Pickleball Paddle with Reinforced Core

The present application is a continuation-in-part of U.S. patent application Ser. No. 18/825,473 filed on Sep. 5, 2024, which is a continuation-in-part of International Patent Application No. PCT/US2023/080521, filed on Nov. 20, 2023, which claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 63/435,317, filed on Dec. 26, 2022, U.S. Provisional Patent Application Ser. No. 63/385,015, filed on Nov. 26, 2022, and U.S. Provisional Patent Application Ser. No. 63/384,980, filed on Nov. 25, 2022, the entire contents of each of which are incorporated herein by reference.

The present disclosure relates to a pickleball paddle. More particularly, the disclosure relates to a pickleball paddle having a reinforced core.

Pickleball has gained in popularity over the past several years and is played in countries around the world. Pickleball games are played both indoors and outdoors, and are played using a paddle and a plastic ball.

For sanctioned games, USA Pickleball (“USAP”) requires the combined length and width of the paddle to not exceed 24 inches, and the length cannot exceed 17 inches. While there are currently no requirements regarding thickness or weight of the paddle, the surface of the paddle is not permitted to include holes or indentations. Additionally, the USAP requires that the paddles have a specific range of rigidity. To meet the USAP rigidity specifications, paddle deflection cannot exceed 0.005 inches when a force of 3 kg is applied to the center of the paddle.

A direct measurement of power was implemented recently in the USAP certification with a maximum PBCoR (Paddle Ball Coefficient of Restitution) of 0.43. In the PBCoR test, the paddle is clamped at its handle and placed in front of a cannon. The cannon launches a ball with a 60 MPH speed at the paddle and the subsequent exit speed is measured. These measured values are then used to compute the PBCoR value.

Many advanced pickleball paddles are structured with a semi-rigid interior core between two flat surfaces. The interior core of the paddle is made of materials such as Nomex or Polypropylene, shaped into a honeycomb configuration. The outer surface may be a carbon fiber skin. The shape of the paddle may be cut from a panel having the interior core sandwiched between top and bottom outer surfaces.

The core edges are exposed with a gap between the top and bottom surfaces when the panel is cut into the shape of the paddle. A plastic edge guard may be placed around the paddle frame to close the gap between the top and bottom surfaces and to protect the paddle edge.

Some pickleball players find it helpful to cause the ball to spin when hitting the ball with the paddle. Two types of spin that are used in pickleball play are topspin and underspin or backspin. Topspin is generated by the forward rotation of the ball, and underspin/backspin is generated by the backward rotation of the ball. To hit a ball with topspin, a player rotates the head of the paddle over the top of the ball as the paddle contacts the ball. This exerts a torque about the center of the ball that causes the ball to rotate with a forward spin during its flight. Hitting a ball with topspin causes a Magnus force to act on the ball perpendicular to the velocity of the ball in the downward direction. Because there is an additional downward force on the ball, pickleball players can use topspin to hit the ball harder with greater speed, and the ball may still land in bounds, therefore providing more consistency in the shots. In addition, balls hit with topspin can be hit higher above the net while still staying in bounds, making the shot more difficult to return. This also results in a higher bounce for the ball after landing.

To hit a ball with underspin or backspin, a player angles their paddle back and slides the paddle underneath the ball when hitting the ball. This type of shot is also called a slice. It exerts a torque about the center of the ball that causes the ball to rotate with a backward spin during its flight. Hitting a ball with underspin causes a Magnus force to act on the ball perpendicular to the velocity of the ball in the upward direction. Because there is an additional upward force on the ball, the ball seems to “float” through the air as it flies. Slice shots are thus generally hit low over the net and with a relatively slow speed to help prevent the ball from going out of the bounds of the court. This results in a lower bounce for the ball. In addition, slicing the ball may allow the player to more easily hit the ball to a precise location in the opponent's court.

There are different ways the pickleball paddle itself can help generating spin during pickleball play. One way is to leverage or increase the surface friction generated when the ball hits the paddle surface. Grit paint or coatings can be used to make the hitting surface of the paddle gritty. However, grit paint and coatings wear off relatively quickly and these types of surfaces become smooth after a short playing period such that the spin capability of the paddle degrades quickly.

Some paddles use high grade raw carbon fiber (such as T700 carbon fiber) as a surface material, and/or an extra layer of fabric material known as peel ply. While these methods typically last longer than grit or painted coatings, they will still wear over time and/or are often prohibitively expensive.

Another way to generate spin using a pickleball paddle is to utilize the compression of the paddle when striking a ball. For paddles having a non-textured finish, the entire paddle structure is typically important. If the paddle is too rigid it will make the paddle less efficient at spinning the ball. On the other hand, a softer paddle can still provide huge amounts of spin even without having a textured paddle surface. A sufficient amount of compression of the hitting surface and the paddle structure underneath can generate a lot of spin. The amount of compression may depend on the surface material of the paddle, the core material of the paddle, and/or the entire structure of the paddle.

In classical mechanics, impulse (J) is the integral of a force (F) divided by the time interval (t) for which it acts. Since force is a vector quantity, impulse is also a vector quantity. Impulse applied to an object produces an equivalent vector change in its linear momentum, also in the resultant direction. A resultant force applied over a longer time, therefore, produces a bigger change in linear momentum than the same force applied briefly.

When a pickleball paddle makes contact with a ball, the force of the paddle on the ball delivers an impulse to the ball while the ball is in contact with the paddle. The magnitude of the force of the paddle on the ball varies with time, starting low at initial contact, then reaching a maximum when the ball compression and the deformity of the paddle surface reaches a maximum, before reducing back to zero as the ball leaves the surface of the paddle. A relatively elastic paddle exerts a strong restoring force on a ball when the ball impacts the paddle, which helps add to the impulse delivered to a ball when the ball is hit by the paddle. Various levels of elasticity of the paddle structure will produce different levels of spin capability.

A pickleball paddle that provides the sense or feel of an increased contact time between the paddle and the ball upon impact, or “dwell time,” is often desired. The increased dwell time improves not only the responsiveness of the paddle, but also the ability of the paddle to generate spin on the ball.

Many current pickleball paddles have a polypropylene honeycomb core. When a ball hits the surface of such a paddle, the honeycomb core does not generate much compression. This results in less “dwell time” between the paddle and the ball, which results in a relatively low amount of spin that is generated. A pickleball paddle that offers improved performance such as increased power and spin may be desired by some players. Maximizing “dwell time” while still conforming to the USAP rigidity and PBCoR specifications can be particularly challenging when designing a pickleball paddle.

The present disclosure relates to a pickleball paddle. The pickleball paddle includes a head portion including a first core portion, a second core portion, a first layer, a second layer, and a reinforcing member. The first core portion defines a first surface and a second surface. The second core portion defines a plurality of sections. At least one section of the plurality of sections has a cross-section that is rectangular. The first layer is disposed adjacent the first surface of the first core portion and is made from a first material. The second layer is disposed adjacent the second surface of the first core portion and is made from the first material. The reinforcing member is disposed in contact with the second core portion, the first layer, and the second layer. The reinforcing member includes a grid structure defining a plurality of open spaces.

In disclosed embodiments, the first core portion is made from a different material from the second core portion.

In disclosed embodiments, the first core portion and the second core portion are both made from foam.

In disclosed embodiments, the foam of the first core portion has a different density than the foam of the second core portion.

In disclosed embodiments, the pickleball paddle includes a handle disposed in mechanical cooperation with the head portion.

In disclosed embodiments, a longitudinal axis extends through the handle portion and a top of the head portion, and the plurality of sections of the second core portion are symmetrical disposed about the longitudinal axis.

In disclosed embodiments, a latitudinal axis extends perpendicularly to the longitudinal axis, and the plurality of sections of the second core portion are symmetrically disposed about the latitudinal axis.

In disclosed embodiments, a latitudinal axis extends perpendicularly to the longitudinal axis, and wherein the plurality of sections of the second core portion are asymmetrically disposed about the latitudinal axis.

In disclosed embodiments, a first section of the plurality of sections of the second core portion is positioned towards a top, left area of the head portion, a second section of the plurality of sections of the second core portion is positioned towards a top, right area of the head portion, a third section of the plurality of sections of the second core portion is positioned towards a bottom, left area of the head portion, and a fourth section of the plurality of sections of the second core portion is positioned towards a bottom, right area of the head portion.

In disclosed embodiments, a fifth section of the plurality of sections of the second core portion is positioned towards a left side of the head portion, and a sixth section of the plurality of sections of the second core portion is positioned towards a right side of the head portion.

In disclosed embodiments, the second core portion includes foam disposed within the plurality of open spaces defined by the reinforcing member.

In disclosed embodiments, a first section of the reinforcing member is oriented at a perpendicular angle relative to the first layer.

In disclosed embodiments, the first core portion includes foam, the second core portion includes foam, and the foam of the first core portion is in direct contact with foam of the second core portion.

In disclosed embodiments, the reinforcing member is made from a fiber-reinforced composite.

In disclosed embodiments, the grid structure forms at least one of a plurality of polygons or a plurality of round shapes.

In disclosed embodiments, the at least one section of the plurality of sections that has a cross-section that is rectangular defines four walls, and wherein the reinforcing member is disposed in contact with each wall of the four walls of the at least one section of the plurality of sections.

In disclosed embodiments, the first material is a fiber-reinforced composite.

In disclosed embodiments, the head portion includes a third core portion disposed along at least a portion of a perimeter of the head portion, the third core portion is made from foam.

In disclosed embodiments, a longitudinal axis extends through the handle portion and a top of the head portion, a latitudinal axis extends perpendicularly to the longitudinal axis, and wherein at least one section of the plurality of sections of the second core portion is non-parallel to the longitudinal axis and is non-parallel to the latitudinal axis.

The present disclosure also relates to the head portion of a pickleball paddle. The head portion includes a first core portion, a second core portion, and a reinforcing member. The first core portion is made from foam having a first density. The second core portion includes a plurality of sections and is made from foam having a second density. The second density is different from the first density. A first section of the plurality of sections is disposed entirely within a first quadrant of the head portion, a second section of the plurality of sections is disposed entirely within a second quadrant of the head portion, a third section of the plurality of sections is disposed entirely within a third quadrant of the head portion, and a fourth section of the plurality of sections is disposed entirely within a fourth quadrant of the head portion. The reinforcing member is disposed in contact with the first core portion and the second core portion. The reinforcing member includes a grid structure defining a plurality of open spaces.

Embodiments of the presently disclosed pickleball paddle and components thereof are now described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views.

In general, the embodiments of pickleball paddles described herein may result in higher absorption of the impact energy of the ball hitting the pickleball paddle, increased duration of the ball in contact with the pickleball paddle, and/or greater angular momentum imparted on the ball when the pickleball paddle rolls over or under the ball.

Various embodiments of pickleball paddles (or “paddles”) are shown in the accompanying figures, and are generally referenced by numeral. As shown in, the paddleincludes a head portioncoupled to a handle portion. Generally, the length “L” of the paddlemay be between 15 inches and 17 inches, and the combined length plus width “W” of the paddledoes not exceed 24 inches. The present disclosure also contemplates paddleshaving larger and/or smaller dimensions for the length “L” and width “W.” Additionally, while the head portionis shown having a rectangular shape with rounded corners, a head portionhaving other shapes, such as oval, isometric, round, teardrop, for example, is encompassed by the present disclosure. With continued reference to, the paddledefines a longitudinal axis “A-A” extending through the handle portion, and a latitudinal axis “B-B” extending perpendicularly to the longitudinal axis “A-A.”

Referring now to, schematic cross-sectional views of a portion of the head portionof the paddleofare shown in accordance with various embodiments of the present disclosure. Here, the head portionof the paddleincludes a first or top layer, a second or bottom layer, a core portion, and an edge portion. In embodiments, the thickness “t” (see) of the head portion, measured between an upper surfaceof the first layerand a lower surfaceof the second layer, is between about 10 mm and about 20 mm. Additionally, the head portioncan define a thickness “t” that is greater than or less than this range without departing from the scope of the present disclosure.

The core portionof the paddlecan be made from any suitable material that can recover its initial shape after impact, such as foam (e.g., elastomeric foam). For instance, the foam of the core portioncan be open-celled (e.g., Polyurethane or “PU”, natural rubber or “NR”, nitrile, Ethylene-Propylene-Diene Monomer or “EPDM”, Polyvinyl Chloride or “PVC”, etc.) or closed-celled (e.g., Ethyl-Vinyl Acetate or “EVA”, neoprene, Styrene-Butadiene Rubber or “SBR”, etc.). The foam may also be thermoplastic or thermoset. Further, the core portioncan be made from any combination of the disclosed materials or other materials, and may include a multi-layer structure.

Various embodiments of the core portionand the edge portionof the paddleare shown in the accompanying figures. While certain combinations of the different embodiments of the core portionand the edge portionare shown, other combinations are also encompassed by the present disclosure.

Additionally, while it is contemplated that embodiments of the paddleinclude the first layerbeing different from the second layer, the embodiments described herein include each paddlehaving the first layerbeing the same as the second layer. For clarity, when one of the first layeror the second layeris described herein with regard to a particular embodiment, the other of the first layeror the second layerin the same embodiment is identical or substantially identical.

Generally, the first layer, the second layerand the core portionform a sandwiched structure.

In each of the embodiments shown in, the first layerincludes the outer surfaceand an inner surface, and the second layerincludes the outer surfaceand an inner surface. In embodiments, each of the first layerand the second layeris made from a woven or non-woven composite fiber material including fibers impregnated with resin, such as epoxy, polyester, and/or metal matrix resins. For instance, the material may include any fiber-reinforced composite (including fiber-reinforced polymers, fiber-reinforced plastics, etc.). Additionally, the material of each of the first layerand the second layercan include multiple layers of material (e.g., where adjacent layers include 45°, 90°, etc. offset grain orientation, for instance).

In disclosed embodiments, the outer surfaces,of the respective first layerand the second layerhave a roughened texture. The roughened texture can be formed by grit, sand, and/or other particles applied to, or positioned under one or more coatings applied to the outer surfaces,.

Another way of forming a roughened texture is by applying an additional layer of a fabric material, such as a peel ply fabric, on the outer surfaces,. In embodiments, the peel ply fabric is a woven fabric, nylon, or polyester, which, during the cure cycle of the manufacturing process, absorbs some of the matrix epoxy resin, for instance, and becomes an integral part of the laminate of each layer,. Following the cure cycle, the peel ply fabric is peeled off or otherwise removed from the first layerand the second layer, which fractures the resin between the peel ply fabric and the outer surfaces,, respectively, and which leaves a fresh, clean, roughened surface of matrix epoxy resin. A further way of forming a roughened texture is by making the outer surfaces,from woven, high-grade raw carbon fiber, other fibrous materials, and/or combinations thereof.

In disclosed embodiments, a ply of planar fiber material is first cut into the shape of the mold corresponding to the shape of the pickleball paddle. The fibers can be co-axially aligned in sheets or layers, braided, or weaved in sheets or layers, and/or chopped and randomly dispersed in one or more layers. In a multiple layer construction, the fibers can be aligned in different directions with respect to the longitudinal axis “A-A” of the paddle, and/or in braids or weaves from layer to layer. The fibers may be formed of a high tensile strength material such as carbon (e.g., T700, T800, 3K, 6K, 12K or 18K carbon fiber). Alternatively, the fibers can be formed of other materials such as glass, graphite, Zylon, Nylon, Aramid, Arylate, Kevlar®, graphene, boron and combinations thereof. Further, any suitable fiber-reinforced composite can be used.

A roughened texture on the outer surfaces,may be useful to some pickleball players by generating a relatively large amount of friction (as opposed to a smooth surface) may making contact with the ball. This roughened texture and increased friction can help a player generate spin, and create an increased amount of angular momentum resulting in the ball travelling with higher angular velocities.

Alternatively, the outer surfaces,of the paddlecan be smooth, and not roughened or textured, which may be preferred by some players.