Composite materials

Abstract

A composite material having a skin optionally including a top surface coating; and one or more layers. The skin is adapted to be used on or to produce sporting equipment, such as on a sport or game paddle. The present teachings also include a paddle having a core, a first skin, and a second skin, where the first skin and the second skin sandwich the core. The skins may be a multi-layer fibrous composite.

Description

COMPOSITE MATERIALSCLAIM OF PRIORITY

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 527,214, filed on July 17, 2023, the contents of which are hereby incorporated by reference in their entireties for all purposes.FIELD

[0002] In general, the present teachings relate to an improved composite material, such as that for sporting goods, and more particularly to a paddle for paddle sports and associated materials with a core sandwiched with multilayer structures.BACKGROUND

[0003] The sporting goods market is a $140 billion market. Current materials used in the sporting goods market may be lightweight and / or durable. However, efforts are still underway to improve these materials for performance, comfort, eco-friendliness, or a combination thereof.

[0004] The popularity of paddle sports in particular, such as pickleball, has skyrocketed in recent years. Requiring only a ball, a net, and paddles for each player, and played on a flat surface, such as a court or table, the game can be enjoyed by people of all ages and skill levels. However, as the game continues to become more competitive, players are constantly looking for improved paddles and improved materials to advance their game performance.

[0005] In particular, players are looking for durable and tough paddles that can withstand even heavy use and handling, especially in the handle area, from the most competitive players. Players want a paddle that is not too heavy but is still durable.

[0006] Players also want a paddle that provides sufficient flex for improved power and control. Traditional paddles or parts thereof are made from fiberglass or carbon fiber alone. While these materials are lightweight, existing materials such as fiberglass and carbon fiber are very stiff and brittle, so there is a limited flex range. These materials also channel vibrations into the body, which can lead to fatigue or injury for the user. Vibrations can also increase the noise of the game. For example, fiberglass composites provide little vibration dampening. Carbon fiber produces a material with less flex and a higher elastic modulus. These materials also produce high CO2 emissions and waste and are not recyclable.

[0007] Players are also looking for improved contact surfaces where their paddle contacts the ball. Players do not want their contact surfaces to delaminate, peel away from the paddle or other layers, so a strong bond between all parts of the paddle is needed.

[0008] Players are also looking to customize their paddles. As the game is played by people of all ages, sizes, and skill levels, the ability to customize weight, balance, shape, handle size, and feel of the paddle are of great importance to regular pickleball players. Additionally, as the sport gains popularity, companies are looking for branding opportunities on equipment such as paddles.

[0009] The International Federation of Pickleball (IFP) and the USA Pickleball Association (USAPA) set the rules and regulations for pickleball paddles. The guidelines for allowable pickleball paddles include restrictions on surface roughness, reflection, size, and appearance.

[0010] Therefore, there is a need in the industry for improved materials, such as those for paddles (e.g., for pickleball), that are durable, rigid, comfortable, have a desired flex, reduce vibrations, tough, or a combination thereof. It is desirable to provide a material that reduces vibrations (e.g., to reduce noise, to reduce fatigue, or both). It is desirable to have customizable materials, depending on the user’s needs, skill level, size, and speed of game play. It is desirable to provide a paddle that performs well without degradation or delamination of layers. It is desirable to provide materials that are eco-friendly, renewable, recyclable, that reduce CO2 emissions, or a combination thereof.SUMMARY

[0011] The present teachings meet the above needs by providing an elegant approach to composite materials, such as skins for paddles and paddles and parts thereof for paddle sports, including but not limited to pickleball. The paddles may be customizable based on the user’s needs, style of play, grip, strength, or a combination thereof. Increased comfort, improved power and control, eco-friendliness, or a combination thereof, may be achieved through the unique materials and combinations of materials (e.g., particular fiber types, weights, direction of fibers). These unique materials and combinations of materials may provide up to about 500% (e.g., about 50% or more, about 100% or more, about 150% or more, about 200% or more, about 500% or less, or any range therebetween) more vibration dampening as compared to traditional materials (e.g., fiberglass and / or carbon fiber alone). These unique materials and combinations may result in improved power and control by providing up to about 1.5 times wider range of flex as compared to traditional materials (e.g.,fiberglass and / or carbon fiber alone). These unique materials and combinations may be renewable and / or recyclable, use recycled materials, or reduce CO2 emissions (e.g., a reduction of up to about 90%).

[0012] The present teachings include a skin having one or more layers. The skin may include an optional top surface coating. The skin may be used on a sport or game paddle (e.g., upon a striking surface of the paddle). The skin may include two or more layers, three or more layers, or four or more layers. The skin may include ten or fewer layers, eight or fewer layers, or six or fewer layers. One or more of the layers, or each of the layers, may have a weight of about 20 gsm or greater, about 400 gsm or less, or both, or any value or range of values therebetween. One or more of the layers, or each of the layers, may include natural fibers, carbon fibers, glass fibers, basalt fibers, ultra-high molecular weight polyolefin fibers, or a combination thereof. A combination of fibers may form a hybrid fabric, such as a natural fiber / carbon fiber hybrid weave fabric. The carbon fibers may be oriented in one direction and the natural fibers oriented generally perpendicular. The top surface coating may include a thin resin layer. The thin resin layer may include a microtexture molded therein.

[0013] The composite may include a layer located beneath the optional top surface coating. Where there is no top surface coating, the layer may be an exterior layer. The layer may have a weight of about 20 gsm or greater. The layer may have a weight of about 400 gsm or less. For example, the layer may be about 100 gsm or more, about 300 gsm or less, or any value or range therebetween. The layer may be a fiberglass layer, a basalt layer, a natural fiber layer, or a hybrid fiber layer. The fibers may be arranged generally unidirectionally. The fibers may be woven.

[0014] The composite may include one or more layers having unidirectional fibers. The layer may have a weight of about 20 gsm or greater. The layer may have a weight of about 400 gsm or less. For example, the layer may be about 20 gsm or more, about 300 gsm or less, or any value or range therebetween. For example, the layer may be a unidirectional natural fiber layer (e.g., flax), a unidirectional basalt layer, or a unidirectional fiberglass layer. In a paddle, the unidirectional arrangement may be oriented generally parallel to the handle, generally perpendicular to the handle, or at an angle therebetween. For example, the unidirectional fibers may be oriented generally parallel to the handle.

[0015] The composite may include one or more woven layers. The layer may be a twill woven fabric. The layer may include basalt (e.g., a woven basalt layer). The layer may include an ultra-high molecular weight polyolefin fiber (e.g., Innegra). The layer may include a basalt and an ultra-high molecular weight polyolefin hybrid layer. The layer may include fiberglass. The layer may be a hybrid layer having two or more fiber types. For example, a layer may be a naturalfiber / carbon fiber hybrid weave fabric. In the natural fiber / carbon fiber hybrid weave fabric, the carbon fibers may be oriented generally perpendicular to the natural fibers. It is contemplated that the carbon fiber may be oriented generally parallel to the handle of the paddle and the natural fibers oriented generally perpendicular to the handle, or vice versa, or at an angle therebetween (e.g., about 45 / -45 degrees relative to an axis generally parallel with the handle). The layer may include a spread tow woven material.

[0016] The composite may include at least one layer impregnated with a resin (e.g., a thermoplastic or thermoset resin). The composite or one or more layers thereof may be about 30% by weight or greater resin. The composite or one or more layers thereof may be about 70% by weight or less resin.

[0017] The present teachings also include a paddle having a core, a first skin, and a second skin, where the first skin and second skin sandwich the core. The paddle may include a handle portion. The handle portion may include a shell. The shell may be formed of a single piece. The shell may be formed of two or more pieces. The shell may be formed by injection molding or 3D printing, for example. The handle portion of the paddle may include a portion of the core material.

[0018] The first skin, the second skin, or both may be a multi-layer material. The first skin, the second skin, or both, may include one or more layers having natural fibers, carbon fibers, glass fibers, basalt fibers, ultra-high molecular weight polyolefin fibers, heat-resistant synthetic fibers, such as Kevlar®, or a combination thereof. One or more of the layers of the first skin, the second skin, or both, may have a weight of about 20 gsm or greater and about 400 gsm or less. One or more of the layers may have fabric layers. One or more of the layers may be woven layers. One or more of the layers may be a fiberglass layer. One or more of the layers may be a natural fiber layer (e.g., a flax layer). One or more of the layers may include basalt. One or more layers may be a basalt layer (e.g., a woven basalt layer or a layer with the basalt fibers oriented generally unidirectionally). One or more of the layers may include an ultra-high molecular weight polyolefin hybrid layer. One or more of the layers may be hybrid layers (e.g., a basalt and ultra-high molecular weight polyolefin fiber (e.g., Innegra) hybrid layer or a carbon fiber and natural fiber hybrid weave fabric). The first skin, the second skin, or both may include an outermost coating. The outermost coating may be a thin resin layer with an optional microtexture.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] FIGs. 1A and 1 B show an exemplary paddle in accordance with the present teachings.

[0020] FIG. 2 shows an exemplary core material for a paddle in accordance with the present teachings.

[0021] FIG. 3 shows an exemplary foam-filled core material for a paddle in accordance with the present teachings.

[0022] FIG. 4 shows an exemplary epoxy-filled core material for a paddle in accordance with the present teachings.

[0023] FIG. 5 shows an exemplary hotmelt-fil led core material for a paddle in accordance with the present teachings.

[0024] FIG. 6 shows a laminate reinforcement for a paddle in accordance with the present teachings.

[0025] FIG. 7 shows an exemplary layer of a high-performance fiber and basalt in accordance with the present teachings.

[0026] FIG. 8 shows a multi-layer skin for a paddle in accordance with the present teachings.

[0027] FIG. 9 shows a sandwich panel, with a multi-layer skin on each side of a core, in accordance with the present teachings.

[0028] FIG. 10 shows an exemplary exploded view of a multi-layer skin in accordance with the present teachings.

[0029] FIG. 11 shows an exemplary exploded view of a multi-layer skin in accordance with the present teachings.

[0030] FIG. 12 shows an exemplary exploded view of a multi-layer skin in accordance with the present teachings.

[0031] FIG. 13 shows an exemplary exploded view of a multi-layer skin in accordance with the present teachings.

[0032] FIG. 14A is an exploded view of a handle of a paddle.

[0033] FIG. 14B is an assembled handle shell in accordance with the present teachings.

[0034] FIGs. 15A, 15B, and 15C illustrate views of a handle in accordance with the present teachings.

[0035] FIG. 16 illustrates an exemplary end cap of a handle in accordance with the present teachings.DETAILED DESCRIPTION

[0036] The present teachings meet one or more of the above needs by the improved composite structures and methods described herein. The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the teachings, its principles, and its practicalapplication. Those skilled in the art may adapt and apply the teachings in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present teachings as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

[0037] As required, detailed embodiments of the present teachings are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the teachings that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present teachings.

[0038] The present teachings relate to composite materials. The composite materials may be used in sporting equipment. Sporting equipment may include paddles for paddle games and paddle sports. While the present application illustrates and describes paddles for pickleball, other paddles are also contemplated within the present teachings, such as paddles for table tennis or ping pong, padel, rackets, or racquets.

[0039] The teachings of International Publication No. WO 2022 / 217045 are hereby expressly incorporated by reference in their entirety for all purposes.

[0040] A paddle (e.g., racket, racquet, pickleball paddle, ping pong paddle, etc.) may include a striking portion, a handle portion, and a tapered portion or rounded therebetween. The paddle may be formed of a sandwich panel having a core structure interposed between two composite laminate layers or skins. The core structure may be formed of a lightweight material but must be rigid enough such that the paddle functions for its intended purpose and / or meets the requirements of the governing body of the sport. For example, a pickleball paddle must meet the requirements of the International Federation of Pickleball (IFP) and the USA Pickleball Association (USAPA).

[0041] The teachings herein are directed to materials and methods relating to forming a composite skin. The composite skin may be useful for a paddle. The paddles described herein may include a core portion and one or more composite skins. The paddles may utilize resins,adhesives, films, tapes or other similar joining means to form the resulting combination of core layer and composite skins. The process for forming the skins and paddles described herein may include one or more heating, curing, pressing or compressing steps. The composite skins may be formed and cured in a separate step and may then be assembled with a core layer, which may also include a curing step. Curing may occur at ambient temperatures. Curing may occur upon exposure to heat, UV light, microwave, induction heat, or another stimulus.

[0042] The present teachings include composite or multi-layer skins. The skins may be applied to, be integrated in, or may form at least a portion of sporting equipment. Such sporting equipment may include paddles for paddle sports. The paddle may include a skin (e.g., a composite skin). The paddle may include generally opposing skins (e.g., positioned on opposing sides of a core material). The opposing skins may be the same compositions. The opposing skins may have different compositions. The composite skin may have one or more components, one or more materials, one or more layers, or a combination thereof. This may include fibrous materials, woven materials, nonwoven materials, fabrics, foils, films, facings, extruded materials, preformed materials, activatable materials, adhesive materials, resins, the like, or a combination thereof.

[0043] The composite skins may be formed of a variety of different natural, synthetic, and / or recycled materials. The composite skins may be formed of combinations of these materials. The composite skins may be formed using multiple layers (e.g., two layers, three layers, four layers, eight layers, ten layers, twelve layers, any number therebetween, or even more layers). There may be an even number of layers. There may be an odd number of layers. When referring to layers, these may exclude an outermost coating on the skin and / or any adhesive or resin material joining adjacent layers. When referring to layers, this may include the outermost coating on the skin and / or any adhesive or resin material joining adjacent layers. Each of the layers may comprise the same materials. Each of the layers may comprise different materials. Some layers may comprise the same materials while others comprise different materials.

[0044] The layers may be selected to alternate two or more materials. Each layer in itself may comprise more than one type of material (e.g., more than one type of fiber, one or more resins in addition to the fibers, or fibers with coatings thereon). The layers may be coated with a resin, impregnated with a resin, or some fibers or each fiber of a layer may be coated with a resin. The layers may be formed of woven or nonwoven materials. The layers may be formed of fibers having a relatively low glass transition temperature. The fibers and / or the resin may be formed from thermoplastic materials that can be repaired, reformed, and / or recycled upon exposure to heat. The resin and / or fibers may be formed of a thermoset or thermosettablematerial. The resin and / or fibers may include a foam material or a material that is adapted to foam upon exposure to a stimulus.

[0045] Each layer may be defined by a directionality (e.g., biaxial, bidirectional, triaxial, uniaxial, unidirectional, etc.), a material (e.g., flax, hemp, Kevlar, carbon, wood, etc.), a weave (e.g., twill, plain, satin, etc.), a density (measured in grams per cubic centimeter (g / cm3), a weight (g / m2or gsm), or a combination thereof.

[0046] One or more of the layers may have a directional weave. Standard weave directions (e.g., 0 degrees, 90 degrees, 45 degrees, -45 degrees, 60 degrees, 30 degrees, the like, or a combination thereof) may be employed to produce a fabric for the skin (e.g., of a paddle). One or more of the layers may have a particular type of weave to produce a fabric for the skin (e.g., of a paddle). Weave types include plain weave, basket weave, unidirectional weave, satin weave, spread tow weave, twill, biaxial weave (e.g., 45Z-45, 0 / 90, 60 / -60, 30 / -30), triaxial weave (e.g., 45 / -45 / 0, 30 / -30 / 0, 60-60 / 0), and quadaxial weave (e.g., 0 / 90 / -45 / 45). The weave may include rovings with a low twist, rovings with a high twist, no twist, or a combination thereof.

[0047] For example, one or more layers may have a unidirectional weave. One or more layers may include a bidirectional weave having threads extending in a first x-direction and having threads extending in a first y-direction. One or more layers may include a +45Z-45 degree weave, where the first x-direction is substantially perpendicular to the first y-direction. One or more layers may include a 90 / 0 degree weave. One or more layers may include a +30 / -30 degree weave. One or more layers may include a +6G / -60 degree weave.

[0048] Layers may be positioned such that the weave of one layer is generally parallel with the weave of another layer. Layers may be positioned such that the weave of one layer is not generally parallel with another layer. Layers may be positioned such that the weave of one layer is positioned within a certain degree of the weave of another layer or within a certain degree of parallel with a central axis. For example, a layer may be positioned such that the threads or direction of the weave are positioned within about 10 degrees of parallel with the central axis, within 5 degrees of parallel with the central axis, or both.

[0049] Certain weaves may be selected to provide enhanced benefits. For example, a spread tow weave of plain natural fibers (e.g., at a 0 / 90 degree weave) may provide a desirable texture at or near the surface of the paddle. A spread tow weave may absorb minimal resin. Exemplary spread tow products may be available from TeXtreme®, in Boras, Sweden. A spread tow weave with a 45Z-45 degree fiber orientation may provide torsional resistance. This may reduce bending and breaking, particularly about the handle. Combinations of spread tow weaves of natural fibers are also contemplated. For example, a spread tow weave with a 0 / 90 degree fiber orientation anda spread tow weave with a 45 / -45 degree fiber orientation may create a balanced, low cost, high strength laminate.

[0050] In another example, a unidirectional fabric of natural fibers, such as flax, may be desirable for reducing vibration and / or increasing stiffness and durability of the layer and of the paddle.

[0051] Materials forming the layers, weave type, and the layers themselves, may be selected based on particular properties desired of the paddle and / or the layer. Certain layers or materials may provide any combination of high stiffness, high strength, low density, non-brittleness, vibration damping, recyclability, reduced processing and / or materials cost, desirable texture, high temperature stability, high energy dissipation, water resistance, higher elasticity for creation of more flex and / or power, UV protection, and high adhesion.

[0052] One or more layers of the skin may include plain natural fibers. For example, natural fibers may provide high stiffness, high strength, low density, non-brittleness, vibration damping, recyclability, or a combination thereof. Plain natural fibers may include, but are not limited to, flax, hemp, jute, bamboo, ramie, kenaf, the like, or a combination thereof.

[0053] One or more layers may include one or more recyclable materials. One or more layers may include one or more renewable materials. One or more layers may include one or more materials derived from rock. One or more layers may include one or more materials derived from recyclable volcanic rock, such as basalt. One or more of the layers may include basalt fibers. Basalt fibers may provide high stiffness, high strength, high temperature stability, vibration damping, reduced material and / or production cost, recyclability, or a combination thereof.

[0054] One or more of the layers may include glass fibers. One or more of the layers may include fiberglass. Fiberglass may be a low-cost material that provides strength and / or stiffness to the layer, the paddle, or both. Woven fiberglass may protect layers beneath from UV, moisture, and / or damage. The surface of a woven fiberglass may create a desirable surface (e.g., flat surface) to minimize texture from other thread layers beneath. This desirable surface may then act to support a top surface coating of a skin or may provide a surface to which additional layers adhere well without delamination.

[0055] One or more of the layers may include carbon fibers. Carbon fibers may provide strength and / or stiffness to the layer, the paddle, or both.

[0056] One or more layers may include one or more synthetic fibers. One or more layers may include one or more olefin fibers. One or more layers may include one or more fibers from polyolefin polypropylene. One or more of the layers may include an ultra-high molecular weight polyolefin fiber. An exemplary fiber is Innegra™, available from Innegra Technologies in Greenville, South Carolina. Such fiber may be tough, lightweight, durable, water resistant, low-density, provide energy dissipation, elastic to create more power and / or flex, low cost, recyclable, or a combination thereof. One or more layers may include aramid synthetic fibers. One or more layers may include heat-resistant synthetic fibers, such as Kevlar®. The fibers may bond to one or more resins (e.g., thermoplastic resins, such as polypropylene or polylactic acid).

[0057] One or more layers may include a blend of fibers. One or more layers may include a hybrid fabric of two or more fiber types. A hybrid material may allow for certain fibers providing certain properties to be combined to improve performance of the layer, the paddle, or both. A hybrid material may allow for certain fibers to be used in areas where they are traditionally unable to be used (e.g., where processing or layer formation would be difficult, where fibers lack particular bonding ability, where fibers are expensive). A hybrid material may allow for a reduction of certain fiber types while retaining the benefits of those fiber types. A hybrid material may increase processability or may aid in formation of a layer (e.g., by improving the ability to bond with other layers or other fibers). A hybrid material may combine different fiber types in any method that creates a desired layer or material having desired properties. For example, the hybrid material may be formed as a laminate. The hybrid material may be a woven material. The woven material may have a particular fiber directionality. The woven material may be a twill weave, satin weave, plain weave material, basket weave, spread tow weave, biaxial weave, triaxial weave, quad axial weave, or a combination thereof. The hybrid material may be a nonwoven material. The hybrid material may be formed of a single layer. The hybrid material may be formed of more than one layer of material combined via one or more processes or using one or more adhesive materials.

[0058] A hybrid material may be formed of any combination of fibers. A hybrid material may be formed of any combination of fibers as previously described, including natural fibers, carbon fibers, glass fibers, basalt fibers, ultra-high molecular weight polyolefin fibers, and heat-resistant synthetic fibers, such as Kevlar®.

[0059] A hybrid material may be selected to increase toughness, durability, energy dissipation, stiffness, vibration damping, or a combination thereof. A hybrid material may be selected to include the fibers that are tough, lightweight, durable, water resistant, low-density, elastic to create more power and / or flex, low cost, recyclable, provide energy dissipation, or a combination thereof. An example of a hybrid material having such properties is one formed of basalt fibers and ultra- high molecular weight polyolefin fibers. The fibers may be woven to produce a hybrid fabric. The hybrid material may be a twill woven fabric, for example.

[0060] A hybrid material may be selected to have high stiffness, high strength, good bonding (e.g., bonding with resins of carbon fiber), or a combination thereof. A hybrid material may be selected to include the fibers that are tough, lightweight, durable, water resistant, low-density,elastic to create more power and / or flex, low cost, recyclable, provide energy dissipation, or a combination thereof. An example of a hybrid material having such properties is one formed of carbon fibers and ultra-high molecular weight polyolefin fibers. The fibers may be woven together. The fibers may be woven together to help adhere the ultra-high molecular weight polyolefin fibers into a laminate.

[0061] A hybrid material may be selected to have high stiffness, high strength, lower cost, or a combination thereof. A hybrid material may be selected to include the fibers that are tough, lightweight, durable, water resistant, low-density, elastic to create more power and / or flex, low cost, recyclable, provide energy dissipation, or a combination thereof. An example of a hybrid material having such properties is one formed of glass fibers (e.g., fiberglass) and ultra-high molecular weight polyolefin fibers. The fibers may be woven together. The fibers may be woven together to help adhere the ultra-high molecular weight polyolefin fibers into a laminate.

[0062] A hybrid material may be selected to combine fibers having high stiffness and strength with fibers having a high toughness, less vibration, and low cost. An example of a hybrid material having such properties is one formed of basalt fibers and carbon fibers.

[0063] A hybrid material may be selected to have high stiffness, high strength, low cost, adhesion, vibration damping, or a combination thereof. A hybrid material may be selected that can be sustainably made. An example of such a hybrid material is one formed of basalt and glass fibers.

[0064] A hybrid material may be selected to have high stiffness, vibration damping, high strength, or a combination thereof. A hybrid material may be selected to include the fibers that are tough, lightweight, durable, water resistant, low-density, elastic to create more power and / or flex, low cost, recyclable, provide energy dissipation, or a combination thereof. An example of a hybrid material having such properties is one formed of natural fibers and ultra-high molecular weight polyolefin fibers. The fibers may be woven together to help adhere the ultra-high molecular weight polyolefin fibers into a laminate.

[0065] A hybrid material may be selected to combine fibers having high stiffness, vibration damping, low cost, strength, toughness, improved adhesion, or a combination thereof. An example of such a hybrid material is formed of natural fibers and basalt fibers. As basalt may adhere to many resins, a woven material of natural fibers and basalt may increase adhesion to a resin of the entire material as compared with natural fibers alone. Natural fibers may include flax, for example. A woven material of flax and basalt may help the material adhere better to resins due to the presence of the basalt.

[0066] A hybrid material may be selected to combine fibers having high stiffness, high strength, stiffness, vibration damping, eco-friendliness, improved adhesion, or a combination thereof. Anexample of such a hybrid material is formed of natural fibers and carbon fibers. As carbon fibers may adhere to many resins better than natural fibers, such as flax, a woven material of natural fibers and carbon fibers may increase adhesion of the entire material to a resin as compared with natural fibers alone. A woven material of natural fibers, such as flax, and carbon fibers may help the material adhere better to resins due to the presence of the carbon fiber. The hybrid material may be a natural fiber and carbon fiber hybrid weave fabric. The carbon fiber may be generally oriented in one direction within the weave, while the natural fiber may be oriented in another direction within the weave. For example, the carbon fiber may be oriented generally perpendicular to the natural fibers. The orientation of the fibers as arranged on a paddle, for example, may be selected relative to an axis of the paddle (e.g., an axis generally parallel to the handle of the paddle). In an example, the carbon fiber may be oriented parallel to the handle and the natural fibers may be oriented perpendicular to the handle.

[0067] A hybrid material may be selected to combine fibers having high stiffness, vibration damping, strength, toughness, low cost, or a combination thereof. An example of such a hybrid material is formed of natural fibers and fiberglass. As fiberglass may adhere to many resins better than natural fibers, such as flax, a woven material of natural fibers and fiberglass may increase adhesion of the entire material to a resin as compared with natural fibers alone. A woven material of natural fibers, such as flax, and fiberglass may help the material adhere better to resins due to the presence of the fiberglass.

[0068] The skin may include a combination of two or more of the fibers or hybrid materials as described herein. A hybrid material may be a two-way, three-way or four-way co-woven hybrid fabric. The hybrid material may use multiple fiber types in a single layer. For example, the hybrid fabric may include two or more or three or more (e.g., three or four) fiber types woven together to combine the benefits of all the fibers. The hybrid fabric may be a biaxial, triaxial, or quadaxial fabric. Combining fiber types into a woven fabric may reduce cost of labor for laminate assembly since there are fewer layers to stack, as opposed to layering separate layers of each of the fiber materials.

[0069] One or more of the layers of the skin, some of the layers, or all of the layers may be impregnated with a resin and cured. It is contemplated that the final skin may be about 20% by weight of the skin or more resin, about 25% by weight or more resin, or about 30% by weight or more resin of the final skin. The final skin may be about 90% by weight of the skin or less resin, about 80% by weight of the skin or less resin, or about 70% by weight of the skin or less resin of the final skin. Any value or range of values within these values is within the scope of the teachings.Each layer may have a different percent by weight of resin. One or more layers may have the same percent by weight of resin. One or mor layers may be free of resin.

[0070] The resin may include, but is not limited to, epoxy resin, thermoplastic resin, thermoset resin, polyester resin, polypropylene resin, polylactic acid, ethylene vinyl acetate resin, vinyl ester resin, phenolic resin, bio resin, or a combination thereof. A combination of resins may be used within a single layer. A combination of resins may be used among the layers (e.g., one layer includes one resin, another layer includes a different resin). The resin may act to bond one or more layers together. The resin may provide desired properties to the paddle (e.g., toughness, durability, energy dissipation, stiffness, vibration damping, or a combination thereof).

[0071] The weight of each layer may be selected to provide sufficient strength, stiffness, or both to the paddle. The weight of each layer may be selected to be sufficiently lightweight for the user. Each layer may have a weight of about 20 gsm or greater, about 50 gsm or greater, about 75 gsm or greater, or about 100 gsm or greater. Each layer may have a weight of about 500 gsm or less, about 450 gsm or less, about 400 gsm or less, about 300 gsm or less, or about 200 gsm or less. At least some layers may have different weights from another layer. At least some layers may have the same or similar weights (e.g., within 50 grams per square meter (gsm) or less, within 25 gsm or less, within 10 gsm or less, or within 5 gsm or less) as another layer.

[0072] The paddles described herein may be treated and / or formed to develop a desirable texture (e.g., roughness) on the exterior surfaces of the paddle. The texture of the paddle is important for spinning the ball and also for allowing graphics and / or paint to adhere to the surface of the paddle. The allowable limits for roughness set forth by the USAPA shall be no greater than 30 micrometers (pm) on the Rz reading (average maximum height, peak to valley), and no greater than 40 micrometers (pm) on the Rt reading (maximum height, peak to valley).

[0073] The top surface coating of a skin may be a thin resin layer. The outermost layer of the skin may include a resin that forms the top surface, rather than or in addition to application of a separate coating. The thin resin layer may include a microtexture molded into the resin. A heated textured roller may be used to impart texture to the skin surface after it has cured where the texture on the roller presses the specific surface texture into the mold. The surface may have a sharp texture like a triangle wave and not a rolling texture like a sine wave. This sharp texture allows for more friction between the ball and striking surface compared to a rounded sine wave like texture.

[0074] Instead of or in addition to a top surface coating, the composite may include a thin veil. The veil may be positioned on or near the A-surface of the composite material (e.g., the surface of the composite material positioned away from the core). The veil may be a nonwoven material.The veil may be a woven material, such as with a biaxial weave. The veil may act to provide a smooth surface to the composite. For example, when positioned over a layer of the composite having a coarse weave or natural fibers, the veil may act to give a smoother surface as compared with the layer immediately beneath. A smooth surface may allow for application of a surface texture; allow for application of a coating or film; allow for application of another material or layer on top of the veil; allow for improved adhesion between layers or materials; or a combination thereof. The veil may be moldable to provide a surface texture. The veil may provide a clean surface upon which a molded texture, film, or spray is applied to achieve a desired surface for the composite. The veil may be impregnated with resin, fibers, or filler, for example, to provide a desired surface texture to the veil. The veil may be lightweight. For example, the veil may have a weight of about 2 gsm or greater, about 6 gsm or greater, or about 15 gsm or greater. The veil may have a weight of about 100 gsm or less, about 50 gsm or less, or about 25 gsm or less. The veil may include carbon fiber, fiberglass, basalt, heat-resistant synthetic fibers such as Kevlar®, natural fibers, the like or a combination thereof.

[0075] In an exemplary, non-limiting example, a skin may include three fabric layers and an optional top surface coating. The top surface coating may be a thin resin layer. The thin resin layer may have a micro texture molded into the resin to enhance or create a desirable spin surface.

[0076] The first layer directly below the optional top surface coating or serving as the outermost layer if no top surface coating is present may act to protect the layers beneath from UV, moisture, damage, or a combination thereof. The first layer may add stiffness and / or strength to the paddle, to the skin, or both. The first layer may create a flat or generally uniform surface upon which to apply the surface coating, so as to minimize texture from other layers below.

[0077] The first layer may have a weight of about 50 gsm or greater, about 75 gsm or greater, or about 100 gsm or greater. The first layer may have a weight of about 250 gsm or less, about 200 gsm or less, about 150 gsm or less, or about 125 gsm or less.

[0078] The first layer may be a woven material. The first layer may include glass fibers. The first layer may be, for example, fiberglass.

[0079] The second layer below the first layer (e.g., located between the core portion and the first layer) may be a material that acts to reduce vibrations. The second layer may add stiffness and / or durability to the paddle, to the skin, or both.

[0080] The second layer may have a weight of about 50 gsm or greater, about 75 gsm or greater, or about 100 gsm or greater. The first layer may have a weight of about 250 gsm or less, about 200 gsm or less, about 150 gsm or less, or about 125 gsm or less.

[0081] The second layer may be a unidirectional weave. The unidirectional weave may be formed of flax fibers. The unidirectional fibers of the second layer may be flax fibers that provide a desirable wooden or natural look to the user of the paddle.

[0082] The third layer beneath the second layer (e.g., located between the core portion and the first and second layers) may act to increase toughness, durability, energy dissipation, stiffness, vibration damping, or a combination thereof.

[0083] The third layer may have a weight that is greater than the weight of the first layer, the second layer or both. The third layer may have a weight of about 50 gsm or greater, about 100 gsm or greater, about 200 gsm or greater, or about 250 gsm or greater. The third layer may have a weight of about 500 gsm or less, about 350 gsm or less, or about 275 gsm or less.

[0084] The third layer may be a woven material. The third layer may be a twill material. The third layer may be a hybrid fabric material. For example, the third layer may be a twill woven basalt and ultra-high molecular weight polyolefin fiber (e.g., Innegra™, available from Innegra Technologies in Greenville, South Carolina).

[0085] In another non-limiting example with a three-layer skin or a skin having at least three layers (e.g., where the number of layers excludes any resin or adhesive layers), the first or outer layer may be a material including basalt. The first layer may have a weight of about 50 gsm or greater or about 100 gsm or greater. The first layer may have a weight of about 300 gsm or about 200 gsm or less. For example, the weight may be about 100 gsm to about 200 gsm. The layer may be a woven layer. The layer may have unidirectional basalt fibers. When arranged on a paddle, the fibers may be generally oriented parallel to the handle.

[0086] The second layer may be a fiberglass layer. The second layer may have a weight of about 20 gsm or greater. The second layer may have a weight of about 300 gsm or less or about 200 gsm or less. For example, the weight may be about 20 gsm to about 200 gsm. The second layer may be a woven layer. The second layer may have unidirectional fibers. When arranged on a paddle, the fibers may be generally oriented parallel to the handle.

[0087] The third layer may be a basalt layer or may include basalt. The third layer may be located adjacent to the core, a material including basalt. The third layer may have a weight of about 50 gsm or greater or about 100 gsm or greater. The third layer may have a weight of about 300 gsm or about 200 gsm or less. For example, the weight may be about 100 gsm to about 200 gsm. The layer may be a woven layer. The layer may have unidirectional basalt fibers. When arranged on a paddle, the fibers may be generally oriented parallel to the handle.

[0088] In another non-limiting example with a two-layer skin (e.g., where the number of layers excludes any resin or adhesive layers), the first layer may be a basalt layer. The first layer mayhave a weight of about 50 gsm or greater or about 100 gsm or greater. The first layer may have a weight of about 300 gsm or about 200 gsm or less. For example, the weight may be about 100 gsm to about 300 gsm. The layer may have unidirectional basalt fibers. When arranged on a paddle, the fibers may be generally oriented parallel to the handle. The first layer may be oriented away from the core of the paddle (e.g., at or toward the outermost position). The first layer may be oriented toward the core of the paddle.

[0089] The second layer may be another basalt layer. The layer may be a woven basalt layer. The weave may be a 0 / 90 degree orientation relative to an axis (e.g., an axis parallel to the handle of the paddle), a 45 / -45 degree orientation relative to an axis, or another angle. The second layer may have a weight of about 50 gsm or greater or about 100 gsm or greater. The second layer may have a weight of about 300 gsm or about 200 gsm or less. For example, the weight may be about 100 gsm to about 300 gsm. The second layer may be oriented toward the core of the paddle. The second layer may be oriented away from the core of the paddle (e.g., at or toward the outermost position).

[0090] In another non-limiting example with a two-layer skin or a skin having at least two layers (e.g., where the number of layers excludes any resin or adhesive layers), the first layer may be a basalt layer. The layer may be a woven basalt layer. The weave may be a 0 / 90 degree orientation relative to an axis (e.g., an axis parallel to the handle of the paddle), a 45Z-45 degree orientation relative to an axis, or another angle. The first layer may have a weight of about 50 gsm or greater or about 100 gsm or greater. The first layer may have a weight of about 300 gsm or about 200 gsm or less. For example, the weight may be about 100 gsm to about 300 gsm. The first layer may be oriented toward the core of the paddle. The first layer may be oriented away from the core of the paddle (e.g., at or toward the outermost position).

[0091] The second layer may be a natural fiber layer. The layer may have natural fibers that are generally arranged unidirectionally. When arranged on a paddle, the fibers may be generally oriented parallel to the handle. The second layer may have a weight of about 50 gsm or greater or about 100 gsm or greater. The second layer may have a weight of about 300 gsm or about 200 gsm or less. For example, the weight may be about 100 gsm to about 300 gsm. The second layer may be oriented toward the core of the paddle. The second layer may be oriented away from the core of the paddle (e.g., at or toward the outermost position).

[0092] In another non-limiting example with a two-layer skin or a skin having at least two layers (e.g., where the number of layers excludes any resin or adhesive layers), the first layer may be a basalt layer. The first layer may have a weight of about 50 gsm or greater or about 100 gsm or greater. The first layer may have a weight of about 300 gsm or about 200 gsm or less. Forexample, the weight may be about 100 gsm to about 300 gsm. The layer may have unidirectional basalt fibers. When arranged on a paddle, the fibers may be generally oriented parallel to the handle. The first layer may be oriented away from the core of the paddle (e.g., at or toward the outermost position). The first layer may be oriented toward the core of the paddle.

[0093] The second layer may be a natural fiber layer. The natural fibers may be woven. The weave may be a spread tow weave. The weave may be a 0 / 90 degree orientation relative to an axis (e.g., an axis parallel to the handle of the paddle), a 45Z-45 degree orientation relative to an axis, or another angle. The second layer may have a weight of about 50 gsm or greater or about 100 gsm or greater. The second layer may have a weight of about 300 gsm or about 200 gsm or less. For example, the weight may be about 100 gsm to about 300 gsm. The second layer may be oriented toward the core of the paddle. The second layer may be oriented away from the core of the paddle (e.g., at or toward the outermost position).

[0094] In another non-limiting example with a two-layer skin or a skin having at least two layers (e.g., where the number of layers excludes any resin or adhesive layers), the first layer may be a basalt layer. The basalt layer may be a woven basalt layer. The weave may be a plain weave. The first layer may have a weight of about 50 gsm or greater or about 100 gsm or greater. The first layer may have a weight of about 300 gsm or about 200 gsm or less. For example, the weight may be about 100 gsm to about 300 gsm. The first layer may be oriented away from the core of the paddle (e.g., at or toward the outermost position). The first layer may be oriented toward the core of the paddle.

[0095] The second layer may be a hybrid material. The hybrid material may be a hybrid weave fabric. The hybrid weave fabric may include natural fibers and carbon fiber. The carbon fiber may be oriented in a direction generally perpendicular to the natural fibers. When arranged on a paddle, the carbon fiber may be oriented generally parallel to the handle an the natural fibers may be oriented generally perpendicular to the handle. The second layer may have a weight of about 50 gsm or greater or about 100 gsm or greater. The second layer may have a weight of about 300 gsm or about 200 gsm or less. For example, the weight may be about 100 gsm to about 300 gsm. The second layer may be oriented toward the core of the paddle. The second layer may be oriented away from the core of the paddle (e.g., at or toward the outermost position).

[0096] In another non-limiting example with a two-layer skin or a skin having at least two layers (e.g., where the number of layers excludes any resin or adhesive layers), the first layer may be a natural fiber layer. The natural fibers may be woven. The weave may be a spread tow weave. The weave may be a 0 / 90 degree orientation relative to an axis (e.g., an axis parallel to the handle of the paddle), a 45 / -45 degree orientation relative to an axis, or another angle. The first layermay have a weight of about 50 gsm or greater or about 100 gsm or greater. The first layer may have a weight of about 300 gsm or about 200 gsm or less. For example, the weight may be about 100 gsm to about 300 gsm. The layer may have unidirectional basalt fibers. When arranged on a paddle, the fibers may be generally oriented parallel to the handle. The first layer may be oriented away from the core of the paddle (e.g., at or toward the outermost position). The first layer may be oriented toward the core of the paddle.

[0097] The second layer may be a hybrid material. The hybrid material may be a hybrid weave fabric. The hybrid weave fabric may include natural fibers and carbon fiber. The carbon fiber may be oriented in a direction generally perpendicular to the natural fibers. When arranged on a paddle, the carbon fiber may be oriented generally parallel to the handle an the natural fibers may be oriented generally perpendicular to the handle. The second layer may have a weight of about 50 gsm or greater or about 100 gsm or greater. The second layer may have a weight of about 300 gsm or about 200 gsm or less. For example, the weight may be about 100 gsm to about 300 gsm. The second layer may be oriented toward the core of the paddle. The second layer may be oriented away from the core of the paddle (e.g., at or toward the outermost position).

[0098] The present teachings contemplate other arrangements or combinations of layers, or of additional layers included with the non-limiting examples as presented herein.

[0099] Any of the layers or skins described herein may be bonded to a core of the paddle. The skins may be bonded to opposing sides of the paddle at the striking portion to form the sandwich panel, such that the core is sandwiched between two composite skins.

[0100] The skin may be bonded using an adhesive material. The skin may be bonded by an adhesive resin. The resin may be a thermoset resin. For example, the resin may be an epoxy resin, a polyester resin, a vinyl ester resin, or the like. The resin may be a thermoplastic resin. For example, the resin may be a polypropylene resin, an ethylene vinyl acetate resin, a polyester resin, or the like.

[0101] The resin may have a weight of about 25 gsm or greater, or about 50 gsm or greater. The resin may have a weight of about 300 gsm or less, or about 250 gsm or less.

[0102] The paddle may include a core structure. The core may be located between skins. The core may extend into the handle (e.g., within a shell of the handle). The core may be lightweight. The core structure may be formed of a lightweight material, such as foam, a polymeric core, aluminum honeycomb, and polymeric honeycomb. The core structure of a pickleball paddle may be rigid enough such that the pickleball paddle meets the requirements of the International Federation of Pickleball (IFP) and the USA Pickleball Association (USAPA). The core may have a porous structure. The core may have a plurality of cells. The core may be a single material. Thecore may be multiple materials. The core may include two or more core materials stacked together or nested within another core material.

[0103] The core may have a total thickness within the allowable range according to standards of the International Federation of Pickleball (IFP) and the USA Pickleball Association (USAPA). The core may have a thickness of about 5 mm or greater, about 10 mm or greater, or about 12 mm or greater. The core may have a thickness of about 20 mm or less, about 18 mm or less, or about 16 mm or less. For example, the core may be about 15 mm thick.

[0104] The core may have a density within the allowable range according to standards of the International Federation of Pickleball (IFP) and the USA Pickleball Association (USAPA). The core may have a density of about 1 lb / ft3or greater, about 2 lb / ft3or greater, or about 3 lb / ft3or greater. The core may have a density of about 10 lb / ft3or less, about 8 lb / ft3or less, or about 6 lb / ft3or less. For example, the core may have a density of about 4 lb / ft3.

[0105] The core may include a honeycomb structure having one or more cells. The honeycomb structure may be formed of a polymeric material. The polymeric material may include polypropylene, polycarbonate, polyethylene terephthalate (PET), recycled polyethylene terephthalate (rPET), polyester, the like, or a combination thereof. The honeycomb structure may be an aramid polymer. For example, the core may include a flame-resistant meta-aramid material, such as Nomex®, available from DuPont.

[0106] The core may include a foam material. The core may include an open-cell foam. The core may include a closed-cell foam. The foam may be a polymeric foam. The foam may be a urethane or polyurethane foam. The foam may include ethylene vinyl acetate, urethane, polypropylene, PET, rPET, the like, or a combination thereof, for example.

[0107] The core may include a lightweight material. The core may include a natural material, such as wood. For example, the core may include balsa wood.

[0108] The paddle may require reinforcement in one or more areas. Reinforcement may provide stability and strength to the paddle. Reinforcement may provide sufficient flex to the paddle without breakage. Reinforcement may be added to the core. The core, or portions thereof, may be free of any reinforcement materials. The core may include one or more reinforcement materials. Reinforcement materials may be lightweight or not add considerable weight to the paddle. Reinforcement materials may be compressive resistant and / or bend resistant materials. For example, the core may include one or more materials adapted to fill at least a portion of a void within a cell. The core may be filled with one or more materials. For example, the core may be foam-filled, epoxy-filled, hotmelt-filled, the like, or a combination thereof. The core may be reinforced by one or more laminate materials. The core may be reinforced with a stiff bandingmaterial. Laminate reinforcement may be combined with other filling options (e.g., hotmelt, foam, epoxy, the like, or a combination thereof). Laminate reinforcement may be positioned on the core. Laminate reinforcement may be positioned on top of, beneath, surrounding (e.g., like a tube) the filling material, or a combination thereof.

[0109] The entirety of the core may be reinforced with one or more reinforcement materials. The core may be selectively reinforced. Reinforcement of the paddle may be provided in areas most likely to break or experience the most stress. For example, reinforcement of the core near the neck of the paddle may be desirable to increase durability in the stress point of the handle. Reinforcement may be added in the sandwich panel above the handle, underneath the grip surface or handle shell, or both.

[0110] The paddle includes a handle portion where the paddle is held by a user. The handle portion may include core material. The handle portion may include a shell surrounding the core material. The handle portion may include infill (e.g., to fill any open space between the core and the handle shell). The handle portion may include a frictional surface for gripping the handle, for ensuring the handle does not slip out of the user’s hand, or both. The handle portion may include a grip material (e.g., grip tape surrounding a shell). The handle portion may include one or more structures to reinforce the core, one or more structures for the user to grip, one or more customizable structures, an end cap, or a combination thereof.

[0111] The handle may have performance or comfort advantages over traditional handles. The handle may have increased comfort and / or strength as compared with traditional handles. The handle may have reduced cost or reduced complexity for production and / or assembly as compared with traditional handles. The handle may be customizable for a specific user, (e.g., with specific dimensions for that unique player). The handle may be customized for a particular type of user (e.g., male, female, child, larger hands, smaller hands, left-handed user, right-handed user). The handle may have a customized length, width, girth, shape, weight, balance, or a combination thereof. The handle may have a customized grip to accommodate a particular hand or particular hand size. The handle may have a customized weight. The infill percentage or type of infill may be selected based on the desired weight of the handle.

[0112] The handle may include a shell that fits over a portion of the core. The shell may be a single piece that is capable of sliding over a unibody construct. The shell may be multiple pieces (e.g., two or more) that secure to each other around the core. The shell may be made of any material capable of withstanding stresses associated with playing pickleball. The shell may be a lightweight material. The shell may be made of a moldable material. The shell may be made of a polymeric material. The shell may be made of a polyester material. The shell may be madeof a material having high strength, low melting point, low thermal expansion, good layer adhesion, high heat resistance, or a combination thereof. For example, the shell may be made of or may include polylactic acid. The shell may be a continuous material extending around the handle. The shell may be a frame capable of supporting another material (e.g., grip tape, a composite skin) wrapped or otherwise positioned therearound. The shell may include an end cap positioned at the end of the handle.

[0113] The shell may be made by any suitable process capable of producing a shaped part. For example, the shell may be injection molded. The shell may be made from machined composite or plastic base material. The shell may be made through 3D printing. The shell may be a single piece. The shell may be two or more pieces. Where two or more pieces are employed, they may be secured together via one or more interlocking features, one or more snaps, one or more adhesives, one or more tapes (e.g., grip tape), one or more fasteners, one or more curable materials, one or more expandable materials, the like, or a combination thereof. The handle may undergo one or more curing steps so the handle is in proper position, the desired infill is achieved, or both.

[0114] The shell may have a shell length measured from one end of the shell to the other end of the shell. The shell may include one or more extended portions that extend toward the striking portion (e.g., toward or into the tapered portion). The extended portions may provide additional strength to the handle, particularly in areas where the most stress is put on the paddle during use. The extended portions may provide an attachment surface for other portions of the paddle, such as a skin, a fastener, grip tape, the like, or a combination thereof. The extended portion may include one or more openings or voids. The openings or voids may act to receive a fastener, an adhesive, or to reduce weight of the shell.

[0115] The shell may have an interior length, interior width, and interior thickness. The interior dimensions may be of sufficient size such that it can receive the core of the paddle that is part of the handle portion. The interior dimensions may be of sufficient size that it can receive a desired type or amount of infill to provide desired features, such as desired paddle / handle weight, desired strength, or the like.

[0116] The shell may have a shell body that has a length, a width, and a thickness. The shell body may be the portion of the handle a user holds during use. The shell may terminate at an end portion. The end portion may have a greater width, thickness, or both than the shell body. This may provide additional stability to the paddle, provide additional weight at the end of the paddle for increased balance, improve feel of the paddle in the user’s hand, prevent the paddle from sliding out of the user’s hand, or a combination thereof.

[0117] The shell may include an end cap. The end cap may have an outer face portion. The outer face portion may have a generally flat surface, a generally rounded surface, or areas that are generally flat and areas that have a general curve. The end cap may allow for additional customization, such as by providing a surface for application of a logo, name tag, or other identifying feature.

[0118] Turning now to the figures, Figures 1 A and 1 B show an exemplary paddle 100. The paddle 100 includes a striking portion 102, a tapered portion 104 leading to a handle portion 106, which terminates at an end cap 108. An edge guard 110 surrounds the striking portion 102 and at least a portion of the tapered portion 104. The edge guard 110 includes generally straight surfaces and generally curved surfaces that follow the contours of the paddle.

[0119] The striking portion 102 is a sandwich panel 112 (see, e.g., Fig. 9) with a core 120 sandwiched between skins 130 (e.g., a first skin 132 and an opposing second skin 134).

[0120] Figure 2 shows a core 120 having a plurality of cells. As shown, the core is not reinforced. Figures 3-6 show possible reinforcement materials for a core 120. Figure 3 shows a foam-filled core 120. Figure 4 shows an epoxy-filled core 120. Figure 5 shows a hotmelt- filled core 120. Figure 6 shows a laminate reinforced core 120. Laminate reinforcement may be used alone or in combination with filling reinforcement (e.g., foam-filled, epoxy-filled, hotmelt-filled). As shown in Figure 6, the laminate reinforcement material 122 is positioned around the edge of the core 120.

[0121] Figure 7 shows an underside of an exemplary skin, where the visible layer includes a basalt / ultra-high molecular weight polyolefin fiber hybrid layer. The dark fibers are the basalt fibers. The lighter fibers are the ultra-high molecular weight polyolefin fibers.

[0122] Figure 8 shows a top view of an exemplary skin, where a transparent fiberglass layer is the top layer. A semi-transparent unidirectional flax layer is located beneath the fiberglass layer. A basalt / ultra-high molecular weight polyolefin fiber hybrid layer is located beneath the unidirectional flax layer.

[0123] Figure 9 shows a complete sandwich panel 112. The sandwich panel 112 includes a core 120, shown as a polypropylene honeycomb core, and a skin 130. A first skin 132 is visible in the figure, and an opposing second skin 134 is located on the opposing surface of the core 120.

[0124] Figures 10-13 illustrate exemplary layers of skins 130 in an exploded view. Adhesives, resins, or other methods of attachments between layers are omitted for clarity. It is contemplated that other configurations, numbers, or arrangements of layers are also within thescope of the teachings herein. For example, the skin may have more than three layers. The first layer 136 may be positioned facing or adjacent to the core. The first layer may be positioned away from the core (e.g., acting as an outer layer or toward an outer layer).

[0125] Figure 10 illustrates a skin having a first layer 136 and a second layer 138. In this example, the first layer 136 is a layer having unidirectional fibers. The unidirectional fibers are shown as extending generally parallel to an axis l_A. Where the skin 130 is applied to a core 120 of a paddle, for example, the axis LAmay be generally parallel to the handle. The second layer 138 is shown as a woven layer. In this example, the woven layer has a 0 / 90 degree orientation, where some fibers extend generally parallel to the axis l_Aand other fibers extend generally perpendicular to the axis l_A.

[0126] It is also contemplated that the skin 130 may have unidirectional fibers that extend generally perpendicular to the axis LA. It is also contemplated that the skin 130 may have unidirectional fibers that extend in a direction that is neither parallel to nor perpendicular to the axis l_A. It is contemplated that the woven fibers may have a 45 / -45 degree orientation, where the fibers extend in directions perpendicular to each other but form an angle of 45 degrees and -45 degrees with the axis l_A.

[0127] Figure 11 illustrates a skin 130 having a first layer 136 and a second layer 138. In this example, the first layer 136 is a woven layer and the second layer 138 is a woven layer. Both woven layers are shown as having a 0 / 90 degree orientation, where some fibers extend generally parallel to the axis LAand other fibers extend generally perpendicular to the axis LA. It is contemplated that the woven fibers may instead extend in a 45 / -45 degree orientation, where the fibers extend in directions perpendicular to each other but form an angle of 45 degrees and -45 degrees with the axis l_A. Other angles therebetween are also possible and within the scope of the teachings herein.

[0128] Figure 12 illustrates a skin 130 having a first layer 136 and a second layer 138. In this example, the first layer 136 is a woven layer and the second layer 138 is a woven layer. One woven layer is shown as having a 0 / 90 degree orientation, where some fibers extend generally parallel to the axis LAand other fibers extend generally perpendicular to the axis l_A. In the other woven layer, the woven fibers extend in a 45 / -45 degree orientation, where the fibers extend in directions perpendicular to each other but form an angle of 45 degrees and -45 degrees with the axis LA.

[0129] Figure 13 illustrates a skin 130 having a first layer 136, a second layer 138, and a third layer 140. In this example, the first layer 136 and the third layer 140 have unidirectional fibers that extend in a direction generally parallel to the axis l_A. The second layer is a woven layershown as having a 0 / 90 degree orientation, where some fibers extend generally parallel to the axis LA and other fibers extend generally perpendicular to the axis LA.

[0130] Variations are also contemplated. For example, one unidirectional layer may have fibers oriented generally parallel to the axis LAwhile another unidirectional layer has fibers oriented generally perpendicular to the axis LA. The woven layer may have fibers extending in a different orientation, such as a 45 / -45 degree orientation, where the fibers extend in directions perpendicular to each other but form an angle of 45 degrees and -45 degrees with the axis LA, for example. All three layers of the skin may have unidirectional fibers. All three layers of the skin may be woven. Where there are multiple layers that have unidirectional fibers, two or more of the layers may have fibers extending in a direction generally parallel to each other. Where there are multiple layers that have unidirectional fibers, two or more layers may have fibers extending in directions that are not generally parallel to each other (e.g., perpendicular or another angle). Where there are multiple woven layers, two or more of the woven layers may have fibers extending in directions generally parallel to each other. Where there are multiple woven layers, two or more of the woven layers may have fibers extending in directions that are not generally parallel to each other. The woven layers may be formed from the same or different weaving processes. For example, a woven layer may be a plain weave, a spread tow weave, a hybrid weave with different fiber types, a basket weave, a satin weave, a biaxial weave (e.g., 45Z-45, 0 / 90, 60 / -60, 30 / -30), a triaxial weave (e.g., 45 / -45 / 0, 30 / -30 / 0, 60-60 / 0), a quadaxial weave (e.g., 0 / 90 / -45 / 45), or a combination thereof.

[0131] Figure 14A shows a sandwich panel 112 with a handle portion 106. A shell 140 is shown in an exploded view, having a first part 142 and a second part 146 that join to form the shell of the handle portion. The shell 140 is a generally hollow member capable of receiving the handle portion of the sandwich panel.

[0132] Figure 14B shows a shell 140 in an assembled configuration. The shell 140 includes a shell body 146, an end portion 148, and a pair of extended portions 150 that extend toward the striking portion of the paddle when installed on the paddle.

[0133] Figures 15A, 15B, and 15C illustrate an exemplary shell 140. The shell 140 includes a shell body 146 and an end portion 148. At the opposing end are a pair of extended portions 150.

[0134] Figure 15A is a side view of the shell 140, with the pair of extended portions 150 extending upwardly. The shell has an interior thickness Tis measured between the two extended portions 150.

[0135] Figure 15B is a front view of the shell 140. The shell has a length Ls, measured from the top of an extended portion 150 to the end of the end portion 148. The body portion 146 has a width WB. The end portion has a length LEPand a width WEp, where the width is measured at the widest point. The width of the end portion is greater than the width of the body portion.

[0136] Figure 15C is a cutaway view of the shell 140 taken along line A-A of Figure 11 A. The hollow portion of the shell interior has a width W|S. The hollow portion of the shell interior is shown as a generally constant width, though a variable width is also possible. The hollow portion of the shell interior has a length L|S. The dimensions of the interior may be sufficient to receive a portion of the core or sandwich panel in the handle portion, filler material, adhesive materials, or a combination thereof.

[0137] The handle portion may include a grip tape or other frictional surface affixed to or incorporated into the shell to allow for additional grip, cushioning, or other customization of the handle.

[0138] Figure 16 illustrates an exemplary end cap 108. The end cap has a thickness TEC. The end cap has an outer face portion 152, where a logo or other design may be affixed, printed, molded, or otherwise positioned for allowing additional customization for the paddle.

[0139] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the teachings. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the teachings. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the teachings.

[0140] As utilized herein with respect to numerical ranges, the terms "approximately,” “about,” “substantially,” and similar terms generally mean + / - 10% of the disclosed values, unless specified otherwise. As utilized herein with respect to structural features (e.g., to describe shape, size, orientation, direction, relative position, etc.), the terms "approximately,” “about,” “substantially,” and similar terms are meant to cover minor variations in structure that may result from, for example, the manufacturing or assembly process and are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.

[0141] It should be noted that the term “exemplary” and variations thereof, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

[0142] The term “coupled” and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic.

[0143] References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

[0144] Although the figures and description may illustrate a specific order of method steps, the order of such steps may differ from what is depicted and described, unless specified differently above. Also, two or more steps may be performed concurrently or with partial concurrence, unless specified differently above.

[0145] It is important to note that any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. Even where only one example of an element from one embodiment that can be incorporated or utilized in another embodiment has been described above, it should be appreciated that other elements of the various embodiments may be incorporated or utilized with any of the other embodiments disclosed herein.

[0146] As used herein, unless otherwise stated, the teachings envision that any member of a genus (list) may be excluded from the genus; and / or any member of a Markush grouping may be excluded from the grouping.

[0147] Unless otherwise stated, any numerical values recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component, a property, or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that intermediate range values such as (for example, 15 to 85, 22 to 68, 43 to 51 , 30 to 32 etc.) are within the teachings of this specification. Likewise, individual intermediate values are also within the present teachings. For values which are less than one, one unit is considered to be 0.0001 , 0.001 , 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

[0148] Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of "about" or "approximately" in connection with a range applies to both ends of the range. Thus, "about 20 to 30" is intended to cover "about 20 to about 30", inclusive of at least the specified endpoints.

[0149] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The term "consisting essentially of” to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms "comprising" or "including" to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist of, or consist essentially of the elements, ingredients, components or steps.

[0150] Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of "a" or "one" to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps.

[0151] It is understood that the above description is intended to be illustrative and not restrictive. Many embodiments as well as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

Claims

CLAIMSWhat is claimed is:

1. A composite comprising: a skin including a plurality of layers, wherein one or more of the layers has a weight of about 20 gsm or greater and about 400 gsm or less; wherein the layers include: a) one or more fabric layers having unidirectional fibers; b) one or more woven layers; or c) both a) and b).

2. The composite of claim 1 , wherein the skin is adapted to be used for sporting equipment.

3. The composite of claim 2, wherein the sporting equipment is a sport or game paddle.

4. The composite of any of the preceding claims, wherein the skin includes 2 or more layers.

5. The composite of any of the preceding claims, wherein the skin includes 8 or fewer layers.

6. The composite of any of the preceding claims, wherein each of the layers have a weight of about 20 gsm or greater and about 400 gsm or less.

7. The composite of any of the preceding claims, wherein one or more of the layers has a weight of about 100 gsm to about 300 gsm.

8. The composite of any of the preceding claims, wherein at least two of the layers have a weight of about 100 gsm to about 300 gsm.

9. The composite of any of the preceding claims, wherein one or more of the layers has a weight of about 20 to about 200 gsm.

10. The composite of any of the preceding claims, wherein one or more of the layers include natural fibers, carbon fibers, glass fibers, basalt fibers, ultra-high molecular weight polyolefin fibers, or a combination thereof.

11. The composite of any of the preceding claims, wherein at least one layer is a unidirectional natural fiber layer (e.g., flax).

12. The composite of any of the preceding claims, wherein at least one layer is a woven natural fiber layer and optionally a spread tow woven natural fiber layer.

13. The composite of any of the preceding claims, wherein at least one layer is a unidirectional basalt layer.

14. The composite of any of the preceding claims, wherein at least one layer is a woven basalt layer.

15. The composite of any of the preceding claims, wherein at least one layer is a fiberglass layer.

16. The composite of any of the preceding claims, wherein at least one layer is a hybrid weave fabric layer.

17. The composite of claim 16, wherein the hybrid weave fabric is a natural fiber / carbon fiber hybrid weave fabric.

18. The composite of any of the preceding claims, wherein the composite includes a top surface coating.

19. The composite of claim 18, wherein the top surface coating comprises a thin resin layer with an optional microtexture molded therein.

20. The composite of claim 19, wherein one or more of the layers is a first layer located beneath the top surface coating.

21. The composite of any of the preceding claims, wherein the composite includes a first layer and a second layer.

22. The composite of claim 20 or 21 , wherein the first layer is a woven layer or a layer having unidirectional fibers.

23. The composite of any of claims 20 to 22, wherein the first layer has a weight of about 100 gsm to about 300 gsm.

24. The composite of any of claims 21 to 23, wherein the second layer is a fabric having unidirectional fibers or a woven layer.

25. The composite of any of claims 21 to 24, wherein the second layer has a weight of about 20 gsm to about 300 gsm, or about 100 gsm to about 300 gsm.

26. The composite of any of the preceding claims, wherein one or more of the layers is a third layer.

27. The composite of claim 26, wherein the third layer has a weight of about 100 gsm to about 325 gsm.

28. The composite of claim 26 or 27, wherein the third layer is a woven fabric or a fabric having unidirectional fibers.

29. The composite of any of the preceding claims, wherein at least one layer is a twill woven fabric.

30. The composite of any of the preceding claims, wherein at least one layer comprises basalt.

31. The composite of any of the preceding claims, wherein at least one layer comprises an ultra-high molecular weight polyolefin fiber (e g., Innegra).

32. The composite of any of the preceding claims, wherein at least one layer is a basalt and an ultra-high molecular weight polyolefin hybrid layer.

33. The composite of any of the preceding claims, wherein at least one of the layers is impregnated with a resin.

34. The composite of claim 33, wherein the resin is a thermoplastic resin or thermoset resin.

35. A paddle comprising the composite of any of the preceding claims.

36. The paddle of claim 35, wherein the paddle includes the composite of any of the preceding claims on opposing sides of the paddle.

37. The paddle of claim 35 or 36, wherein the paddle includes a handle portion, wherein the handle portion optionally includes a shell.

38. The paddle of claim 37, wherein at least one of the layers of the composite has unidirectional fibers oriented generally parallel to the handle portion.

39. The paddle of claim 37 or 38, wherein at least one of the layers is a woven layer having at least a portion of the fibers oriented generally parallel to the handle portion.

40. The paddle of any of claims 37 to 39, wherein the shell is formed of a single piece.

41. The paddle of any of claims 37 to 40, wherein the shell is formed of two or more pieces.

42. The paddle of any of claims 37 to 41 , wherein the shell is formed by injection molding,3D printing, or both.

43. A paddle comprising: a. a core; b. a first skin comprising the composite of any of the preceding claims; c. a second skin comprising the composite of any of the preceding claims; wherein the first skin and the second skin sandwich the core.

44. The paddle of claim 43, wherein the paddle includes a handle portion.

45. The paddle of claim 43, wherein the handle portion includes a portion of the core.

46. The paddle of claim 44 or 45, wherein the handle portion includes a three-dimensional printed shell.

47. The paddle of any of claims 43 to 46, wherein the first skin, the second skin, or both is about 30% by weight or greater resin, about 70% by weight or less resin, or both.

Images