Multi-Layered and/or Non-Uniform Weight Distributed Pickleball Ball

This application claims priority from U.S. Provisional Patent Application No. 63/660,563 filed Jun. 16, 2024, the entire content of which is herein incorporated by reference.

This disclosure relates to pickleball, and more particularly to pickleball balls.

The sport of pickleball is played in indoor setting or outdoor settings, and the players may range through a variety of skill levels, age groups and other categorizations. Pickleballs balls that are available in the market are made of one plastic type. For indoor pickleball, balls are made with a softer plastic, like polypropylene, for better control on smooth gym floors. The softer plastic materials are considered to provide more precise volleys and softer touches. For outdoor pickleball, balls that have tougher shells of harder plastic, like polyethylene, to withstand the demands of asphalt or concrete courts are used. Such tougher shells are more resilient to wear and tear and have a faster, livelier bounce for outdoor rallies.

Given the wide range of settings in which pickleball is played and the wide range of skill levels of players, pickleball ball characteristics may be customized and/or improved for particular conditions.

According to an embodiment, a pickleball ball comprises an outer shell having a first set of apertures, and an inner shell having a second set of apertures. At least one aperture of the first set of apertures overlaps an aperture of the second set of apertures, and/or the outer shell and the inner shell are made of different materials.

In some examples, apertures in the first set of apertures go through (e.g. extend through) the outer shell and apertures of the second set of apertures go through the inner shell.

In some example, the first set of apertures and the second set of apertures are arranged in a same pattern, and/or comprise apertures of a same size.

In some examples, at least one aperture in the first set of apertures does not overlap with any aperture in the second set of apertures.

In some examples, the inner shell comprises a spongy and/or soft material.

In some examples, the pickleball ball further comprises one or more intermediate shells arranged between the outer shell and the inner shell.

In some examples, the outer shell is less smooth than the inner shell and is configured to increase drag.

In some examples, the inner shell surrounds a hollow core of the pickleball ball.

In some examples, the outer shell and the inner shell are attached using a glue, fusion, heat, or a coating mechanism, or by submerging the pickleball in gas, vapor or liquid.

In some examples, a first aperture from the first set of apertures has a funnel shape extending from an outer surface of the outer shell to an inner surface of the outer shell, and a second aperture from the second set of apertures has a funnel shape extending from an outer surface of the inner shell to the inner surface of the inner shell. The size and/or shape of an opening of the funnel shape of the first aperture at the inner surface of the outer shell may be of a same size and/or shape of the funnel shape of the second aperture at the outer surface of the inner shell. The first aperture and the second aperture at least partially overlap to enable flow of air, from outside the pickleball ball to a hollow area surrounded by the inner shell, through the first aperture and the second aperture.

In an embodiment, a pickleball ball is configured for biased ball movement. The pickleball ball comprises a hollow sphere-shaped shell with a plurality of apertures arranged on the surface of the shell. The shell may have a non-uniform distribution of weight and/or at least one of the apertures having an entry and an exit that have different lateral alignment, size, and/or shape.

In some examples, the sphere-shaped shell has a non-uniform distribution of weight. The sphere-shaped shell may be configured to be heavier on one side of the ball. The additional weight may be added to selected areas of the ball. The sphere-shaped shell may be constructed with materials of different weights in a first area and a second area. The sphere-shaped shell may have a non-uniform thickness.

In some examples, at least one of the apertures has an entry and an exit that have different lateral alignment, size, and/or shape. At least one of the apertures may have an entry and an exit that have different lateral alignment. At least one of the apertures may have an entry and an exit that have different sizes and/or different shapes.

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the disclosure. However, it will be apparent to those skilled in the art that the disclosure, including structures, systems, and methods, may be practiced without these specific details. The description and representation herein are the common means used by those experienced or skilled in the art to most effectively convey the substance of their work to others skilled in the art. In other instances, well-known methods, procedures, components, and circuitry have not been described in detail to avoid unnecessarily obscuring aspects of the disclosure.

References in the specification to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

This disclosure relates to “Pickleball,” a game that has in recent years seen a massive increase in popularity among all age groups of players, including among senior citizens. Pickleball is a game that can be described as combining aspects of tennis, badminton, and ping-pong. It is played on a badminton-sized court, with paddles and a ball similar to a wiffle ball, but slightly smaller in size. The net used in pickleball is similar to a tennis net in some ways, but is lowered at the center.

Pickleball has recently become very popular and is played both indoors and outdoors, as either doubles or singles. The rules are relatively simple and the game is easy for beginners to learn. However, among skilled players, pickleball can develop into a quick, fast-paced, and competitive game.

shows an example pickleball courtthat includes a pickleball playing surfaceand a pickleball net. The playing surfacecomprises two left serve areasand, two right serve areasand, and two non-volley areasand, with one of the left serve areas, one of the right serve areas, and one of the non-volley areas being on each side of the pickleball net. The net is 36 inches tall at the edges, and lowered to 34 inches in the middle. The areas-are defined by baselinesandeach 20 feet, sidelinesandeach 44 feet, center linesandeach 15 feet, and non-volley linesandeach the same size as a baseline. Each of the lines may be 2 inches wide. The term “court line” is used in this disclosure to refer to any sideline, baseline, centerline or non-volley line on the pickleball court. Non-volley areasand, each extending 7 feet from the net, are also referred to as the “kitchen”.

The game of pickleball is played with a pickleball paddleand pickleball ball. The ballis typically made of plastic and has a 3-inch diameter. Similar to a wiffleball, the ballhas through holes throughout the surface. Different types (e.g., with different levels of hardness and different sizes of the through holes) may be used for playing the game on the various types of pickleball courts (e.g., indoor, outdoor, hard surface, soft surface etc.).

Pickleball can be played as singles or doubles, and is most commonly played as doubles. Each point begins with an underarm serve. The serve is performed diagonally beginning at the right-hand service square. A valid serve sends the ball from one left serve area to the other left serve area or from one right serve area to the other right serve area. The serve must clear the non-volley-zone. The serve must bounce before being hit by the receiver. The return of serve must also bounce before being hit (this is known as thebounce rule). After the serve and the return of the serve, the ball can land anywhere on the opposite side of the playing surface. Volleys can only be performed outside of the non-volley zone. Volleys, that is, hitting the ball in the air without first letting it bounce, can only be made after thebounce rule has been followed. However, if the ball is hit from within the kitchen, then it cannot land in the kitchen on the other side of the net.

A fault is any action that stops play due to a rule violation. A fault by the receiving team results in the servers earning a point. A fault by the serving team results in the server's loss of service and/or side out. A fault is committed when the serve touches any part of the non-volley zone (including the line) or the ball is hit out of bounds.

Pickleball games are typically played without a referee and are self-judged. Each player makes the line calls as to whether the ball is in or out when the ball contacts the playing surface on that player's side. The game continues to at least 11 points and requires a 2-point difference for a win.shows another view of a pickleball court.

As noted above, pickleball is played by people of all ages and all skill levels. It is important that pickleball organizations provide as many options as possible to facilitate enjoyable play among players with different skill levels, practice needs, athletic capabilities, etc. The pickleball ball can be constructed in manners that provide for facilitating such options for players.

An example pickleball ballis shown in. Specifications for pickleball balls are established by United States Pickleball Association (USPA). The specification defines requirements for construction, approval, size, bounce, compression, and design of pickleball balls. These specifications are intended for maintaining consistent playing characteristics across all pickleballs. Most pickleball balls approved for competition use are compliant with the USPA specifications.

Construction specifications require that the ball is made of a durable material molded with a smooth surface and free of texturing. The ball may have a slight ridge at the seam, as long as it does not significantly impact the ball's flight characteristics. Size specifications require that the ball shall be 2.87 inches (7.29 cm) to 2.97 inches (7.54 cm) in diameter. The maximum out-of-round diameter variance shall not be greater than +/−0.020 inch (0.51 mm). This provides a circumferencebetween 9.03 inches (22.93 cm) and 9.34 inches (23.72 cm). Weight specifications require that the ball shall weigh between 0.78 and 0.935 ounces (22.1 and 26.5 grams).

The specifications also require certain bounce characteristics and compression characteristics for the ball. Further, the specifications require that the ball shall have a minimum of 26 to a maximum of 40 circular holes (e.g., holes), with spacing of the holes and overall design of the ball conforming to flight characteristics.

One technique of manufacturing pickleball balls is a process referred to as injection molding. The core ingredient is very often polyethylene-a type of plastic known for its toughness and elasticity. However, the type of plastic can differ depending on whether the ball is for indoor or outdoor play. Indoor balls use softer plastic (e.g., polypropylene) for better control on smooth surfaces, while outdoor balls have shells made of harder plastic to endure the wear and tear of rough courts like asphalt or concrete.

The injection molding process involves melting down the plastic into a liquid state and then forcing the liquid plastic with high pressure into a mold made of two halves. These molds are designed to create the exact shape and size of a pickleball, including the holes on the surface. The pressure ensures the plastic fills the mold in a manner that results in a consistent ball construction throughout. The two halves of the filled mold are then fused together forming a complete ball. Thereafter, the new ball cools down until the plastic hardens and retains its shape.

Rotational molding is another process that is used for manufacturing pickleballs. In this technique, plastic powder is poured into a heated mold that rotates on two axes. As the mold rotates, the plastic melts and coats the inside evenly. The mold is then cooled, and the finished ball is removed. In general, rotational molding is considered a less-costly process than injection molding, but it offers less flexibility in the ball design. Thus, injection molding is generally preferred.

Pickleballs balls that are available in the market are made of one plastic type. The material composition may be tailored to particular playing surfaces. As mentioned above, for indoor pickleball, balls are made with a softer plastic, like polypropylene, for better control on smooth gym floors. The softer plastic materials are considered to provide more precise volleys and softer touches. For outdoor pickleball, balls that have tougher shells of harder plastic, like polyethylene, to withstand the demands of asphalt or concrete courts are used. Such tougher shells are more resilient to wear and tear and have a faster, livelier bounce for outdoor rallies.

The characteristic of the plastic type is a key factor that determines the durability, bounce, hardness and weight of the ball. Typically, a pickleball ball is considered to last for 3-5 games at maximum performance before it is typically recommended to be switched out.

Currently available pickleball balls are constructed from one material such as polyethylene or polypropylene, and has holes spaced evenly throughout the surface. Balls with different numbers of holes are available. While most available pickleball balls have circular holes, balls that have holes that are shaped as stretched circles (e.g., stretched from top and bottom of circle) are also available. The holes may function to reduce the drag imposed on the ball when in flight, and to reduce the weight of the ball. The even distribution of the holes may be instrumental in providing for consistent rotation and spin behavior of the ball. Consistent rotation and spin behavior can improve predictability of the ball's path to a player.

There are several issues to be preferably addressed in relation to currently available pickleball balls. For example, the short lifespan of 3-5 games can be inconvenient and expensive for players. Therefore, one need is to extend the lifespan of a pickleball ball, especially, when pickleball is played outdoor on a hard surface. Another issue is that pickleball balls generate a loud noise when they hit the ground and/or the paddle. Pickleball is a noisy sport and could disturb the neighborhood peace. Also, the hard surface of the pickleball may cause injuries to occur when a ball hits the face, in particular the eye.

It is also often the case that more flexibility is desired to control drag force on the ball (aerodynamic properties of the ball). For example, in such situations such as when playing in windy weather, an increased capability of the ball to control drag force may be desirable. Additionally, more consistency on how the ball bounces may be desired.

Still further, improved and more consistent grip and traction is needed when the ball is struck with a paddle. This allows players to apply more spin and have greater shot control.

Yet a further need is to simulate the ball behavior in outdoor environments (e.g., with unpredictable wind effects) in a ball for indoor play.

In some embodiments of the present disclosure, a pickleball ball with at least two punctured layers is provided. The at least two punctured layers include at least an outer layer (outer shell) and an inner layer (inner shell). An example two-layer (two-shell) pickleball ballis shown in, with only the lower half of the ball being illustrated in disassembled form. In some embodiments, the inner shellsurrounds a hollow coreof the ball. Each holeof a first set of holes (also referred to as punctures or apertures) extends laterally across (through) the outer shelland each holeof a second set of holes extends through the inner shell. The two layers overlap in at least one of the holes, thereby enabling airflow between the hollow coreof the ball and the external environment of the ball.

The outer shell and the inner shell are constructed from different materials, or different material combinations. In some embodiments, the outer shell is configured for reduced noise generation when the ball hits the pickleball court surface and/or the striking surface of the pickleball paddle, and the inner shell is configured for structural support. For example, the outer shell is constructed from a softer material than the inner shell. In some embodiments, the inner shell is constructed from a softer material than the outer shell and serves to reduce generated noise by substantially dampening vibrations that are generated upon ball contact with the surface of the court or the paddle.illustrates the bottom half of a two-layer ballwith the cross-sectionillustrating the configuration of a circular holethat is on shell. As illustrated in cross-section, the inner shellis constructed with a different material than the outer shell. Materials of different layers may be selected based on their desired characteristics. For example, outer shell material may be of a material to reduce noise and reduce the likelihood of ball getting broken or cracked. The inner shell material may be selected based on its firmness. In an example, the inner shellmay be constructed with the same material than the outer shell. In an example (now shown in), the inner or outer material may cover the edges of the holes depending on the process used for manufacturing the ball.

In some embodiments, the first set of holes and the second set of holes have the same pattern of arrangement and may have same sized and same shaped holes. The first set of holes and the second set of holes overlap on a majority of the holes such that airflow between the outside of the ball and the hollow core of the ball is enabled through each pair of overlapping holes. Each pair of overlapping holes form an extended two-segment tunnel through which the air can flow. In some embodiments, such as when the sizes and shapes of the first set of holes are the same as the sizes and shapes of the second set of holes, each hole of the first set fully overlaps a hole in the second set and the airflow is maximized. The ballsandare examples of all holes in the outer shell overlapping with a corresponding hole in the inner shell. In some embodiments, one or more holes of the first set may only partially overlap respective holes in the second set, thereby enabling less than the maximum amount of airflow between the hollow core of the ball and the outside of the ball. In yet some other embodiments one or more holes of the outer shell may not overlap a corresponding hole in the inner shell. For example,illustrates pickleball ballin which outer shellhas more holesthan the number of holeson the inner shell. Having more holes on the outer shell than there are holes in the inner shell may provide for having a higher level of drag-inducing roughness on the outer shell without corresponding drag-reducing holes that permit airflow through the hollow core of the pickleball. Thus, embodiments may configure the first set of holes and the second set of holes in particular manners to facilitate particular behavior of the ball.

In an example, one of the layers may comprise a graphene layer. The graphene layer may be applied through various methods like chemical vapor deposition, liquid phase exfoliation, or transfer techniques. The graphene layer may offer several advantages, including increased stiffness and rigidity for enhanced control and accuracy, improved durability and wear resistance, reduced wind interference due to a streamlined surface, minimal air resistance, better responsiveness and/or power transfer during impact.

In some embodiments, one or more additional layers/shells may be added between the outer shell and the inner shell.illustrates a part of pickleball ballthat has an intermediate shellwith holesthat is inserted between the outer shellwith holesand inner shellwith holes. Such intermediate layers, or intermediate shells, may be configured to serve to reduce or increase a ball's weight, to provide more structural support, to provide better noise suppression behavior, particular flight behaviors and/or particular bounce behaviors. The configuration aspects for each shell may include, but are not limited to, the construction material, thickness of the shell, number and/or pattern of holes, and size and/or shape of holes.

Moreover, in some embodiments, the holes in the first set and/or the second set are configured to have different shapes and/or sizes at the entrance to the hole and to the exit from the hole. For example, a hole can have a funnel shape (e.g., radius of the aperture gradually increases from entrance to exit or vice versa) in which the entrance to the hole is larger than the exit from the hole. In some embodiments, the exit from a hole in the first set fully or partially overlaps holes in the second set.illustrates an outer shellhaving a funnel shaped holewith a larger entrythan exitand an inner shellhaving a funnel shaped holewith an entrythat fully overlaps with exit. The exitof holeis smaller than its entrythus yielding the funnel shape. The funnel-shape may increase the pressure as air flows through the funnel-shaped tunnel and thus affect the flight of the ball in a particular way.illustrates a tunnel formed of two holesandof outerand innershells, in which the entryto the outer shell has a different shape (elongated/stretched circle). The exitof the outer shell, and the entranceand exitof the inner shellare circular. The differently shaped entrance (or exit) may reduce the smoothness of airflow through a hole such that the flight of the ball is affected in a particular manner.illustrates an example pickleball ballin which the holein the inner shellhas a smaller diameter (and thus its entranceand exitbeing smaller) than the exitof the outer shellholethat has a funnel shape from its entryto its exit. The partial overlap of the inner shell tunnel with the outer shell tunnel may provide for increased pressure in the airflow such that the ball movement affected in a particular manner.

Thus, some embodiments of the present disclosure may combine different characteristics in the construction materials of the outer and inner shells, the configuration of the set of holes in the outer shell and the set of holes in the inner shell, and a number and construction of one or more intermediate shells arranged between the outer and inner shells in order to construct pickleball balls with particular desired behaviors.

The respective shells of the pickleball ball can be constructed from different plastic types, or different plastic compounds. The construction material for the outer shell may be tailored to particular type of playing surface (e.g., indoor, outdoor). For indoor pickleball, balls are made with the outer shell constructed from a softer plastic, like, for example, polypropylene, for better control on smooth gym floors. The softer plastic materials are considered to provide more precise volleys and softer touches. Pickleball balls for indoor use, according to some embodiments, have the outer shell having a softer material than the inner shell. This material configuration can provide reduced noise and reduced likelihood of injury, for example, because of the softer outer shell, while providing good structural support for the ball.

For outdoor pickleball, balls that have an outer shell of tougher or harder plastic (e.g., polyethylene) that can withstand the demands of asphalt or concrete courts are used. Such tougher shells are more resilient to wear and tear and have a faster, livelier bounce for outdoor rallies. Pickleball balls for outdoor use, according to some embodiments, have the outer shell having a harder material than the inner shell. This material configuration can provide reduced wear-and-tear, livelier bounce and noise suppression, for example, because of the softer inner shell of the ball.

In some embodiments, the outer shell is constructed from a plastic or plastic compound and the inner shell is constructed from a rubber or rubber compound. The hardness of the plastic and/or the rubber may be configurable to the levels desired for the sought ball characteristics such as, but not limited to, weight and bounce.