Pick racket

Abstract

The present application provides a pike racket including a handle portion and a head portion coupled to the handle portion. The head portion may include an outer frame extending around the opening, a core within the opening, and a core flexure member extending between the perforated core and the handle portion within the opening.

Description

BACKGROUND

[0001] Pickleball is the fastest growing racquet sport. There is an ongoing need for pickleball racquets that can improve a player's performance and / or confidence. BRIEF DESCRIPTION OF DRAWINGS

[0002] Figure 1 is an elevational view showing portions of an example pickleball racquet.

[0003] Figure 2 is a cross-sectional view of the pickleball racquet in Figure 1 taken along line 2-2.

[0004] Figure 3 is a cross-sectional view of one example embodiment of the pickleball racquet in Figure 1 taken along line 2-2.

[0005] Figure 4 is a cross-sectional view of one example embodiment of the pickleball racquet in Figure 1 taken along line 2-2.

[0006] Figure 5 is a cross-sectional view of one example embodiment of the pickleball racquet in Figure 1 taken along line 2-2.

[0007] Figure 6 is a cross-sectional view of one example embodiment of the pickleball racquet in Figure 1 taken along line 2-2.

[0008] Figure 7 is an elevational view showing portions of an example pickleball racquet.

[0009] Figure 8 is an elevational view showing portions of an example pickleball racquet.

[0010] Figure 9 is an elevational view of portions of a pickleball racquet.

[0011] Figure 10 is a cross-sectional view of the pickleball racquet of Figure 9 .

[0012] Figure 11 is an elevational view showing portions of an example pickleball racquet of Figure 9 .

[0013] Figure 12 is a cross-sectional view of the pickleball racquet in Figure 11 taken along line 12-12.

[0014] Figure 13 is an end view of the pickleball racquet in Figure 11 .

[0015] Figure 14 is Figure 11 a cross-sectional view taken along line 14-14 of the pickleball paddle in

[0016] Figure 15 is a perspective view of a ply or layer arrangement of fiber composite layers.

[0017] Figure 16 is Figure 15 a top perspective view of a ply of fiber composite layers of

[0018] Figure 17 is Figure 15 a perspective view of a ply of fiber composite layers in

[0019] Figure 18 is a perspective view of a ply of fiber composite deposition material layers and a yoke fiber composite ply, wherein the ply of fiber composite deposition material layers is removed from the mandrel and bent to approximate the shape of a pickleball paddle.

[0020] Figure 19 is Figure 18 a perspective view of a ply of fiber composite layers in

[0021] Figure 20 is an exploded perspective view of placing the plies of layers into a pickleball outer frame forming mold.

[0022] In all of the drawings, like reference numerals refer to like parts throughout the several views. The drawings are not necessarily to scale; the emphasis instead being placed on the principles of the example(s) and / or embodiment(s). Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. Additionally, the drawings provide examples and / or embodiments consistent with the description; however, the description is not limited to the examples and / or embodiments provided in the drawings. DETAILED DESCRIPTION

[0023] Some examples of pickleball paddles are disclosed herein that can improve a player's performance. These example pickleball paddles have internal structures to help isolate the main sweet spot and impact area of the paddle from the handle portion of the paddle. In some embodiments, the internal structures can dampen the vibrations and other forces generated from a pickleball impact, thereby inhibiting the transfer of these forces to the handle portion of the pickleball paddle. In some embodiments, the internal structures enhance the responsiveness of the impact portion of the pickleball by promoting a degree of float or movement of the impact area (sometimes referred to as a core) relative to the handle portion.

[0024] Unless otherwise noted, example racquet balls meet the requirements or standards for racquet balls used in officially sanctioned events or competitive play. Unless otherwise noted, example racquet balls meet the requirements specified in the 2023 edition of the USA Racquetball Equipment Standards Manual. Unless otherwise noted, example racquet balls have a maximum length and a maximum width that sum to less than or equal to 24 inches. Unless otherwise noted, example barrel racquet balls have opposing racquet ball striking surfaces with a maximum dynamic coefficient of friction of less than or equal to 0.1875 when tested in accordance with protocol IAW ASTM D1894-14. It will be appreciated that the specific properties of example racquet balls can be modified such that the racquet ball no longer meets the requirements or standards for racquet balls used in officially sanctioned events or competitive play, but such modified racquet balls still incorporate the performance enhancing features disclosed in example racquet balls.

[0025] The present application discloses an example racquet ball that includes a handle portion and a head portion. The head portion is coupled to the handle portion. The head portion can include an outer frame extending around an opening, a racquet ball striking area or “core” located within the opening, and a core flexing member located within the opening extending between the core and the handle portion. In some embodiments, the outer frame can be a tube having an interior space. In some embodiments, the tube can include external grooves, indentations, or channels along the top and / or sides of the head portion that can potentially increase the strength and stiffness of the outer frame.

[0026] In some embodiments, the tube can be filled with other materials, such as foam, within the tube. In some embodiments, the tube can be free of any materials within the tube, or can contain a bladder or other volume that is free of any solid materials, but the bladder or other volume contains a gas, such as air, within the bladder or other volume. In some embodiments, the tube can be pressurized with a gas (e.g., air) within the tube during the molding and shaping process of the tube to form the outer frame. In some embodiments, the outer frame is made of one or more fiber composite materials that are initially formed around a bladder supported by a mandrel, where the mandrel is removed and the bladder is inflated during the molding of the tube (and curing or hardening of the fiber composite materials). In other embodiments, the tube can be made of other materials and can be formed in other ways. In some embodiments, the tube can be formed and hardened with an inflated bladder, and subsequently the inflated bladder is deflated and removed after the tube is hardened and shaped.

[0027] In some embodiments, the tubular can additionally form portions of the handle portion. For example, in some embodiments, the tubular can form a loop so as to form the head portion, with the end portions of the tubular extending substantially parallel to each other and forming an inner core of the handle portion. In some embodiments, an additional yoke piece can be secured across spaced apart portions of the loop opposite the handle portion, with an opening provided between the yoke and the handle portion in the pickleball paddle.

[0028] In the examples of the pickleball paddle disclosed above, the core is perforated. In some embodiments, the core can include one or more layers having a honeycomb configuration or honeycomb core. In some embodiments, the core can include one or more layers having a lattice. For example, the core can include a lattice formed by additive manufacturing (e.g., 3D printing). The perforated nature of the core provides a certain stiffness while also reducing the weight of the pickleball paddle. In yet further embodiments, the core can be non-perforated. In some embodiments, the core has a compressive stiffness of at least 200 psi (pounds per square inch) and no more than 300 psi (measured according to ASTM C365).

[0029] In the embodiments of the pickleball paddle disclosed above, the core flexing member extends partially around or partially encloses the core. For example, the core flexing member can have a semi-circular or U-shaped structure around the lower perimeter of the core between the core and the handle portion. In some embodiments, the core flexing member can completely wrap or extend around the perimeter of the core in a continuous manner without interruption. In some embodiments, the core flexing member can extend on all sides of the core, along the top and bottom of the core, and both sides of the core, but where the core flexing member includes a plurality of different spaced apart sections or segments along and around the core. In some embodiments, the core flexing member can have a uniform width along its extent. In other embodiments, the core flexing member can have a varying width along its extent, for example, with increased thickness of the core flexing member in those areas proximate to the handle portion and decreased thickness in those areas distal from the handle portion. In some embodiments, the width of the core flexing member is at least 5 mm, at least in the region between the core portion and the handle portion. In some embodiments, the width of the core flexing member is at least 10 mm, at least in the region between the core portion and the handle portion. The increased width can provide a greater coefficient of restitution and enhance the bending performance of the core.

[0030] The core flex component has a stiffness or hardness that is less than the stiffness or hardness of the core. The core flex component can have a higher compressibility than the compressibility of the core. In some embodiments, the core flex component comprises a foam material that forms a foam layer. In one embodiment, the core flex component comprises a foam polymer. In some embodiments, the core flex component comprises an ethylene vinyl acetate (EVA) foam having a density of 2 to 6 pounds. In some embodiments, the core flex component has a Shore 00 hardness of 40 to 60.

[0031] In some embodiments, the core flex component is made of other polymer foam materials, such as urethane foam or polyurethane foam. In other embodiments, the core flex component can comprise a flexible compressible sleeve, tube, or film that is hollow on the inside, or filled with a material that is more flexible and / or compressible than the material that forms the core. In other embodiments, the core flex component can have other structures or be made of other materials.

[0032] For purposes of the present disclosure, the word “coupled” shall mean the joining of two members directly or indirectly to one another. Such joining can be stationary or moveable in nature. Such

[0033] For purposes of the present disclosure, the phrase “configured to” means physically and / or structurally designed to perform the function / usage indicated in the phrase “configured to” prior to the physical characteristics of the feature that is the subject of the phrase “configured to”.

[0034] For purposes of the present disclosure, the term “releasable” or “removable” with respect to the attachment or coupling of two structures means that the two structures can be repeatedly connected and disconnected to one another without causing substantial damage to either of the two structures or their functionality.

[0035] Figure 1 and Figure 2 A partial structure of an example pickleball paddle 20 is shown. The structure of the pickleball paddle 20 can enhance a player’s performance. Figure 2 is along Figure 1FIG. 2 is a cross-sectional view of the racquet 20 taken along line 2-2 in FIG. 1. The internal structure of the racquet 20 helps to isolate the main sweet spot or center point of the racquet and the impact area from the handle portion of the racquet. The internal structure can dampen the vibrations and other forces generated by impact with a pickleball and inhibit the transmission of these forces to the handle portion of the racquet. The internal structure of the racquet 20 helps to enhance the responsiveness of the impact portion of the racquet by facilitating a degree of float or movement of the impact area (sometimes referred to as the core) relative to the handle portion.

[0036] The racquet 20 meets the requirements or standards for a pickleball racquet used in officially sanctioned events or competitive play. Unless otherwise noted, each example pickleball racquet meets the requirements set forth in the 2023 November edition of the USA Pickleball Equipment Standards Manual. The combined maximum length and maximum width of the racquet 20 is less than or equal to 24 inches. The racquet 20 has an opposing pickleball impact surface having a maximum dynamic coefficient of friction that is less than or equal to 0.1875 when tested in accordance with protocol IAW ASTM D1894-14.

[0037] The racquet 20 includes a handle portion 24 and a head portion 28. The head portion 28 is coupled to the handle portion 24 and includes an outer frame 32 extending around an opening 34, a core 36, a core flexing member 40, and face panels 44-1 and 44-2 (collectively, face panels 44). The handle portion 24 is sized to be easily held by a player’s hand. In some embodiments, the handle portion 24 can have a circular or oval cross-section. In other embodiments, the handle portion 24 can have a polygonal cross-section. The handle portion 24 can include an outer wrapping member, such as a polymeric, rubber, or leather material. In some embodiments, the handle portion 24 has an internal core provided by an extension of the outer frame 32. In other embodiments, the handle portion 24 can be joined or fixed to the outer frame 32.

[0038] The head portion 28 provides a ball striking surface for the racquet 20. The outer frame 32 forms an outer rim that extends around the opening 34 and forms a perimeter of the head portion 28. In some embodiments, a dampening member, a cushioning member, a weight, or a wrapping member made of a protective material can be provided on the outside of the outer frame 32. The outer frame 32 and the handle portion 24 define a maximum width of the racquet 20 and together define a maximum length of the racquet 20. The outer frame 32 and the handle portion 24 meet the requirements set forth in the 2023 November edition of the USA Pickleball Equipment Standards Manual. The entire length of the racquet 20, i.e., extending from the truncated end of the handle portion 24 to the top of the head portion 28, forms the maximum length of the racquet 20. The maximum width of the head portion 28 (measured perpendicular to the central axis of the handle portion 24) forms the maximum width of the racquet 20. The sum of the maximum length and the maximum width of the racquet 20 is less than or equal to 24 inches.

[0039] The outer frame 32 can be a shaped strip or tubular material that forms a loop that defines the opening 34. As noted above, in some embodiments, portions of the strip or tube can further extend in parallel to form a core of the handle portion 24. In some embodiments, the strip or tube that makes up the outer frame 32 can be solid, without any internal voids, lumens, or internal cavities. If the strip or tube has internal voids, the voids can be filled with other materials, such as foam. In some embodiments, the strip or tube that forms the outer frame 32 can have a hollow interior, without any solid material or filler. For example, the interior of the hollow strip or tube can contain a gas, such as air.

[0040] The core 36 extends across and fills a substantial portion of the opening 34 defined by the outer frame 32. In the illustrated example, the core 36 is perforated, having openings, channels, or voids that extend completely through the core 36 from the first surface to the second, opposite surface. In some embodiments, the core 36 can have a honeycomb structure. For example, the core 36 can be made of a polymeric material, such as polyethylene. In other embodiments, the core 36 can be formed of other materials, such as other polymers or plastics. In other embodiments, the core 36 can have a lattice structure. For example, the core 36 can include any of the lattice structures described in pending U.S. Patent Application Serial No. 17 / 177,899, entitled “Pickleball Paddle,” filed February 17, 2021, to Thurman et al., the entire disclosure of which is incorporated by reference herein. In other embodiments, the core 36 can be non-porous. For example, the core 36 can be formed of solid wood, polymeric, or foam materials that have greater rigidity and less compressibility than the core flex member 40. In some embodiments, the core 36 can be made of one or more layers of non-foam polymeric material with perforations, foam layers with perforations, cellulose (wood) or paperboard-based materials with perforations, and the like, where the core 36 has greater rigidity and / or less compressibility than the core flex member 40. In some embodiments, the core 36 has a compressive stiffness of at least 200 psi (pounds per square inch) and no more than 300 psi (measured according to American Society for Testing and Materials (ASTM) C365 standard). In other embodiments, the core 36 can have a compressive stiffness value outside of 200 to 300 psi.

[0041] The core flex member 40 (as Figure 2The core flex member 40 includes a structure extending between the handle portion 24 and the core 36 that has a higher compressibility and / or a lower stiffness or hardness than the core 36. In the illustrated example, the core flex member 40 can wrap around or extend uninterrupted around the entire perimeter of the core 36. In the illustrated example, the core flex member 40 has a width W in the region between the core 36 and the handle portion 24 of at least 5 mm. In some embodiments, the core flex member 40 has a width W in the range of 5 mm to 25 mm, and in some embodiments, the width W is at least 10 mm.

[0042] The core flex member 40 has a lower stiffness or hardness than the core. The core flex member 40 can have a higher compressibility than the core. In some embodiments, the core flex member 40 comprises a foam material. In one embodiment, the core flex member 40 is an ethylene vinyl acetate (EVA) foam having a density of 2 to 6 pounds. In some embodiments, the core flex member has a Shore 00 hardness of 40 to 60. In some embodiments, the core flex member is formed of other polymeric foam materials, such as urethane foam or polyurethan foam.

[0043] In other embodiments, the core flex member 40 can comprise a flexible compressible sleeve, tube, or membrane that is hollow on the inside, or filled on the inside with a material that is more flexible and / or compressible than the core material. In other embodiments, the core flex member 40 can take other structures or be formed of other materials. In some embodiments, the core flex member 40 can be glued, welded, fastened, or mechanically interlocked to one or both of the outer frame 32 and the core 36.

[0044] In some embodiments, the core 36 is embedded within the core flex member 40, rather than being directly bonded or secured to the core flex member 40. Thus, the core 36 can compress in a direction perpendicular or normal to the surface of the racquet (e.g., upon impact with a pickleball), relative to the core flex member 40. In some embodiments, the core 36 is supported by the flex member 40 in a manner similar to a trampoline, with the support of the flex member 40 analogous to the springs in a trampoline. In such embodiments, the coefficient of restitution of the core 36 can be enhanced. In some embodiments, the coefficient of restitution of the core 36 supported at least in part by the core flex member 40 is at least 0.40, and in some embodiments, the coefficient of restitution is at least 0.46. In such embodiments, the opposing faces of the core 36 and the core flex member 40 can be directly bonded to the inner surface of the face plate 44.

[0045] The core flexure member 40 helps to isolate the main sweet spot or center point and impact area of ​​the racket 20 from the handle portion 24 of the racket 20. The core flexure member 40 can dampen vibrations and other forces generated upon impact with the pickle, thereby inhibiting the transmission of these forces to the handle portion 24 of the pickle 20. The core flexure member 40 can enhance the responsiveness of the impact portion of the pickle by facilitating a degree of floating or movement of the impact area (sometimes referred to as the core) relative to the handle portion 24. In some embodiments, the core flexure member 40 can reduce noise generated during the impact of the pickle. The core flexure member 40 is located between the core 36 and the handle portion 24 such that the core 36 does not directly contact the handle portion 24. In some embodiments, the core flexure member 40 allows the core 36 to move independently of the handle portion 24 during impact with the pickle.

[0046] Panel 44 extends on opposite sides of head portion 28 and provides the surface for pickle impact. Panel 44 extends across, covers, and spans core 36 and core flexure member 40. In some embodiments, panel 44 completely covers the front and rear surfaces of outer frame 32. In other embodiments, panel 44 partially extends across and partially covers the front and rear surfaces of outer frame 32. Panel 44 is generally smooth and may be formed of polymer, cellulose material, or other materials or combinations thereof. In the example shown, panel 44 meets the requirements specified in the November 2023 edition of the U.S. Pickle Equipment Standards Manual. When tested according to protocol IAW ASTM D1894-14, the maximum coefficient of kinetic friction for each panel 44 is less than or equal to 0.1875.

[0047] Figures 3-6 For along Figure 1 Cross-sectional views of various specific examples of racket 20 taken from line 2-2. Figure 3 A Peak racket 120 is shown. The Peak racket 120 is similar to the Peak racket 20 described above, except that the racket 120 includes an outer frame 132 and a core flexure component 140, which is a specific example of the outer frame 32 and core flexure component 40 described above. The remaining components of the racket 120 corresponding to those of the racket 20 are represented by similar reference numerals and / or combinations. Figure 1 It has been shown and described.

[0048] The outer frame 132 includes a tubular structure 148, which, as Figure 1A loop is formed as shown. As described above, in some embodiments, the end portions of the tubular 148 may extend substantially parallel to each other, thereby forming the inner core portion of the handle portion 24. The tubular 148 has a hollow interior 149 that is omitted or contains no solid material. In the illustrated example, the tubular 148 has an internal air bladder 150 containing a gas, such as air. In some embodiments, the air bladder 150 is pressurized with air to maintain the shape of the tubular 148 when it solidifies or forms a permanent shape. In some embodiments, the tubular 148 may be formed from one or more fiber composite sheet layers, wherein the air bladder 150 is formed from a flexible polymer, rubber, or synthetic rubber material. In other embodiments, the air bladder 150 may be omitted, for example, the tubular 148 may be extruded into a shape... Figure 1 The loop shown. After the tubular structure 148 is molded and cured, the airbag 150 can be removed from the tubular structure. In some embodiments, a film or one or more layers are molded or wrapped around a sacrificial mandrel or core, wherein the mandrel or core is removed to leave a hollow tubular structure 148. Although the tubular structure 148 shown in the figure has a generally rectangular or square cross-section, in other embodiments, the tubular structure 148 may have external or internal grooves, an elliptical cross-section, a circular cross-section, or a polygonal cross-section.

[0049] The core flexure component 140 includes one or more layers of foam material sandwiched between the core 36 and the handle portion 24 between layers 44-1 and 44-2. In the illustrated example, the core flexure component 140 includes one or more layers of foam material that completely surround the core 36 in a continuous and uninterrupted manner. In other words, the core flexure component 140 comprises a continuous and complete loop surrounding the core 36.

[0050] The core flexure member 140 has a width W (e.g., between the handle portion 24 and the core 36) Figure 1 (As shown). In some embodiments, the width W is at least 5 mm and no more than 25 mm. In some embodiments, the width W is uniformly distributed along the entire length of the core flexure 40 surrounding the core 36. In other embodiments, the width W may vary as it extends around the core 36. In some embodiments, the core flexure 40 comprises a foam material. In one embodiment, the core flexure 40 comprises ethylene-vinyl acetate (EVA) foam with a density of 2 to 6 pounds. In some embodiments, the Shore 00 hardness of the core flexure 40 is 40 to 60. In some embodiments, the core flexure 40 is formed of other polymeric foam materials (e.g., urethane foam or polyurethane foam).

[0051] In some embodiments, the material that forms the core flex component 40 is pre-formed and cut or molded to the desired size and shape before being inserted into the opening 34 formed by the outer frame 32. The pre-formed core flex component 40 can be positioned within the opening 34 before the core 36 is inserted or after the core 36 is inserted into the opening 34. In some embodiments, no adhesive or other fastener is used between the core flex component 40 and the core 36. In some embodiments, the core flex component 40 can be formed by depositing a fluid foam or foaming material into the opening 34 around the core 36 (or a temporary removable shaped around the core 36) with the core flex component 40 positioned between the core 36 and the outer frame 32. In some embodiments, the fluid foam or foaming material can be injected into a space or volume defined on the sides by the tubular 148 and the core 36 and on the top and / or bottom by the plate 44-1 and / or the plate 44-2.

[0052] Figure 4 A pickleball paddle 220 is shown. The pickleball paddle 220 is similar to the pickleball paddle 120 described above, except that the paddle 220 includes an outer frame 232, which is one specific example of the outer frame 32 described above. The remaining components in the paddle 220 that correspond to components of the paddle 20 and / or the paddle 120 are labeled with similar reference numbers and / or are described in connection with Figure 1 and Figure 3 are shown and described.

[0053] The outer frame 232 is similar to the outer frame 132 described above, except that the tubular 148 omits the inner bladder 158 and the tubular 148 surrounds an inner solid frame core 252. In some embodiments, the frame core 252 includes a foam or foaming material. In some embodiments, the frame core 252 includes a foam, such as an EVA foam, a urethane foam, or a polyurethane foam. The foam can be injected or otherwise provided into the interior of the tubular 148 during the forming and molding of the tubular 148 to help maintain the structural integrity and shape of the tubular 148 during the process of molding and forming the tubular 148 into the loop of the outer frame 32. In other embodiments, the foam material that forms the frame core 252 can be injected into the interior of the tubular 148 after the tubular 148 is formed. In yet other embodiments, one or more layers can be molded around or wrapped around the frame core 252 before the forming and hardening or curing or after the forming, hardening, or curing to form the tubular 148 around the core 252; the combined tubular 148 and core 252 form the outer frame 232.

[0054] Figure 5A pickleball paddle 320 is shown. The pickleball paddle 320 is similar to the pickleball paddle 220 described above, except that the paddle 320 includes a core 336 and a core flexing component 340, i.e., specific examples of the core 36 and the core flexing component 40. The remaining components of the paddle 320 that correspond to components of the paddle 20 and / or the paddle 220 are numbered similarly and / or are described in connection with Figure 1 and 4 are shown and described.

[0055] The core 336 can include a perforated core, which is a specific example of the core 36. In some embodiments, the core 336 can have a decreasing thickness along its perimeter. In some embodiments, the core 336 can have a honeycomb structure or a lattice structure. The core 336 can extend outwardly to abut or near abut the outer frame 32, or can terminate before reaching the inside of the opening 34 defined by the outer frame 32. Like the core 36, the core 336 can be made of one or more non-foam polymer layers with perforations, foam layers with perforations, cellulose (wood) or paperboard-based materials with perforations, and the like. In some embodiments, the core 336 is made of a polymer such as polyethylene, nylon, polyurethane, and the like.

[0056] The core flexing component 340 includes one or more layers of material that extend between portions of the core 336 and the outer frame 232. In the illustrated example, the one or more layers of material encapsulate and / or impregnate the perforations, the hollow portions of the honeycomb, or the voids in the lattice to mechanically interlock the core flexing component 340 and the core 336. In some embodiments, the core flexing component 340 is injected as a fluid along the perimeter of the core 336, along the opening 34, and the inside of the outer frame 232 into the perforations of the core 336, where the fluid is allowed to cure or harden to form the final core flexing component 340. In some embodiments, the fluid material is a foam or a foamed material. In some embodiments, the fluid material is injected to form the core flexing component 340 while the core 336 is positioned within the opening defined by the outer frame 232. In other embodiments, the fluid material can be injected to form the core flexing component 340 before the core 336 is positioned into the opening 34, where the interlocked core 336 and core flexing component 340 (cured) are subsequently inserted into the opening 34 and secured to the outer frame 232 by other means, e.g., by adhesive, fusion, melting, and the like.

[0057] Figure 6 A pickleball paddle 420 is shown. The pickleball paddle 420 is similar to the pickleball paddle 320 described above, except that the paddle 420 includes the frame 132 described above in place of the outer frame 232. The components of the paddle 420 that correspond to the remaining components of the paddle 20 and / or the paddle 320 are numbered similarly and / or are described in connection with Figure 1 and Figure 5are shown and described.

[0058] Figure 7 An example of a pickleball paddle 520 is shown. The pickleball paddle 520 is similar to the pickleball paddle 20, except that the paddle 520 contains a core flexing member 540 in place of the core flexing member 40, and spacers 560-1, 560-2, and 560-3 (collectively, spacers 560). The remaining components of the pickleball paddle 520 that correspond to components of the pickleball paddle 20 are numbered similarly and / or are described in conjunction with the description of the pickleball paddle 20. Figure 1 are shown and described.

[0059] The core flexing member 540 is similar to the core flexing member 40, except that the core flexing member 540 does not comprise a continuous, uninterrupted loop, i.e., does not extend continuously around the core 36 in an uninterrupted manner. Rather, the core flexing member 540 is interrupted by the spacers 560. As with the pickleball paddle 20, the pickleball paddle 520 can employ any of the specific example configurations shown and described above in conjunction with the pickleball paddle 20, but with the addition of the spacers 560 at specific locations around the core 36. For example, the outer frame 32 can take the form of the outer frame 132 or the outer frame 232. The core 36 can take the form of the core 36 or the core 336. The core flexing member 540 can have the composition and cross-sectional structure of the flexing member 140 or the flexing member 340. Figure 3 The core flexing member 540 is similar to the core flexing member 40, except that the core flexing member 540 does not comprise a continuous, uninterrupted loop, i.e., does not extend continuously around the core 36 in an uninterrupted manner. Rather, the core flexing member 540 is interrupted by the spacers 560. As with the pickleball paddle 20, the pickleball paddle 520 can employ any of the specific example configurations shown and described above in conjunction with the pickleball paddle 20, but with the addition of the spacers 560 at specific locations around the core 36. For example, the outer frame 32 can take the form of the outer frame 132 or the outer frame 232. The core 36 can take the form of the core 36 or the core 336. The core flexing member 540 can have the composition and cross-sectional structure of the flexing member 140 or the flexing member 340.

[0060] The spacers 560 interrupt the otherwise continuous nature of the core flexing member 540. In some embodiments, the spacers 560 are formed of one or more materials that are stiffer and less flexible than the flexing member 540. In some embodiments, the spacers 560 can be made of a polymer or a metal. In some embodiments, the spacers 560 are secured to the outer frame 32 by fastening, welding, fusing, bonding, or other means. In some embodiments, the spacers 560 can instead be secured to the core. In some embodiments, the spacers 560 can be integrally formed with the core 36 as part of a single, unitary body that includes a portion that protrudes outward relative to the core 36. For example, the core 36 can have a generally oval shape as shown, with protruding tabs or bumps that form the spacers 560. In such embodiments, the spacers 560 can be perforated. In some embodiments, the spacers 560 and the core 36 can have a honeycomb structure, and the spacers 560 can be extensions relative to the core 36. In some embodiments, the spacers 560 can have a reduced thickness, with the core flexing member 540 filling or impregnating the perforations, such that the core flexing member 540 mechanically interlocks with the protruding portions relative to the core 36, as described above in relation to the paddle 320 or the paddle 420.

[0061] The spacers 560 can limit or control any relative motion of the core flexing member 540 relative to the outer frame 32. In the illustrated example, spacers 560-1, 560-2, and 560-3 are disposed at the 3 o'clock, 9 o'clock, and 12 o'clock positions, respectively, as shown. In other embodiments, such spacers 560 can be disposed at other locations. In other embodiments, a greater or lesser number of spacers can be used, and the relative size of each spacer 560 can be adjusted. Figure 7

[0062] Figure 8 An example of a pickleball paddle 620 is shown. The pickleball paddle 620 is similar to the pickleball paddle 20, except that the paddle 520 includes a core flexing member 640 in place of the core flexing member 40 and an upper wrapping member 660. The components of the pickleball paddle 620 that correspond to the remaining components of the pickleball paddle 20 are numbered similarly and / or described in connection with Figure 1 the components of the pickleball paddle 20 are shown and described above.

[0063] The core flexing member 640 is similar to the core flexing member 40, except that the core flexing member 640 is not formed from a continuous, uninterrupted loop, i.e., does not continuously extend around the core 36 in an uninterrupted manner. Rather, the core flexing member 640 extends along a lower portion of the core 36, between the core 36 and the handle portion 24, terminating at the upper wrapping member 660. In the illustrated example, the core flexing member 640 is semicircular, semi-elliptical, or U-shaped. As with the pickleball paddle 20, the pickleball paddle 620 can have any of the specific example configurations shown and described above with respect to the pickleball paddle 20, but terminating at the wrapping member 660. For example, the outer frame 32 can be a specific form of the outer frame 132 or the outer frame 232. The core 36 can be in the form of the core 36 or the core 336. The core flexing member 640 can have the composition and cross-sectional structure of the flexing member 140 or the flexing member 340. Figures 3-6

[0064] The core wrapping member 660 extends along a distal end of the paddle 620, which is furthest from the handle portion 24. In the illustrated example, the wrapping member 660 is shown as extending at least 180° around the center of the core 36, around a majority of the core 36. In other embodiments, the wrapping member 660 can extend to a greater or lesser extent around the core 36. The wrapping member 660 provides a different feel or different pickleball impact characteristics to the distal end of the paddle 620 compared to those portions closer to the handle portion 24.

[0065] ​​In some embodiments, the wrapping member 660 is made of a material that is stiffer and less flexible than the core flexural member 640, such as a stiffer or less compressible polymer or metal. In some embodiments, the wrapping member 660 is secured to the outer frame 32 by fastening, welding, fusion, bonding, or other means. In some embodiments, the wrapping member 660 may alternatively be secured to the core 36. In some embodiments, the wrapping member 660 may be integrally molded with the core 36 as part of a single monolithic body, the single monolithic body including an outwardly projecting portion relative to the core 36. In some embodiments, the wrapping member 660 and the core 36 may be molded as a single unit. The core 36 may be generally elliptical as shown, with extensions forming the core wrapping member 660. In such embodiments, the wrapping member 660 may be perforated.

[0066] Figure 9 and Figure 10 An example of the Peak 720 racket is shown. Figure 10 This is a cross-sectional view of racket 720. Racket 720 includes a handle portion 724 and a head portion 728. The head portion 728 is coupled to the handle portion 724 and includes an outer frame 732 extending around an opening 734, a core 736, a core flexure member 740, and a faceplate 744 (one of which is shown in the figure). The handle portion 724 is sized for easy grip by a player. In some embodiments, the handle portion 724 may be circular or elliptical. In other embodiments, the cross-section of the handle portion 724 may be polygonal.

[0067] like Figure 10 As shown, a hollow tubular member 748 forms part of the outer frame 732 and the handle portion 724. The hollow tubular member 748 has end portions 749 shaped to extend substantially parallel to each other, thereby forming the handle core 770. The handle portion 724 also includes a pallet 772 and an outer covering 774. The pallet 772 extends around the end portions 749 of the outer tubular member 748, thereby forming a uniform outer surface for the handle portion 724. The pallet 772 may be formed into an external polygon. In other embodiments, the pallet 772 may have other external shapes. In some embodiments, the pallet 772 may be made of wood (e.g., balsa wood), foam material, or other materials.

[0068] An outer cover 774 surrounds the end portion 749 and the handle support 772. The outer cover 774 provides a gripping surface and texture for the handle portion 724. The outer cover 774 may include a sleeve or wrapping tape. The outer cover 774 may be made of a polymer, rubber, or leather material. In other embodiments, the handle portion 724 may not be partially formed by the tubular portion 748, wherein the handle portion 724 may be pre-formed separately and attached to the head portion 728.

[0069] The head portion 728 provides a ball striking surface for the racquet 720. The outer frame 732 forms an outer rim that extends around the opening 734 and forms a perimeter of the head portion 728. In some embodiments, a dampening component, a cushioning component, a weight, or a wrapping component made of a protective material can be disposed outside of the outer frame 732. In other embodiments, the outer tube 748 of the outer frame 732 can form the outer rim of the head portion 728. The outer frame 732 and the handle portion 724 define a maximum width of the pickleball racquet 720 and together define a maximum length of the pickleball racquet 720. The outer frame 732 and the handle portion 724 meet the requirements specified in the 2023 November edition of the USA Pickleball Equipment Standards Manual. The entire length of the racquet 720, i.e., extending from the truncated end of the handle portion 724 to the top of the head portion 728, forms the maximum length of the racquet 720. The maximum width of the head portion 728 (measured perpendicular to the central axis of the handle portion 724) forms the maximum width of the racquet 720. The sum of the maximum length and the maximum width of the racquet 720 is less than or equal to 24 inches.

[0070] The outer frame 732 is composed of the shaped tube 748 and the yoke 776. The tube 748 forms a loop, the lower end of which is closed by the yoke 776, thereby defining the opening 734. As described above, in the illustrated example, portions of the tube can further extend in parallel to form the core of the handle portion 724. In the illustrated example, the tube 748 that makes up the outer frame 732 is hollow, having a hollow interior 778 that is free of any solid material or filler. For example, the interior of the hollow band or tube can contain a gas, such as air. In some embodiments, the tube 748 can be an air bladder, filled with air or other gas. In other embodiments, the tube 748 can be solid, omitting any internal void, lumen, or interior cavity, e.g., the interior void of the tube is filled with additional material (e.g., foam).

[0071] The yoke 776 includes a band or tube that bridges between opposite portions of the tube 748 at the top of the racquet 720 opposite the handle portion 724. The yoke 776 forms a portion of the outer frame 732 directly above the handle portion 724. The tube 748 continues below the yoke 776 to form a throat 780 of the racquet 720, which extends between the handle portion 724 and the head portion 728. The throat 778 has an opening 782 defined by the tube 748 and the yoke 776 between the yoke 776 and the handle portion 724.

[0072] In the illustrated example, the yoke 776 includes a tubular 784, the ends of which are fused, bonded, or otherwise integrated with the tubular 748. In the illustrated example, the tubular 784 is filled with a filler 785, e.g., a foam. In other embodiments, the tubular 784 can be hollow, omit any filler, or can have other configurations. In other embodiments, the yoke 776 can be omitted, e.g., the ends 749 of the tubular 748 are connected together at a 90 degree angle, thereby omitting any opening, e.g., the opening 782.

[0073] The core 736 extends over and fills a majority of the area of the opening 734 defined by the outer frame 732. In the illustrated example, the core 736 is perforated, having openings, channels, or voids extending completely through the core 736 from a first surface to a second, opposite surface. In the illustrated example, the core 736 has a honeycomb configuration. In other embodiments, the core 736 can alternatively include a lattice configuration. For example, the core 736 can include any of the lattice structures described in co-pending U.S. Patent Application Serial No. 17 / 177,899, entitled “Pickleball Paddle,” to Thurman et al., filed February 17, 2021, the entire disclosure of which is incorporated by reference herein. In other embodiments, the core 736 can be non-perforated. For example, the core 736 can be made of polyethylene, solid wood, one or more other polymers or foam materials that have greater rigidity and less compressibility than the core flex member 740. In some embodiments, the core 736 can be made of one or more non-foam polymer layers with perforations, foam layers with perforations, cellulose (wood) or paperboard based materials with perforations, etc., where the core 736 has greater rigidity and / or less compressibility than the core flex member 740. In the illustrated example, the core 736 is made of polypropylene, having a thickness in the range of 6 to 32 mm. In some embodiments, the thickness of the core 736 is in the range of 12 to 18 mm.

[0074] The core flex component 740 includes a structure extending between the handle portion 724 and the core 736, where the structure has a higher compressibility and / or a lower stiffness or hardness compared to the core 736. In the illustrated example, the core flex component 740 completely wraps around or extends continuously and uninterrupted around the perimeter of the core 736. In the illustrated example, the core flex component 740 has a width of at least 5 mm, in some embodiments at least 10 mm, at least in the region between the core 736 and the handle portion 724. In other embodiments, the core flex component 740 can not extend completely around the core 736, for example, the core flex component 740 has a similar configuration as the core flex component 540 (with the spacer 560) or as the core flex component 640 (with the wrap component 660).

[0075] The core flex component 740 has a lower stiffness or hardness than the core. The core flex component 740 can have a higher compressibility compared to the compressibility of the core. In some embodiments, the core flex component 740 comprises a foam material. In one example embodiment, the core flex component 740 includes a foam material. In one example embodiment, the core flex component 740 includes an ethylene-vinyl acetate (EVA) foam having a density of 2 to 6 pounds. In some embodiments, the core flex component 740 has a Shore 00 hardness of 40 to 60. In some embodiments, the core flex component 740 is made of other polymeric foam materials, for example, urethane foam or polyurethane foam. In some embodiments, the core flex component 740 can be positioned between the core 740 and the frame 732 without the use of adhesives or other fasteners on the surface between the core flex component 740 and the core 740 and on the surface between the core flex component 740 and the frame 732.

[0076] In other embodiments, the core flex component 740 can include a flexible compressible sleeve, tube, or membrane that is hollow inside or filled with a material that is more flexible and / or compressible than the material forming the core. In other embodiments, the core flex component 740 can take other configurations or be formed of other materials. In some embodiments, the core flex component 740 can be bonded, welded, fastened, or mechanically interlocked to one or both of the outer frame 732 and the core 736.

[0077] In other embodiments, the core flex component 740 can include a flexible compressible sleeve, tube, or membrane that is hollow inside or filled with a material that is more flexible and / or compressible than the material forming the core 736. In other embodiments, the core flex component 740 can take other configurations or be formed of other materials. In the illustrated example, the core flex component 740 can be bonded, welded, fastened, or mechanically interlocked to one or both of the outer frame 732 and the core 736.

[0078] In the illustrated example, the core 736 is embedded within the core flexing member 740, rather than being directly bonded or fixed to the core flexing member 740. Thus, the core 736 can be compressed in a direction perpendicular or normal to the face of the racquet (e.g., upon impact with a pickleball), relative to the core flexing member 740. In some embodiments, the core 736 is supported by the flexing member 740 in a manner similar to a trampoline, with the flexing member 740 acting similar to springs in a trampoline. In such embodiments, the coefficient of restitution of the core 736 can be enhanced. In some embodiments, the coefficient of restitution of the core 736, at least partially supported by the flexing member 740, is at least 0.40, and in some embodiments, the coefficient of restitution is at least 0.46. In such embodiments, the opposing surfaces of the core 736 and the core flexing member 740 can be directly bonded to the inner surface of the faceplate 744.

[0079] The core flexing member 740 helps to isolate the primary sweet spot and impact area of the racquet 720 from the handle portion 724 of the racquet 720. The core flexing member 740 can dampen vibrations and other forces resulting from impact with a pickleball, thereby inhibiting the transmission of these forces to the handle portion 724 of the pickleball racquet 720. The core flexing member 740 can enhance the responsiveness of the impact portion of the pickleball by facilitating a degree of floating or movement of the impact area (sometimes referred to as the core) relative to the handle portion 724.

[0080] Similar to the faceplate 44, the faceplate 744 extends on opposite sides of the head portion 728 and provides the surfaces for pickleball impact. The faceplate 744 extends over and covers the core 736 and the core flexing member 740. In some embodiments, the faceplate 744 completely covers the front and back surfaces of the outer frame 732. In other embodiments, the faceplate 744 partially extends over and partially covers the front and back surfaces of the outer frame 732. The faceplate 744 is generally smooth and can be made of a polymer, a cellulosic material, or other material or combination of materials. In the illustrated example, the faceplate 744 meets the requirements specified in the 2023 edition of the United States Pickleball Equipment Standards Manual. The maximum coefficient of kinetic friction for each faceplate 744 is less than or equal to 0.1875 when tested in accordance with the protocol IAW ASTM D1894-14.

[0081] While the illustrated pickleball racquet 720 has a hollow interior, is free of any filler, and has a core flexing member 740, in other embodiments, the pickleball racquet 720 can have a core 736 that is at least partially filled with a filler material, such as a foam, a gel, or other material or combination of materials. In such embodiments, the core 736 can be directly bonded or fixed to the core flexing member 740, or the core 736 can be embedded within the core flexing member 740. Figures 3-6Any of the specific example configurations shown and described. For example, the outer frame 732 can take the specific form of the outer frame 132 or the outer frame 232. The core 736 can take the form of the core 36 or the core 336. The core flex member 740 can have the composition and cross-sectional structure of the flex member 140 or the flex member 340.

[0082] Figures 11-14 The racquet 720 is shown without the core 736, the core flex member 740, and the handle wrap 774. Figures 11-14 The tubular 748 and the remaining components that form the handle portion 724 are shown. Figure 11 is an elevational view of the illustrated portion of the racquet 720. Figure 12 is a cross-sectional view of the racquet 720 taken along line 12-12. Figure 11 is a cross-sectional view of the illustrated portion of the racquet 720. Figure 13 is a top view of the illustrated portion of the racquet 720. Figure 14 is a cross-sectional view of the racquet 720 taken along line 14-14. Figure 11 is a cross-sectional view of the racquet 720.

[0083] As noted above, the outer frame 732 and the handle portion 724 define the maximum length L of the racquet 720. The outer frame 732 further defines the maximum racquet width PW. The outer frame 732 and the handle portion 724 meet the requirements specified in the 2023 edition of the USA Pickleball Equipment Standards Manual. The sum of the maximum length L and the maximum width PW of the racquet 720 is less than or equal to 24 inches.

[0084] As further shown, the outer periphery of the outer frame 732 is composed of grooves or channels. As further shown, Figures 11-14 As further shown, the top 786 of the outer frame 732 has an indentation or groove 788 that projects inwardly into the tubular 748. The groove 788 has an end and terminates before reaching the side 790 of the outer frame 732. As further shown, Figure 12 and 13 As further shown, the top 786 of the outer frame 732 has an indentation or groove 788 that projects inwardly into the tubular 748. The groove 788 has an end and terminates before reaching the side 790 of the outer frame 732. As further shown, Figure 14As shown, the sides 790 of the outer frame 732 have indentations or grooves 792 that protrude inward into the tubular 748. The grooves 788 and 792 do not compromise the structural integrity of the tubular 748, but merely include an inwardly curved deformed outer peripheral surface of the tubular 748. Such grooves can help to enhance the rigidity or stiffness of the outer frame 732. While the grooves 788 and 792 shown in the figures are V-shaped, it is understood that such grooves can have other cross-sectional shapes, such as U-shaped, semi-circular, semi-ovular, and other curved or irregular shapes, and can have other relative dimensions and depths, for aesthetic considerations. In some embodiments, the grooves 788 and 792 can be replaced by a single continuous groove or channel that extends continuously around and along the top 786 and sides 790. In some embodiments, the grooves 788 and 792 are molded into the tubular 748 during the forming process. In one embodiment, the top 786 can not be formed with grooves 788, while the sides 790 can include grooves 792. In another embodiment, the top 786 can be formed with grooves 788, while the sides 792 can not be formed with grooves 792.

[0085] Figures 15-20 One example method of forming the outer frame 732 of the pickleball paddle 720 is shown. In Figures 15-20 In the example method shown, the tubular 748, and in some embodiments the yoke 776, is made of a fiber composite material. The term "fiber composite material" or "composite material" as used herein refers to a plurality of fibers within and permeating through a resin. The fibers can be arranged coaxially in a sheet, in a ply or plies, or woven or braided into a sheet or ply, and / or chopped and randomly dispersed into a layer or layers. A single ply typically includes hundreds or thousands of fiber bundles that are initially arranged coaxially with and parallel to each other through an initially uncured resin. Each fiber bundle includes a plurality of fibers. The fibers are made of a high tensile strength material, such as carbon fiber. Alternatively, the fibers can be formed of other materials, such as glass, graphite, boron, basalt, carrot fiber, Kevlar fiber, Spectra fiber, poly-para-phenylene-terephthalate (PBO), hemp, flax, other natural fibers, and combinations thereof. In one set of preferred embodiments, the resin is preferably a thermoset resin, such as a cyclo-aliphatic epoxy resin or a polyester resin. In other preferred embodiments, the resin can be a thermoplastic resin. The composite material is typically wrapped around a mandrel and / or analogous structure and cured under heat and / or pressure. Upon curing, the resin is configured to flow and fully disperse and extend throughout the fiber matrix. In a multi-layer or multi-ply structure, the fibers can be arranged in different directions relative to the longitudinal axis, and / or arranged in a woven or braided manner from layer to layer.

[0086] Referring to Figure 15which shows a portion of a fiber composite layer 860. The layer 60 is composed of one or two fiber composite ply layers 862 (862a and 862b). A ply layer 862 of fiber composite refers to the arrangement of fibers 864 and fiber tows 866 in a resin 868, where the fibers 864 and fiber tows 866 are arranged and aligned such that the fibers 864 and fiber tows 866 extend generally coaxially with each other and generally parallel to each other. The fibers 864 or fiber tows 866 are preferably formed to extend along the ply layer 862 and to generally form the same angle relative to an axis, such as a composite axis 870. The ply layer 862 is generally identified at least in part by the magnitude and polarity of the angle formed by the fibers 864 or fiber tows 866 relative to the axis 870. As shown in Figure 15 ply layer 62a, and the fibers 864 and fiber tows 866 in the ply layer 62b are arranged at a negative 45 degree ply angle. In other embodiments, the ply layers 862 can include fibers 864 or fiber tows 866 that constitute a positive 30 degree ply angle, a negative 30 degree ply angle, a positive 45 degree ply angle, a negative 45 degree ply angle, a positive 40 degree ply angle, a negative 40 degree ply angle, a positive 35 degree ply angle, a negative 35 degree ply angle, a 90 degree ply angle (extending perpendicular to the axis), and a 0 degree ply angle (extending parallel to the axis). Other positive and negative angles for the ply layers can also be used. Thus, in this application, a single ply layer 862 refers to a single layer of fiber composite in which the fiber tows 866 extend in substantially the same direction along the longitudinal axis of the single layer, such as a positive 45 degree or a negative 30 degree. A layer 860 formed of a pair of ply layers 862 is also referred to as a ply arrangement, where the angles of the fibers 864 of the pair of ply layers 862 are generally the same but opposite in polarity. This pattern of arrangement generally extends throughout the fiber composite. The alternating angular arrangement of the fiber tows 866 and fibers 864 is important to achieve and maintain the structural integrity of a component or structure formed from the fiber composite. The overlap region of the two ply layers 862a and 862b is important to ensure that the fiber composite has the required strength, durability, toughness, and / or reliability after curing.

[0087] During the heating / molding and curing process, the resin 868 can flow between the ply layers 862 and within the fiber tows 866. The thickness of the ply layers 862 is generally preferably in the range of 0.002 to 0.015 inches. Other thickness ranges can also be used in other embodiments.

[0088] As Figure 16As shown, in other embodiments, one or more layers 860 may comprise a plurality of braided fibers 862c. The braided fibers 862c may extend at an angle of at least 35 degrees relative to the ply axis 870 and have both positive and negative polarity. In other embodiments, the braided fibers 862c may extend at an angle of at least 40 degrees relative to the ply axis 870 (and have both positive and negative polarity).

[0089] Figures 17-20 An example process or method is shown by which a tubular object 748 can be formed and fused to form the head portion 728, the throat portion 780, and the handle portion 724. See also Figure 17 When layer 860 is wrapped or stacked around air bladder 876 and mandrel 874, plate layer 862 is no longer arranged in a flat sheet-like manner, and therefore fiber bundles 866 and fibers 864 no longer follow or form generally parallel lines. Instead, fiber bundles 866 and fibers 864 are adjacent to each other and are bent or otherwise shaped to follow substantially the same adjacent paths. For example, when plate layer 862 is wrapped around air bladder 876 and mandrel 874, plate layer 862 may take on a generally cylindrical or tubular shape, and fiber bundles 866 and fibers 864 may travel along the same cylindrical path or may define a helical path (depending on their angle within plate layer 862). Fibers 864 remain adjacent to each other, aligned with each other, and follow substantially similar paths, for example, when viewed from a cross-sectional view of a single plane or other finite segment of plate layer 862, these paths are substantially parallel (or even coaxial).

[0090] In one embodiment, the mandrel 874 may include a pull tab 882 to facilitate pulling or removing the mandrel 874 from the plurality of layers 860 surrounding the airbag 876 and the mandrel 874. Figure 17 The layup 880 in the airbag and layup 880 has not yet cured. In one embodiment, the mandrel 874 can be pulled out, removed, or otherwise removed from the airbag and layup 880 using a pull tab 882.

[0091] refer to Figure 18 and Figure 19 After removing the mandrel 874 from the air bladder 876 and the ply 880, the uncured ply 880 can be gently shaped into the racket frame. An uncured yoke ply 884 made of fiber composite material can be prepared and placed next to the curved ply 880. (Example:) Figure 19As shown, the layup can be shaped similar to portions of the outer frame 732, and a yoke layup 884 can be attached to the layup 880. In one embodiment, additional relatively short strap or banding plies can be applied over the connection points of the yoke layup 884 and the layup 880. In other embodiments, a pre-fabricated yoke structure can be used in place of the yoke layup, and the pre-fabricated yoke structure can be attached to the layup 880 prior to molding.

[0092] Referring to Figure 20 The uncured layup 880 and the uncured yoke layup 884 are placed within a mold cavity 888 of a racquet forming mold 890. A supply line 886 can be attached to the bladder 876 for supplying air or other gas to the bladder, and the components of the racquet forming mold 890 can be placed around the layup 880 and the yoke layup 884. The bladder 876 can be pneumatically pressurized to a preset pressure (e.g., using a pressure valve 886 connected to the bladder 876), and the racquet forming mold 890 can then be placed in an oven or furnace for heating, or heated to a preset temperature where the mold is heated. Once subjected to heat and pressure, the viscosity of the resin 868 in the layup 880 and the yoke layup 884 decreases, and the resin 868 flows through the plies 862 of the layup 880 and the yoke layup 884 in the mold cavity 888, thereby forming a more uniform structure and positioning the fibers 864 into the shape of the mold cavity. After a first preset amount of time, the racquet forming mold 890 is removed from the heat source to allow the layup 880 and the yoke layup 884 to cool. After a second preset amount of time, the racquet forming mold 890 is opened and the outer frame 732 is removed from the mold 890. Thereafter, the bladder 876 is removed from the tubular to further reduce the weight of the racquet 720 and to avoid any noise that can be generated by the bladder 876 remaining in the tubular.

[0093] The method of manufacturing a frame for a racquet 720 made of a fiber composite material using a bladder molding method described above is significantly superior to using an activated foam as an internal pressure source during the molding process to shape a tubular fiber composite object. Incorporating a bladder into the molding process of the frame 732 of a pickleball racquet 720 allows a preset internal pressure to be applied to the tubular during the molding and curing process, which helps to prevent the formation of undesirable conditions such as air bubbles, wrinkles, folds, and uneven wall thickness. All of the above conditions can negatively impact the consistency, durability, and playability of the frame 732 and the racquet 720. Furthermore, a fiber composite pickleball racquet frame made using an activated foam will necessarily fill the fiber composite tubular with foam. The foam will add weight and can negatively impact the playability of the racquet. The present method is the first to use a bladder molding method to manufacture a pickleball racquet.

[0094] While the present disclosure has been described with reference to example embodiments, it will be understood by those skilled in the art that various changes can be made and equivalents can be substituted for elements thereof without departing from the scope of the claimed subject matter. For example, although different example embodiments can have been described as including particular features, one or more of these features from different example embodiments can be interchanged or removed and the example embodiments can include other technical features, such as technical features described in the following disclosure. Since the technology according to the present disclosure can vary somewhat from case to case, not all technical variations can be foreseeable. The present disclosure, which is described with reference to example embodiments and illustrated in the claims below, is obviously intended to be as broad as possible. For example, unless otherwise explicitly stated, a single process element recited in a claim can be a plural number of such elements. The terms "first", "second", "third", and the like in the claims are used only to distinguish different elements, and are not necessarily specifically correlated with the particular order or particular figure reference numbers of the elements in the disclosure, unless otherwise specifically stated.

Claims

1. A Peak racket, comprising: Handle part; The head portion is connected to the handle portion, and the head portion includes: An outer frame extending around the opening; A perforated core within the opening; and The core flexure component extends within the opening between the perforated core and the handle portion.

2. The Peak racket according to claim 1, wherein, The core flexure component completely surrounds the perforated core within the opening.

3. The Peak racket according to claim 1, wherein, The core buckling component includes a foam layer.

4. The Peak racket according to claim 3, wherein, Perforated cores include honeycomb cores.

5. The Peak racket according to claim 4, wherein, The foam layer completely surrounds the honeycomb core within the opening.

6. The Peak racket according to claim 5, wherein, The external frame consists of tubular structures.

7. The Peak racket according to claim 6, wherein, The tube is hollow.

8. The Peak racket according to claim 7, wherein, The outer frame includes a loop extending around the opening, with each end portion of the loop forming a part of the handle portion.

9. The Peak racket according to claim 8, further comprising a yoke between the opening and the handle portion, wherein, The foam layer extends between the yoke and the honeycomb core.

10. The Peak racket according to claim 9, wherein, The width of the foam layer is at least 10 mm.

11. The Peak racket according to claim 10, wherein, Peak rackets meet the standards specified in the November 2023 edition of the U.S. Peak Equipment Standards Manual.

12. The Peak racket according to claim 10, wherein, The sum of the maximum length and maximum width of a Peak racket is less than or equal to 24 inches.

13. The Peak racket according to claim 10, further comprising: The first panel spans an opening over the first surface of the honeycomb core and the first surface of the foam layer; The second panel spans the opening above the second surface of the honeycomb core and the second surface of the foam layer. The first and second panels have faces facing away from each other, and when tested according to the protocol IAW ASTM D1894-14, the maximum coefficient of dynamic friction of each face is less than or equal to 0.1875.

14. The Peak racket according to claim 1, wherein, The maximum length and maximum width of the Peak racket are less than or equal to 24 inches, wherein the core flexural component includes a foam layer, and wherein the outer frame includes tubular elements that form loops extending around openings, with the end portions of the loops forming portions of the handle portion.

15. The Peak racket according to claim 14, wherein, Perforated cores include honeycomb cores.

16. The Peak racket according to claim 14, wherein, The width of the foam layer is at least 10 mm.

17. The Peak racket according to claim 1, wherein, The outer frame includes an outer surface and grooves that extend into and along the outer surface.

18. A method for forming a peak racket, the method comprising: The hollow tubular object is pneumatically pressurized when it is located inside a heated mold and the hollow tubular object is formed as a loop extending around an opening and the loop has parallel end portions for forming a handle portion. A perforated core is installed inside the opening; A core flexure component is provided between the perforated core and each parallel end portion within the opening.

19. The method according to claim 18, wherein, The perforated core includes a honeycomb core, and wherein the core flexural component includes a foam layer that completely surrounds the honeycomb core.

20. A Peak racket, comprising: Handle part; and The head portion is connected to the handle portion, and the head portion includes: An outer frame extending around the opening; The core within the opening; and A foam layer surrounds the core within the opening.

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