.
[0421] 7. The pickleball paddle definition 4, wherein the different
colors form a logo.
[0422] Miscellaneous Features
[0423] 1. A pickleball paddle comprising: [0424] a handle extending
along an axis; and [0425] a head coupled to the handle, the head
comprising: [0426] an inner layer having tubular unit cells, each
tubular unit cell extending along a cell axis parallel to the
handle axis; [0427] a first outer faceplate coupled to a first face
of the inner layer; and [0428] a second outer faceplate coupled to
a second face of the inner layer.
[0429] 2. A pickleball paddle comprising: [0430] a handle; [0431] a
head coupled to the handle, the head comprising: [0432] an inner
layer comprising: [0433] a first portion having a first
two-dimensional array of unit cells having a first density of unit
cells; and [0434] a second portion having a second two-dimensional
array of unit cells having a second density of unit cells different
than the first density; [0435] a first outer faceplate coupled to a
first face of the inner layer; and [0436] a second outer faceplate
coupled to a second face of the inner layer.
[0437] 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.
[0438] 4. The pickleball paddle of definition 2 comprising a
non-orthogonal lattice forming the two-dimensional array of unit
cells.
[0439] 5. The pickleball paddle of definition 1, wherein the first
outer faceplate is translucent.
[0440] 6. The pickleball paddle of definition 2, wherein the second
portion surrounds the first portion in a plane parallel to the
first outer faceplate.
[0441] 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.
[0442] 8. A pickleball paddle comprising: [0443] a handle; and
[0444] a head coupled to the handle, the head comprising: [0445]
the first inner layer comprising a first two-dimensional array of
unit cells; [0446] a second inner layer comprising a second
two-dimensional array of unit cells; [0447] a first outer faceplate
coupled to the first inner layer; and [0448] a second outer
faceplate coupled to the second inner layer.
[0449] 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.
[0450] 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.
[0451] 11. The pickleball paddle of definition 10, wherein the
first outer faceplate is translucent.
[0452] 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.
[0453] 13. The pickleball paddle of definition 8 comprising a
non-orthogonal lattice forming the first two-dimensional array of
unit cells.
[0454] 14. The pickleball paddle of definition 8, wherein the first
outer faceplate is translucent.
[0455] 15. A pickleball paddle comprising:
[0456] a handle; and
[0457] a head coupled to the handle, the head comprising a support
portion and at least one removable faceplate removably connected to
support portion.
[0458] 16. The pickleball paddle of definition 15, wherein the
support portion comprises an outer frame.
[0459] 17. The pickleball paddle of definition 15, wherein the
support portion comprises an inner layer.
[0460] 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.
[0461] 19. A pickleball paddle comprising: [0462] a handle; [0463]
a head; and [0464] a yoke connecting the handle from the head.
[0465] 20. The pickleball paddle of definition 19, wherein the
handle has a length of less than 4 inches.
[0466] 21. The pickleball paddle of definition 19, the handle has a
length of less than 3 inches.
[0467] 22. The pickleball paddle of definition 19, wherein the
handle has a length less than 2 inches.
[0468] 23. The pickleball paddle of definition 19, where the yoke
has a Y-shape.
[0469] 24. The pickleball paddle of definition 19, wherein the yoke
defines an opening.
[0470] 25. A pickleball paddle comprising: [0471] a handle; and
[0472] a head, wherein the handle is removably mounted to the
head.
[0473] 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.
[0474] 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.
[0475] 28. A pickleball paddle comprising: [0476] a handle; and
[0477] a head coupled to the handle, the head comprising: [0478] an
inner layer comprising a two-dimensional array of panel folds;
[0479] a first outer faceplate coupled to a first face of the inner
layer; and [0480] a second outer faceplate coupled to a second side
of the inner layer.
[0481] 29. A pickleball paddle comprising: [0482] a handle; and
[0483] 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.
[0484] 30. A pickleball paddle comprising: [0485] a handle; and
[0486] a head coupled to the handle, the head comprising: [0487] an
inner mesh layer; [0488] a front outer face plate coupled to a
first side of the inner mesh layer; and [0489] a second outer face
plate coupled to a second side of the inner mesh layer.
[0490] 31. A pickleball paddle comprising: [0491] a handle; and
[0492] a head coupled to the handle, the head comprising: [0493] an
inner layer having a peripheral edge; [0494] a peripheral rim at
least partially covering the peripheral edge; [0495] a first outer
faceplate coupled to the inner layer; and [0496] 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.
[0497] 32. The pickleball paddle of definition 31, wherein the
inner layer comprises a two-dimensional array of unit cells.
[0498] 33. The pickleball paddle of definition 32, wherein the
inner layer comprises a non-orthogonal lattice forming the
two-dimensional array of unit cells.
[0499] 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.
* * * * *