Bat System with Performance Limiting Structure and Methods of Making Same

This application is a continuation-in-part of U.S. patent application Ser. No. 18/079,319, filed 12 Dec. 2022 (Now U.S. Pat. No. 12,390,706), which is a continuation-in-part of U.S. patent application Ser. No. 17/223,126, filed 6 Apr. 2021 (Now U.S. Pat. No. 11,524,215), which is a continuation-in-part of U.S. patent application Ser. No. 16/661,208, filed 23 Oct. 2019 (Now U.S. Pat. No. 10,967,235), which claims priority under 35 U.S.C. § 119 to U.S. Provisional Patent Application No. 62/749,759, filed on 24 Oct. 2018 and entitled “Bat System with Performance Limiting Structure and Methods of Making Same,” the contents of which are hereby incorporated by reference in their entirety.

Generally, the performance of a bat is related to the efficiency with which the bat can impart force to a ball upon impact. Bat manufacturers often evaluate a bat's coefficient of restitution (COR) to measure its performance. Previously, bat manufacturers typically sought to improve the performance of bats to achieve an increased COR. Today, however, bat manufacturers are typically concerned with manufacturing bats that provide the greatest performance possible but without exceeding maximum performance metrics of various leagues and other organized forms of play.

Generally, increased deformation experienced by a bat upon impact with a ball corresponds to an increased COR of the bat. Some existing bat designs aim to prevent a bat from exceeding an imposed COR limit by limiting deformation of the bat upon impact of the bat with a ball. For example, U.S. Pat. No. 8,632,428 to Burger describes a bat that includes a central tube positioned coaxially within the barrel and one or more rigid, “washer-shaped” restriction members to limit the deformation of the bat upon impact with a ball. The washer-shaped restriction members have an outer diameter that is less than the inner diameter of the barrel, such that the barrel is able to deform until the inner wall of the barrel contacts the washer-shaped restriction members. By controlling the amount of possible deformation, it is thus possible to control the amount of deformation experienced by a bat at impact, and thus, limit the maximum COR provided by the bat.

While such a design may sufficiently limit the maximum COR provided by a bat, the bat's performance at lower impact forces may be unnecessarily reduced. That is, at lower forces (e.g., lower swing speed or lower ball speed), deformation of the bat does not need to be limited to prevent the bat from exceeding the maximum COR limit, but the high rigidity and incompressibility of a washer-shaped restriction member would likely prevent deformation of the bat's barrel even at lower forces such that performance of the bat at the lower forces is unnecessarily reduced. More particularly, such a bat may perform substantially differently within three ranges of ball speed. At low speed impacts (e.g., a low speed range), only the barrel may flex. At higher speeds (e.g., a medium speed range), a single side of the barrel (e.g., the portion of the barrel impacting the ball) may engage the washer-shaped restriction member, and at still higher speeds (e.g., a high speed range), two sides of the barrel (e.g., the portion of the barrel impacting the ball and the portion of the barrel directly opposite the impact location) may engage the washer-shaped restriction member. For impacts in the high speed range, the incompressible nature of the washer-shaped restriction member may prevent flex of the washer-shaped restriction member and of the barrel system, as a whole, which can be detrimental to bat performance, particularly at high-force impacts (e.g., impacts with a ball in the high speed range).

What is needed, therefore, is a bat designed to maximize performance within a given set of guidelines at high impact forces while simultaneously maximizing absolute performance of the bat at lower impact forces. It is to such a bat that embodiments of the present invention are primarily directed.

Embodiments of the present invention relate to a baseball or softball bat having a hollow barrel and one or more deformable rings suspending within the hollow barrel by a plurality of rods positioned longitudinally within the hollow barrel. Each of the plurality of rods can be offset from a central axis of the hollow barrel by a common radius, and the deformable ring can have a substantially circular outer wall that has a diameter less than an inner diameter of the hollow barrel. The deformable ring can also have a plurality of holes positioned equidistantly about a circumference corresponding to the common radius, with each hole at least partially receiving a rod of the three or more rods. Thus, the deformable ring can be positioned such that it is in coaxial alignment with the hollow barrel when the bat is at rest. Embodiments can also include an end cap that has holes extending partially therethrough, with each end cap hole at least partially receiving an end of a rod.

According the disclosed technology, a bat can include a hollow barrel and an internal assembly disposed within the hollow barrel. The internal assembly can comprise a plurality of rigid rods disposed longitudinally within the hollow barrel, an alignment insert, a deformable ring, and an end cap. The alignment insert can have an outer diameter approximately equal to an inner diameter of the hollow barrel and a plurality of through-holes that are each (i) axially extending through the alignment insert, (ii) offset from a central axis of the alignment insert by a common radius and positioned such that the plurality of through-holes is disposed equidistantly along a circumference corresponding to the common radius, and (iii) configured to receive a portion of a corresponding rigid rod. The deformable ring can comprise an outer wall having an outer diameter smaller than the inner diameter of the hollow barrel and a plurality of holes disposed equidistantly about the circumference corresponding to the common radius. Each hole of the deformable ring can be configured to at least partially receive a corresponding rigid rod. The end cap can be configured to insert into an end of the hollow barrel, and the end cap can have a plurality of recesses disposed equidistantly about the circumference corresponding to the common radius. Each recess can be configured to receive an end of a corresponding rigid rod. The end cap and the alignment insert can be configured to maintain the plurality of rigid rods in a predetermined configuration when the bat is at rest. The predetermined configuration can correspond to each of the plurality of rigid rods being parallel. The plurality of rigid rods can be configured to maintain the deformable ring in a predetermined suspended position within the hollow barrel such that, when the bat is at rest, each point along the outer wall of the deformable ring is disposed a predetermined gap distance from an inner surface of the hollow barrel.

The hollow barrel can be configured to flex inwardly responsive to receiving force from an impact with an object such that the inner surface of the hollow barrel contacts the outer wall of the deformable ring.

The hollow barrel can be configured to transfer at least some of the force from the impact to the deformable ring. The deformable ring can be configured to at least partially deform from an original shape to a deformed shaped upon receiving at least some of the force from the impact, and the deformable ring can be configured to return from the deformed shape to the original shape.

The deformable ring can be configured to transfer a rebound force to the hollow barrel as the deformable ring returns from the deformed shape to the original shape.

The alignment insert can have a plurality of lobes.

The alignment insert can comprise EVA foam.

The bat can comprise a plurality of deformable rings.

The deformable ring can comprise aluminum.

The deformable ring can comprise a plurality of inner lobes. Each of the plurality of holes of the deformable ring can be at least partially disposed within a corresponding inner lobe of the plurality of inner lobes.

The deformable ring can comprise a hollow inner portion.

At least some of the plurality of rigid rods can comprise carbon.

At least some of the plurality of rigid rods can be hollow.

At least some of the plurality of rigid rods can be substantially solid.

The end cap can comprise a protrusion configured to at least partially insert into a notch of the hollow barrel. The notch can be disposed on an interior wall of the hollow barrel proximate a distal end of the hollow barrel. The protrusion and notch can be configured to interlock.

According to the disclosed technology, a method for manufacturing a bat can comprise providing a hollow barrel and assembling an internal assembly. Assembling the internal assembly can include inserting each of a plurality of rigid rods into a corresponding through-hole of a plurality of through-holes in an alignment insert having an outer diameter approximately equal to an inner diameter of the hollow barrel. Each of the plurality of through-holes can be axially extending through the alignment insert and can be offset from a central axis of the alignment insert by a common radius and positioned such that the plurality of through-holes is disposed equidistantly along a circumference corresponding to the common radius. Assembling the internal assembly can include inserting each of the plurality of rigid rods into a corresponding hole of a plurality of holes in a deformable ring comprising an outer wall that has an outer diameter smaller than the inner diameter of the hollow barrel. The plurality of holes can be disposed equidistantly about the circumference corresponding to the common radius. Assembling the internal assembly can include inserting an end of each of the plurality of rigid rods into a corresponding recess of a plurality of recesses in an end cap. The plurality of recesses in the end cap can be disposed equidistantly about the circumference corresponding to the common radius. Assembling the internal assembly can include inserting the end cap into an end of the hollow barrel.

Assembling the internal assembly can comprise positioning the plurality of rigid rods such that the plurality of rigid rods is in a predetermined configuration when the bat is at rest. The predetermined configuration can correspond to each of the plurality of rigid rods being parallel.

Assembling the internal assembly can comprise positioning the deformable ring in a predetermined suspended position within the hollow barrel such that, when the bat is at rest, each point along the outer wall of the deformable ring is disposed a predetermined gap distance from an inner surface of the hollow barrel.

The disclosed technology can include a bat which has a hollow barrel and an internal assembly configured to resist deformation of the hollow barrel. The internal assembly can include a rod disposed longitudinally in the hollow barrel, a ring attached to the rod, a deformable sleeve disposed around the ring and extending longitudinally in the hollow barrel. The sleeve can include an outer diameter smaller than an inner diameter of the hollow barrel. The bat can include an end cap attached to an end of the hollow barrel and having a recess configured to receive an end of the rod. The rod can be configured to maintain the deformable sleeve in a predetermined suspended position within the hollow barrel such that, when the bat is at rest, the sleeve is disposed a predetermined gap distance from an inner surface of the hollow barrel.

Responsive to receiving force from an impact with an object, the hollow barrel can be configured to flex inwardly such that the inner surface of the hollow barrel contacts the deformable sleeve.

The hollow barrel can be configured to transfer at least some of the force from the impact to the deformable sleeve. The deformable sleeve can be configured to at least partially deform from an original shape to a deformed shaped upon receiving the at least some of the force from the impact and return from the deformed shape to the original shape.

The deformable sleeve can be further configured to transfer a rebound force to the hollow barrel as the deformable sleeve returns from the deformed shape to the original shape.

The ring can be a deformable ring and the hollow barrel can be configured to transfer at least some of the force from the impact to the deformable ring. The deformable ring can be configured to at least partially deform from an original shape to a deformed shaped upon receiving the at least some of the force from the impact and return from the deformed shape to the original shape.

The ring can be a first ring and the internal assembly can further include a second ring. The second ring can be attached to the rod and spaced a distance from the first ring. The sleeve can extend between the first ring and the second ring.

The sleeve can include a first outer diameter proximate the first ring and proximate the second ring and a second outer diameter between the first ring and the second ring. The second outer diameter can be greater than the first outer diameter. The second outer diameter can be less than the first outer diameter. The sleeve can include a first thickness proximate the first ring and proximate the second ring and a second thickness between the first ring and the second ring. The second thickness can be greater than the first thickness. The second thickness can be less than the first thickness.

The sleeve can comprise a composite material.

The internal assembly can further comprise an alignment insert comprising an outer diameter approximately equal to the inner diameter of the hollow barrel and a lobe configured to receive a portion of the rod.

The bat can further include a plurality of rods. The ring can comprise a plurality of holes. Each hole of the plurality of holes can be configured to at least partially receive a respective rod of the plurality of rods.

The bat can have a central axis and the ring can have a central axis aligned with the central axis of the bat. The plurality of holes of the ring can be disposed equidistantly about a circumference corresponding to a radial distance from the central axis of the bat.

The end cap can further comprise a plurality of recesses configured to at least partially receive an end of a respective rod of the plurality of rods. The end cap can have a central axis aligned with the central axis of the bat and the plurality of recesses of the end cap can be disposed equidistantly about a circumference corresponding to a radial distance from the central axis of the bat.

The bat can further include an alignment insert comprising an outer diameter approximately equal to the inner diameter of the hollow barrel and a plurality of lobes. Each lobe can be configured to at least partially receive a respective rod of the plurality of rods. Each of the plurality of lobes of the alignment insert can be offset from a central axis of the alignment insert by a radial distance. The plurality of lobes of the alignment insert can be disposed equidistantly along a circumference corresponding to the radial distance.

The disclosed technology can include an internal assembly for a bat comprising a rod, a deformable ring attached to the rod, and a deformable sleeve disposed around the deformable ring and configured to extend longitudinally in a hollow barrel of the bat. The sleeve can have an outer diameter smaller than an inner diameter of the hollow barrel. The rod can be configured to maintain the deformable sleeve in a predetermined suspended position within the hollow barrel such that, when the bat is at rest, the sleeve is disposed a predetermined gap distance from an inner surface of the hollow barrel.

The ring can be a first ring and the internal assembly can further comprise a second ring. The second ring can be attached to the rod and spaced a distance from the first ring. The sleeve can extend between the first ring and the second ring. The internal assembly can further comprise an alignment insert comprising an outer diameter approximately equal to an inner diameter of a hollow barrel of the bat and a lobe configured to at least partially receive a portion of the rod.

These and other objects, features and advantages of the present invention will become more apparent upon reading the following specification in conjunction with the accompanying drawing figures.

Throughout this disclosure, certain example embodiments are described in relation to bats including a plurality of rods and a deformable ring. Some embodiments of the disclosed technology will be described more fully hereinafter with reference to the accompanying drawings. This disclosed technology may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. The components described hereinafter as making up various elements of the disclosed technology are intended to be illustrative and not restrictive. Many suitable components that would perform the same or similar functions as components described herein are intended to be embraced within the scope of the disclosed electronic devices and methods. Such other components not described herein may include, but are not limited to, for example, components developed after development of the disclosed technology.

In the following description, numerous specific details are set forth. But it is to be understood that embodiments of the disclosed technology may be practiced without these specific details. In other instances, well-known methods, structures, and techniques have not been shown in detail in order not to obscure an understanding of this description. References to “one embodiment,” “an embodiment,” “example embodiment,” “some embodiments,” “certain embodiments,” “various embodiments,” etc., indicate that the embodiment(s) of the disclosed technology so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment” does not necessarily refer to the same embodiment, although it may.

Throughout the specification and the claims, the following terms take at least the meanings explicitly associated herein, unless the context clearly dictates otherwise. The term “or” is intended to mean an inclusive “or.” Further, the terms “a,” “an,” and “the” are intended to mean one or more unless specified otherwise or clear from the context to be directed to a singular form.

Unless otherwise specified, the use of the ordinal adjectives “first,” “second,” “third,” etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described should be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

According to some embodiments, the disclosed technology relates to a bat, such as baseball bat or a softball bat. In some embodiments, the bat can include a hollow barrel and an internal assembly that is configured to resist deformation of the hollow barrel, especially deformation of the hollow barrel upon impact with a ball, for example. In certain embodiments, the internal assembly can be configured to resist, but not entirely prevent, deformation of the bat upon contact the hollow barrel's inner wall with an outer edge or surface of the deformable ring. In certain embodiments, the internal assembly can include a deformable ring that is suspended within the hollow barrel by a plurality of rods that extend longitudinally within the hollow barrel.

is an isometric view of a bataccording to some embodiments of the disclosed technology. The batcan include a barrel, which is depicted as transparent into clearly show the internal components of the bat. In some embodiments, the batcan include an internal assembly, which can include one or more deformable ringsand a plurality or rods. The deformable ring(s)can be configured to limit (but not prevent) barrel flex at comparatively high impact forces while still allowing the barrelto freely flex at comparatively low impact forces. In certain embodiments, a deformable ringcan be placed at a location along the length of the barrelcorresponding to the peak performance of the bat, or the bat's “sweet spot.” While some embodiments may include a single deformable ring, other embodiments can include two, three, four, five, six, or more deformable rings. Increasing the number of deformable ringscan provide a more constant control of deformation of the hollow barrelupon impact with a ball, but increasing the number deformable ringscan also increase the overall weight of the bat, which can negatively impact performance of the bat. To provide uniformity of deformation about the exterior diameter of the bat, some embodiments can include three or more rods. For example, some embodiments can include three, four, five, six, or more rods. Similar to the number of deformable ringsused, an increased number of rodscan provide increased positional securely of the deformable ring, but increasing the number of rodscan increase the overall weight of the bat, which may negatively impact the performance of the bat. Accordingly, some embodiments can include as few as two rods, which can reduce the overall weight of the bat, but may do so at the cost of uniformity of deformation about the exterior diameter of the bat. Some embodiments can also include an alignment insert, which can provide limited or no effect on the deformation of the hollow barrel. According to some embodiments, the rodscan be solid. In some embodiments, the rodscan be substantially hollow, such as is depicted in. According to some embodiments, the rodscan comprise carbon tubes. In certain embodiments, the rodscan comprise metal, resin, carbon, glass fibers, or some mixture thereof. In some embodiments, each rodcan have a diameter in the range of approximately 1 mm to approximately 50 mm. For example, some embodiments can include rodshaving a diameter in the range of approximately 5 mm to approximately 30 mm.

In some embodiments, the alignment insertcan have a shape that mirrors the interior shape of the hollow barrel. For example, the alignment insertcan have a substantially cylindrical shape. Alternately, the alignment insertcan have a frustoconical shape. The alignment insertcan have an exterior diameter that is substantially equal to the interior diameter of the hollow barrel. The alignment insertcan include a plurality of holes or lobes extending axially therethrough. Each hole of the alignment insertcan be positioned at a common radius from a center of the alignment insert, and in certain embodiments, the holes can be positioned equidistantly about a circumference corresponding to this common radius. Each hole of the alignment insertcan be dimensioned to receive a corresponding rod. The alignment insertcan include a plurality of axially extending slits, and each slit can align with a corresponding hole of the alignment insert. Thus, each hole of the alignment insertcan be configured to receive a rodthrough the slit such that each rodis passed through a slit and into a corresponding hole in a radially inward direction.

The alignment insertcan have other shapes. For example, the alignment insertcan have a plurality of lobes formed between adjacent niches, such as is shown in. Each niche can correspond to a rodof the internal assembly, and each niche can be configured to receive at least a portion of the corresponding rod. Regardless of the shape, in some embodiments, the alignment insertcan be configured to substantially maintain the rodsin a predetermined alignment and/or position. In addition, the alignment insertcan also provide subjective benefits regarding the sound of the batstriking a ball (i.e., the ball-striking sound of a batwith an alignment insertcan be more pleasing to a general audience than the ball-striking sound of a batwithout an alignment insert). In some embodiments, the alignment insertcan comprise a light yet sturdy material. In some embodiments, the alignment insertcan comprise a polymer, copolymer, and/or foam, such as EVA foam. The alignment insertcan include a central hole (e.g., as shown in), which can reduce the weight of the alignment insert(and thus the overall weight of the bat). The central hole can be dimensioned such that weight is reduced without negatively impacting the necessary rigidity of the alignment insertthat is required to maintain the rodsin alignment with other components of the internal assemblyand/or other components of the bat. Certain embodiments can exclude the alignment insert. In some embodiments, the batcan include an end cap. As discussed more fully below, in some embodiments, the end capcan be configured to fit securely into a distal end of the barreland can be configured to receive an end of each of a plurality of rodsand maintain the end of each rodin a predetermined alignment and/or position.

Referring to, the deformable ringcan include a circular outer walland a plurality of holes, where each holeis configured to at least partially receive a rod. In some embodiments, the circular outer wallhas an outer diameter that is less than an inner diameter of the hollow barrelsuch that, upon impact of the hollow barrelwith a ball, the hollow barrelis permitted to deform a predetermined amount or a predetermined distance before contacting the circular outer wallof the deformable ring. According to some embodiments, the deformable ringis configured to at least partially deform upon receiving force from the impact of the hollow barrelwith a ball via contact of the hollow barrelwith the circular outer wallof the deformable ring. In some embodiments, the deformable ringcan be configured to return to its original shape subsequent to deforming.

According to certain embodiments, the deformable ringcan include one or more holesthat extend entirely through the deformable ring. Each holecan be located in a corresponding inner lobeof the deformable ring(e.g., as shown in). In some embodiments, each holeof the deformable ringcan be positioned at a common radius from a center of the deformable ring, and in certain embodiments, the holescan be positioned equidistantly about a circumference corresponding to this common radius. The positions of the holesof the deformable ringcan correspond to, and align with, the holes of the alignment insert. It should be understood that the circumference corresponding to the common radius does not necessarily correspond to a circumference of the circular outer wall. In some embodiments, when the holesreceive the rods, the deformable ringcan be positioned such that it is suspended within the hollow barrel, and in coaxial alignment with the hollow barrel, when the batis at rest (e.g., when the batis not striking a ball). As will be discussed more fully below, because the outer diameter of the deformable ring(i.e., the diameter of the circular outer wall) can be less than the internal diameter of the portion of the hollow barreladjacent to the deformable ring, a gap can be formed between the deformable ringand the hollow barrel.

In some embodiments, the end capcan include a number of holesthat extend partially into the end cap. In some embodiments, each holecan correspond to a rod. As shown in, in some embodiments, the end capcan include multiple protrusions extending from an inner surface of the end capwith each protrusion including a partial hole. This can permit the end capto comprise a relatively lower amount of material, which can decrease the overall weight of the bat.