Hybrid hot-press fusion process tennis racket

Abstract

A racquet includes a core having a first portion and a second portion. The first portion can define a first width between first and second side edges of the racquet. The second portion can define a second width between the two side edges of the racquet. The racquet generally includes a core and a frame attached to the core. The core includes a first portion attached to the frame and a second portion located in a frameless portion. The frame defines a framed portion including the frame and the racquet components between the frame. The frameless portion includes the remaining portion of the racquet. The first portion defines a first width that is less than the second width defined by the second portion. The core accommodates the frame around the first portion having the smaller width to facilitate a continuous transition between the framed portion and the frameless portion.

Description

Technical Field

[0001] This disclosure relates to rackets used in ball sports, particularly Peak rackets. Background Technology

[0002] Pickleball is a ball sport played with rackets and perforated plastic balls on a court similar to a tennis court. Players hit the ball over a net (similar to a tennis ball) on the ground, with the goal of preventing the opponent from returning the shot.

[0003] Typically, rackets used in pickleball can be made of metal, wood, or composite materials. The racket's structure and weight characteristics affect how the ball bounces off the racket when a player hits it. The effect of hitting the ball differs when a player hits it near the edge of the racket compared to hitting it near the center. Generally, hitting near the edge results in a loss of power, while hitting near the center produces more power. Different players may prefer greater power or better control. Therefore, rackets with different characteristics but also sufficient stiffness and strength are needed.

[0004] Therefore, this area needs improvement. Utility Model Content

[0005] Some embodiments include a racket for playing pickle. The racket typically includes a racket core located within the racket face. The racket core typically includes a first portion and a second portion. The first portion is located at the proximal end of the racket, and the second portion is located at the distal end of the racket. Furthermore, the first portion may define a first width between a first side and a second side of the racket. The second portion may define a second width between the two sides of the racket.

[0006] The core may also include a stepped structure located at the boundary between the first portion and the second portion. The first portion may be near the stepped structure and located on the proximal side of the stepped structure, defining a first width. Conversely, the second portion may be near the stepped structure and located on the distal side of the stepped structure, defining a second width. In one embodiment, the first width is smaller than the second width.

[0007] The core is typically a rounded rectangle. A first portion defines a first pair of parallel edges that extend along the length of the core to the side of the racket. The first portion also defines a first width between the first pair of parallel edges. Similarly, a second portion defines a second pair of parallel edges that extend along the length of the core to the side of the racket. The second portion also defines a second width between the second pair of parallel edges. In one embodiment, the first pair of parallel edges extends to between one-fifth and one-quarter of the core length.

[0008] The core can be composed of multiple honeycomb-shaped units and can be cut from a larger sheet. One or more units surrounding the core can be destroyed. The core may optionally contain foam located within the units surrounding the core.

[0009] The racket may also include a frame attached to the core. This frame is typically located near the proximal end of the racket. In one embodiment, the frame extends through the handle of the racket and partially into the racket face. The frame may be positioned along the periphery of the core along a first portion of the core. For example, the frame may extend to a stepped structure on the core. The frame and core define a frame portion of the racket, which includes the frame and the first portion of the core. Typically, the frame portion may include the frame and a racket area within the frame. A frameless portion of the racket extends beyond the frame toward the distal end of the racket. The frameless portion may include a second portion of the core and typically includes the remainder of the racket excluding the frame portion. The racket may also include an edge protector attached to the racket face. The edge protector may extend along the frameless portion and surround the second portion of the core.

[0010] The frame typically defines the frame thickness, while the stepped structure of the core defines the step width. Edge protectors can define the thickness of the edges. In one embodiment, the frame thickness approximates the combination of the edge protector thickness and the step width. In another embodiment, the frame thickness approximates the step width. For example, the frame thickness can approximate the step width and / or the combination of the edge protector thickness and the step width, with a difference within 1 mm, 2 mm, 5 mm, and / or other values. Setting similar widths in this way helps to create a uniform shape throughout the racket.

[0011] In one design, the frame extends to positions corresponding to the 3 o'clock and 9 o'clock positions around the core, with the handle positioned at the 6 o'clock position as a reference. In another design, the frame extends to positions corresponding to the 5 o'clock and 7 o'clock positions around the core. In yet another design, the frame extends to positions corresponding to the 2 o'clock and 10 o'clock positions around the core.

[0012] This disclosure also provides a method for manufacturing a Peak racket. The method typically involves winding a composite material onto a central tube to form a long, thin roll. The long, thin roll is then arranged along the core to form a racket blank. The long, thin roll is typically arranged near a first portion of the core, but not around a second portion of the core. The racket blank is then placed into a mold cavity.

[0013] After the racket blank is placed into the mold, the mold is heated. During the heating process, the composite material fuses with the frame. The frame is typically integral with a center tube embedded in the frame. Additionally, the core is usually attached to the frame in this step, forming the racket's body. The racket's body includes a handle and a racket face, with the frame passing through the handle and partially extending into the racket face, and the core located within the racket face.

[0014] Next, remove the racket body from the mold. After removal, attach the edge protector to the racket body along the periphery of the core, around the second part of the core. As mentioned above, the frame does not extend along the periphery of the core around the second part of the core.

[0015] In one embodiment, the strip-shaped roll comprises a first roll and a second roll. The first roll is arranged along a first side of the core, and the second roll is arranged along a second side of the core. The frame may consist of two separate units. These two units may be formed by heating the first roll and the second roll, respectively.

[0016] In one embodiment, the central tube is an inflatable tubular bladder, and the method further includes several additional steps. The method may also include connecting a source of compressed gas to the inflatable tubular bladder. The compressed gas can then be supplied to inflate the elongated roll of material in the mold, causing the composite material to expand and fill the mold cavity.

[0017] Optionally, the faceplate can be mounted on the opposite surface of the racket body before or after the racket body is placed into the mold. Additionally, an edge protector can be mounted on the racket body around the second part of the core, along its periphery.

[0018] Further forms, objects, features, aspects, benefits, advantages, and embodiments of this utility model will become apparent from the detailed description and accompanying drawings provided herein. Attached Figure Description

[0019] Figure 1 This is a perspective view of a Peak racket.

[0020] Figure 2 yes Figure 1 An exploded perspective view of the racket shown.

[0021] Figure 3 yes Figure 1 The racket shown is a perspective view of its components—core, frame, and edge protection.

[0022] Figure 4 yes Figure 3 A perspective view of the core shown.

[0023] Figure 5 yes Figure 3 The front view of the core shown.

[0024] Figure 6 yes Figure 3 Perspective view of the frame shown.

[0025] Figure 7 yes Figure 3 Top perspective view of the core and frame shown.

[0026] Figure 8 yes Figure 3 Bottom perspective view of the edge protector shown.

[0027] Figure 9 yes Figure 3 Top perspective view of the edge protector shown.

[0028] Figure 10 yes Figure 3 Bottom perspective view of the core and edge protection shown.

[0029] Figure 11 It is used for manufacturing Figure 3 A perspective view of one embodiment of the composite material and central tube of the frame shown.

[0030] Figure 12 It includes Figure 11 A perspective view of the composite material and the roll of the central tube.

[0031] Figure 13 It includes Figure 12 In the roll material and Figure 3 A perspective view of the racket blank in the core area.

[0032] Figure 14 It is a mold and includes Figure 3 A perspective view of the racket's main body, including the core and frame.

[0033] Figure 15 It is manufacturing Figure 1 The flowchart shows the method of using the racket shown. Detailed Implementation

[0034] To facilitate understanding of the principles of this invention, embodiments shown in the accompanying drawings will now be described using specific language. However, it should be understood that this is not intended to limit the scope of the invention. Any changes and further modifications to the described embodiments, as well as any further applications of the principles of the invention described herein, will be readily apparent to those skilled in the art. One embodiment of the invention has been shown in detail, but those skilled in the art should understand that certain features unrelated to the invention may not have been shown for clarity.

[0035] The directional terms used in this specification, such as front, back, up, down, etc., are for reference only to the specific embodiments shown for clarity. However, it should be understood that these terms are not limiting terms.

[0036] This disclosure generally relates to the field of rackets for racket sports (such as pickleball). Aspects of this disclosure include racket cores for such rackets, the racket having a framed portion and a frameless portion. More specifically, the racket core includes a first portion and a second portion defining different widths. The racket includes a frame, a portion of which extends along the racket face and surrounds the first portion of the racket core. The width of the second portion (optionally with edge protection) approximates the total width of the first portion and the frame, such that the transition from the framed portion to the frameless portion has a continuous racket shape.

[0037] This disclosure also relates to a method of manufacturing such rackets. One aspect of this disclosure involves rackets formed using plastic or composite molding materials. More specifically, a sheet of composite material is wrapped around an inflatable bladder and placed in a mold. While the mold is heated, the bladder is inflated, causing the composite material to expand and fill the mold cavity. The material is then cured to form a rigid frame for the racket. For example, U.S. Patent No. 11,597,169 describes a method for manufacturing a racket frame. The frame may be wrapped around a portion of the core before heating and curing, and the heating and curing steps may fuse the frame to the core. A faceplate and edge protectors are added to the core before or after the racket blank and frame are placed in the mold to complete the racket.

[0038] The International Pickleball Federation (IFP) and the USA Pickleball have approved the rules for pickleball championships and international competitions. The rules include requirements for equipment and specify the permissible characteristics of rackets. Pickle rackets must be made of a relatively rigid, incompressible material. The striking surface of the racket must not have holes, dents, textured materials, or any properties that increase the spin of the ball. The racket surface is not permitted to use rubber, synthetic rubber, sandpaper, moving parts that increase momentum, springs or similar spring materials, or flexible membranes or compression materials that create a trampoline effect.

[0039] The stiffness and compressibility of a racket are determined through a deflection test. A common deflection test method involves applying a 3 kg force to the center of the racket. The deflection of the racket under this 3 kg force is recorded to measure its stiffness. A racket with a deflection of no more than 0.005 inches in the 3 kg test meets the stiffness requirements.

[0040] In addition to regulating racket stiffness, the IFP and the US Peak Association also stipulate size requirements. The total length and width of the racket must not exceed 24 inches. These dimensions include any additional length or width added by the siding or sole cap at the end of the racket handle. There are no restrictions on the weight or thickness of the racket.

[0041] Figure 1 and Figure 2 An embodiment of a Peak racket 50 is shown. The racket 50 includes a handle 54 and a racket face 56. The handle 54 is located near the proximal end 64 of the racket 50. The racket face 56 is located near the distal end 66 relative to the handle 54. The racket face 56 comprises a core 80, a frame 110, a front shell 130, and a rear shell 132. The frame 110 is generally arranged along a portion of a first side 60 and a second side 62 of the racket 50. An edge protector 124 may be located at the distal end 66 and a portion of both sides 60 and 62. The front shell 130 defines a front planar surface 68, and the rear shell 132 defines a symmetrical rear planar surface 70. Surfaces 68 and 70 are the portions of the racket face 56 that are struck during play.

[0042] It should be understood that the terms "front" and "back" used to describe the surface and shell of a racket are relative terms and are used to describe the racket shown in the diagram only for ease of description. Similarly, the terms "far end," "near end," and "lateral" used to describe a racket are also relative terms and are used only for ease of description. In actual use, the orientation of the racket and its surface is not important. The racket can be held in any way, and either side of the racket can be used to hit a playing object, such as a pickle.

[0043] The handle 54 may optionally include grip structures located at the front and rear of the handle, such as a panel, cover, or thermoplastic overmolded foam. The handle 54 may also include a handle cap attached to the proximal end 64.

[0044] like Figure 1 , 2As shown in Figure 3, racket 50 has a framed portion 72 and a frameless portion 74. The framed portion 72 includes a frame 110 and the area of ​​racket 50 located between the frames 110. The frameless portion 74 includes the remainder of racket 50. The frame 110 may extend only along a portion of the edge of racket 50. In the illustrated example, the frame 110 extends through the handle 54 and partially extends into the racket face 56. Compared to a conventional framed racket, using a partially framed racket 50 can provide the user with better control when hitting the ball. A conventional frame extends to the entire edge of the racket, making the racket more rigid and allowing the user to bounce the ball with greater force when hitting it. A partially framed racket 50 allows the user to bounce the ball with similar force, but with better control. For example, the frameless portion 74 may be slightly curved, providing the user with better control or "feel". The framed portion 72 can remain rigid, allowing racket 50 to transfer a large amount of energy to the ball when hitting it. When using the partial frame racket 50, users may notice an improvement in control, while the decrease in power is not significant compared to using a conventional frame racket.

[0045] In some embodiments, with the handle 54 at the six o'clock position, the framed portion 72 extends around the racket face 56 from the three o'clock position to the nine o'clock position. In alternative embodiments, the framed portion 72 extends around the racket face 56 from the five o'clock position to the seven o'clock position. In other embodiments, the framed portion 72 extends around the racket face 56 from the two o'clock position to the ten o'clock position. The edge protector 124 may extend precisely around the frameless portion 74, for example, from the nine o'clock position to the three o'clock position, from the seven o'clock position to the five o'clock position, or from the ten o'clock position to the two o'clock position. Alternatively, the edge protector 124 may overlap with the frame 110 at one or more locations.

[0046] like Figure 2-5 As shown, the shape of the core 80 allows the frame 110 to be partially embedded therein. For example, the shape of the core 80 near the framed portion 72 may differ from its shape near the frameless portion 74 to accommodate the frame 110. The core 80 may extend to the periphery of the racket face 56 at the frameless portion 74, but at the framed portion 72, the core 80 may have a recess such that the frame 110 surrounds the core 80 and extends along the periphery of the racket face 56. Shaping the core 80 in this way helps maintain the overall shape of the racket 50, especially the shape of the racket face 56. The frame 110 may be attached to the core 80 by adhesive, welding, or other means.

[0047] The core 80 is located within the racket face 56 of the racket 50 and provides the internal structure for the racket face 56. The core 80 can be made of a generally rigid material, such as plastic. For example, the core 80 can comprise polypropylene, carbon fiber, and / or other types of plastic materials. In the illustrated embodiment, the core 80 is honeycomb-shaped, having multiple hexagonal units. Alternatively, the core 80 can be solid or employ different unit structures. The core 80 can be formed by cutting the desired shape from a larger sheet of material. For example, the core shape can be cut from a larger honeycomb material sheet using a water jet, cutting machine, milling cutter, and / or other tools. Alternatively, the core 80 can be formed using a mold and / or other equipment. Forming the core 80 in this way allows the core 80 to be shaped into a specific form.

[0048] like Figure 5 As shown, the core 80 defines a core periphery 82 around its perimeter. Since the core 80 may have multiple cells, such as a hexagonal honeycomb structure, the outer periphery of the core 80 may be irregular and / or jagged at cell cut points. The core periphery 82 can be defined as an interpolation curve between peripheral points. For example, the core periphery 82 may be the path followed by a water jet and / or other tool when cutting the core 80 from a material plate. The interpolation curve may mirror the shape of the frame 110 and / or edge protector 124, where the frame 110 and / or edge protector 124 are connected to the core 80. Furthermore, one or more cells surrounding the core periphery 82 may be broken. In other words, these holes may not form closed internal regions within the plane of the core 80. Because the holes around the core periphery 82 may have openings or breaks, the core 80 may contain foam and / or other materials to fill these holes. For example, the holes along the core periphery 82 may be filled with foam to form a smooth, continuous portion along the core periphery 82. Filling these holes also prevents small fragments from making a rattling sound inside the cutting holes, such as residual fragments produced when cutting the core 80 using a water jet or other tools. By filling the holes around the core periphery 82, the core 80 can have a tightly bound shape and unwanted noise can be avoided.

[0049] The core 80 defines a core length 84 along a longitudinal axis 86. The longitudinal axis 86 typically extends from a proximal end 64 on the handle 54 to a distal end 66 on the racket face 56. The core 80 also includes a first portion 88 and a second portion 90. The first portion 88 is positioned closer along the longitudinal axis 86 than the second portion 90 relative to the proximal end 64. The first portion 88 and the second portion 90 are typically rectangular with curved sections at the corners. The first portion 88 may define a first pair of parallel edges 96 on a first side 60 and a second side 62 of the core 80. The extension length of the first pair of parallel edges 96 may be between one-quarter and one-fifth of the core length 84. Alternatively, the extension length of the first pair of parallel edges 96 may be one-third or half of the core length 84. Similarly, the second portion 90 may define a second pair of parallel edges 98 on the first side 60 and the second side 62 of the core 80. The extension length of the second pair of parallel edges 98 may be between one-quarter and one-fifth, one-third, or half of the core length 84. The core 80 can be in various shapes to form various racket face shapes on the racket 50.

[0050] The core also defines a first width 92 and a second width 94. A first portion 88 defines the first width 92, while a second portion 90 defines the second width 94. The combined width of the first portion 88 and the frame 110 may approximate the second width 94, or the combined width of the second portion 90 and the edge protector 124. In this document, "approximately" may mean that the difference between the two is within one percent of the finished total width of the racket 50 and / or within 5 mm, 2 mm, 1 mm, or other small distances. In one example, the first portion 88 may define a first width 92 between a first pair of parallel edges 96, while the second portion 90 may define a second width 94 between a second pair of parallel edges 98. The core 80 may include a stepped structure 100 located at the boundary between the first portion 88 and the second portion 90. The first width 92 and the second width 94 may be defined by the first portion 88 and the second portion 90 immediately adjacent to both sides of the stepped structure 100. For example, the first portion 88 may define a first width 92 on the proximal side of the step structure 100, while the second portion 90 may define a second width 94 on the distal side of the step structure 100. The step structure 100 defines a step width 102. The step width 102 may be half the difference between the first width 92 and the second width 94. For example, the core 80 may define equal step widths 102 on its first side 60 and second side 62 at the boundary between the first portion 88 and the second portion 90.

[0051] The core may optionally include a throat 104. The throat 104 may extend into the boundary between the racket face 56 and the handle 54 of the racket 50. In the illustrated embodiment, the core 80 does not extend through the handle 54. Alternatively, the core 80 may be shaped to extend through all or part of the handle 54.

[0052] Figure 6 A frame 110 of one embodiment is shown. The frame 110 is generally rigid and includes a racket face portion 112 and a handle portion 114. In the illustrated embodiment, the racket face shape is generally a rectangle with rounded corners, tapering towards the handle 54. Alternatively, the racket face shape may be perfectly circular, such as a circle or oval, or other shapes. The racket face portion 112 is shaped to fit against the core 80 along a portion of the core periphery 82 (particularly around a first portion 88 of the core 80). The handle portion 114 is generally straight. In some embodiments, the frame 110 is hollow and defines an internal channel 118.

[0053] In the illustrated embodiment, the frame is divided into two individual pieces 116. The two individual pieces 116 may have the same shape. For example, the two individual pieces 116 may be symmetrical about each other along a longitudinal axis 86. Each individual piece 116 may define an internal channel 118. Alternatively, the frame 110 may be a single piece. The two individual pieces 116 may optionally be joined at one or more locations in the handle portion 114, or be joined continuously through the handle portion 114 to form a single, integral frame 110. In one example, the handle 54 of the finished racket 50 may be hollow, with gaps between the individual pieces 116 of the frame. In another example, foam or other filler material may be added to the gaps between the individual pieces 116 of the frame in the handle 54.

[0054] Frame 110 defines a frame thickness 120 at the racket face portion 112. In the example shown, frame 110 defines a consistent frame thickness 120 at both the racket face portion 112 and the handle portion 114. The frame thickness 120 can approximate the combined width of the edge protector 124 and the stepped structure 100 on the core 80. For example, the difference between the frame thickness 120 and the combined width of the stepped structure 100 and the edge protector 124 can be within 1% of the first width 92, the second width 94, and / or the finished total width of the racket 50. As another example, this difference can be in the range of 1 mm, 2 mm, 5 mm, and / or other values. By setting it to approximate the combined width of the stepped structure 100 and the edge protector 124, the frame thickness 120 allows the framed portion 72 and the frameless portion 74 to form an integral shape around the periphery of the racket face 56.

[0055] Alternatively, the frame thickness 120 can be close to the step width 102 to form a monolithic shape around the frame 110 and core 80 before the edge protector 124 is installed. Figure 7As shown, the frame 110 can extend to the stepped structure 100 on the core 80. The total width of the frame 110 and the first portion 88 of the core 80 is approximately equal to the width of the second portion 90 of the core 80, and optionally also includes the thickness of the edge protector 124. For example, the difference between the frame thickness 120 and the stepped width 102 can be within 1% of the first width 92, the second width 94, and / or the finished total width of the racket 50. Alternatively, this difference can be within 1 mm, 2 mm, 5 mm, and / or other values. The framed portion 72 can smoothly transition and be flush with the frameless portion 74 and / or the edge protector 124 to maintain a similar appearance to a conventional racket.

[0056] In some embodiments, the frame 110 may be made of graphite or a composite material. As used herein, “graphite” or “composite material” should have its commonly accepted meaning in the art and generally includes fibers in a resinous material. These fibers are typically made of graphite, carbon, glass, boron, or synthetic fibers (e.g., The composite sheet or prepreg sheet may be formed from fibers arranged in parallel and / or woven in a resin matrix. The frame 110 may be formed by heating and curing the composite material. In an alternative embodiment, the frame 110 may be formed by subtractive manufacturing, for example, by shaping the material using a cutter, milling cutter, waterjet, or other tools.

[0057] Figure 8 and Figure 9 An edge protector 124 according to one embodiment is shown. The edge protector 124 may be disposed on the outer periphery of the racket. The edge protector 124 generally prevents damage to the edge of the racket, especially around the frameless portion 74. Since the core 80 may be exposed at the frameless portion 74, the edge protector 124 can protect the core 80 from damage. The edge protector 124 may be made of rubber, plastic, vinyl, silicone, or any other suitable material for protecting the edge of the racket. In one embodiment, the edge protector 124 extends only to the outer periphery of the racket face 56 on the frameless portion 74. For example, as... Figure 10 As shown, the edge protector 124 may be positioned around the second portion 90 of the core 80 along the core periphery 82, but its extension toward the proximal end 64 does not exceed the stepped structure 100. Alternatively, the edge protector 124 may extend substantially around the periphery of the racket face 56, but not around the periphery of the handle 54, or it may cover selected locations.

[0058] The edge protector 124 may include a lip 126. The lip 126 may cover portions of the front shell 130 and the rear shell 132 on the racket 50. The lip 126 may help secure the edge protector 124 to the racket 50 by providing additional surface area for adhering the edge protector 124 to the racket 50.

[0059] Edge protector 124 defines an edge protector thickness 128. The edge protector thickness 128 can be relatively small compared to the first width 92 and the second width 94 of the core 80. In some embodiments, the edge protector thickness 128 approximates the difference between the frame thickness 120 and the step width 102. In such an embodiment, the paddle face 56 defines a continuous shape at the transition between the frame 110 and the edge protector 124. This arrangement facilitates attaching the edge protector 124 only to the frameless portion 74, and not to the framed portion 72. In an alternative embodiment, the frame thickness 120 approximates the step width 102, such that the frame 110 and the second portion 90 of the core 80 form a continuous shape at the transition between them. For example, the boundary between the frame 110 and the core 80 can be smooth and continuous around the periphery of the paddle face 56. This arrangement facilitates mounting the edge protector 124 around the frameless portion 74 and on the framed portion 72.

[0060] Figures 11 to 15 A manufacturing method 200 for racket 50 is shown. One or more steps in method 200 can be performed manually by an operator or automatically by a machine or equipment. It should be understood that the various steps of method 200 can be performed by different operators or machines.

[0061] like Figure 11 As shown, the manufacturing process first uses a piece of composite material 140 and a central tube 142. In a preferred embodiment, the central tube 142 is an inflatable tubular bladder 143. The bladder 143 is preferably formed as a hollow tube with an open end 144. The other end of the bladder 143 can be closed, optionally using a seal or plug. In an alternative embodiment, both ends 144 of the bladder 143 can also be open. In another alternative embodiment, the central tube 142 can be polyurethane foam or other materials, configured as a strip, solid, or hollow tube.

[0062] In step 210, the composite material 140 is wound around the central tube 142. First, the central tube 142 is longitudinally positioned on the composite material 140. Then, as... Figure 12 As shown, the composite material 140 is tightly wound around the central tube 142 to form a strip-shaped roll 138. The strip-shaped roll 138 has a first end and a second end. The end 144 of the central tube may slightly protrude from the end of the strip-shaped roll 138, especially when the central tube 142 is a tubular capsule 143. In some embodiments, two strip-shaped rolls 138 are formed for each racket 50. For example, it can be... Figure 6 The two frame pieces 116 shown each form a long strip of roll material 138.

[0063] In step 212, the roll material 138 is arranged along the core 80 to form the racket blank 160. For example... Figure 13 As shown, roll 138 is positioned against core 80 along core periphery 82. Roll 138 may extend along a first section of core periphery. For example, roll 138 may be disposed against stepped structure 100 of core 80 and arranged along core periphery 82 toward proximal end 64. The length of roll 138 extends beyond core 80 toward proximal end 64 to form handle 54. In the illustrated embodiment, racket blank 160 includes a first roll 146 arranged along a first side 60 and a second roll 148 arranged along a second side 62. The first roll 146 and the second roll 148 each extend to the vicinity of a first portion 88 of core 80 and extend along handle 54. The first roll 146 and the second roll 148 may be symmetrically arranged relative to each other along longitudinal axis 86.

[0064] The open ends 144 of the first roll 146 and the second roll 148 may be located near the proximal end 64 of the racket 50. In an example using a single roll 138, each end 144 of the roll 138 may be located near the stepped structure 100 of the core 80 of the first side 60 and the second side 62. In such an example, the middle portion of the roll 138 may extend beyond the proximal end 64 of the racket 50 and form a 180-degree curve.

[0065] In step 214, the front shell 130 and the rear shell 132 are placed on the racket blank 160. For example... Figure 13 As shown, the front shell 130 and the rear shell 132 can be placed on the core 80 and the strip-shaped roll 138 before the frame 110 is formed by the heating and curing steps. In another embodiment, the front shell 130 and the rear shell 132 can be attached to the core 80 at another point in the manufacturing process, for example, after the frame 110 has been heated and cured. The front shell 130 and the rear shell 132 can be secured using adhesives or a hot-melt process. Alternatively, fasteners can also be used.

[0066] In step 216, the racket blank 160 is placed into the mold 150. Figure 14In the illustrated embodiment, mold 150 defines a cavity 152 containing a racket cavity 154 and a handle cavity 156. Mold 150 may be a two-part mold, with its top and bottom engaging with each other when closed. A racket blank 160 may be placed in the cavity 152, and a roll 138 may be located simultaneously in both the racket cavity 154 and the handle cavity 156. A core 80 may be located in the racket cavity 154. In an alternative embodiment, mold 150 may define a channel for receiving the roll 138 and shaping the roll 138 into the final shape of the frame 110. Method 200 may optionally include multiple molds and forming steps. For example, in some embodiments, the roll 138 may be placed in a first mold to form the frame 110, and then the core 80, the frame 110, and optionally a front shell 130 and a rear shell 132 may be placed in a second mold for a second forming and / or welding step. The ends of the roll and / or the ends of the bladder 144 may protrude slightly beyond the mold 150, for example, beyond the handle cavity 156.

[0067] In step 218, the mold 150 is heated. Heating the mold 150 causes the composite material 140 in the roll 138 to fuse and form the frame 110. In a preferred embodiment, a compressed gas source is connected to the end 144 of the opening of the bladder 143. In an example with a single roll 138 and bladder 143, the compressed gas source may be connected to only one end 144. The compressed gas may be ambient air, an inert gas, or a non-reactive gas. When the mold 150 is heated, the compressed gas causes the bladder 143 to inflate, thereby stretching the composite material 140 and conforming the shape of the composite material 140 to the mold cavity 152. The composite material 140 inflates and adheres to the core 80, the mold 150, and optionally the front shell 130 and the rear shell 132. In an alternative embodiment, the roll 138 is first placed in a separate mold to be heated and inflated to form the frame 110. The composite material 140 is then cured and fused to form Figure 14 The frame 110 is shown. During this process, the bladder 143 may melt, leaving internal channels 118 and channel openings in the frame 110. In an alternative embodiment, the central tube 142 in the roll 138 may be a foam center, and heating the mold 150 causes the composite material 140 to fuse with the foam center, forming the frame 110 as a single piece.

[0068] In the heating step of step 218, the frame 110 is attached to the core 80 to form the racket body 162. The heating mold 150 may fuse the frame 110 to the core 80, or the core 80 may be attached to the frame 110 in other ways. In another embodiment, the frame 110 may be fused to the core 80 in a separate heating step, for example, using a different mold than the one used in the previous step. In another example, the core 80 may be attached to the frame 110 in a separate step using adhesives or even fasteners. Similarly, the front shell 130 and the rear shell 132 may be fused to the racket body 162 in the heating step of step 218. In another embodiment, the front shell 130 and the rear shell 132 may be attached to the racket body 162 in a separate step.

[0069] After the curing process is complete, in step 222, the racket body 162 is removed from the mold 150. The racket body 162 is then allowed to cool outside the mold 150. In some embodiments, the internal channel 118 left in the finished frame 110 by the bladder 143 is empty. In other embodiments, the channel 118 may be filled with a filler material, such as foam, rubber, or silicone. The filler material can be used to provide additional support for the racket 50 and can also reduce sound or vibration when the racket 50 hits a playing object (e.g., a pickle). Furthermore, the racket body 162 may be sanded with putty and / or sandpaper to remove any imperfections on surfaces 68 and 70. After sanding with putty or sandpaper, paint and / or decals may be applied to surfaces 68 and 70.

[0070] In step 224, the edge protector 124 is attached to the racket body 162. In the illustrated embodiment, the edge protector 124 is attached after the face shells 130 and 132 are attached to the racket 50. The edge protector 124 can be attached using adhesive or a hot-melt process. In another embodiment, the edge protector 124 can be attached before the face shells 130 and 132 are attached. Optionally, a grip structure can be added to the handle 54, such as in the form of a panel, a cover, or overmolded foam.

[0071] According to any embodiment herein, the hitting characteristics of racket 50 can be selected or customized based on the arrangement of frame 110. The shape of the frame affects the weight distribution of racket 50. When frame 110 extends to the 9 o'clock and 3 o'clock positions of racket face 56, with handle 54 set at the 6 o'clock position as a reference, racket 50 may have a specific balance point and rebound characteristics. Using frame 110 extending to the 7 o'clock and 5 o'clock positions of racket face 56 may change the balance point and rebound characteristics of racket 50. For example, when using a frame at the 5 o'clock to 7 o'clock positions, the balance point may be closer to the proximal end 64 of racket 50 than when using a frame at the 3 o'clock to 9 o'clock positions. As another example, when using a frame extending to the 10 o'clock and 2 o'clock positions, the optimal hitting point may be closer to the distal end 66. Generally, at the optimal hitting point, more rebound energy is transferred to the ball compared to other parts of the racket. Moving the balance point of racket 50 moves the optimal hitting point of the racket. Adjusting the ratio of the framed portion 72 to the frameless portion 74 affects the balance point and the optimal hitting point. Players can choose a racket with the best combination of framed and frameless portions to move the optimal hitting point to the best position suitable for that player.

[0072] Adjusting the material of frame 110 allows for further fine-tuning of the balance point and rebound characteristics of racket 50. Using a framed portion 72 that is larger than the frameless portion 74 increases the stiffness of racket 50. Increasing the stiffness of racket 50 allows it to transfer more rebound energy to the ball, resulting in greater hitting power. Lower stiffness can exchange some power, giving the player better control. Optionally, the material of frame 110 can be changed to increase or decrease its stiffness at one or more locations. In some embodiments, the material composition of frame 110 can be altered by changing the material on the strip roll 138 or by adding more material at precise locations on the strip roll 138. Optionally, materials such as glass fiber, Kevlar fiber, or ceramic can be added to selected portions of roll 138 to affect strength, stiffness, flexibility, density, or other properties.

[0073] Although the present invention has been described in detail in the accompanying drawings and the foregoing description, these descriptions should be regarded as illustrative rather than restrictive. It should be understood that only preferred embodiments have been shown and described, and it is intended to protect all variations, equivalents and modifications that fall within the spirit and scope of the present invention as defined by the claims.

Claims

1. A Peak racket, characterized in that, include: The core portion located in the face of the racket includes: A first portion positioned near the proximal end of the racket, the first portion defining a first width from a first side of the racket to a second side of the racket; A second portion located at the distal end of the first portion, the second portion defining a second width from the first side to the second side; and A stepped structure located at the boundary between the first part and the second part; Wherein, the first portion defines the first width adjacent to the stepped structure and located on the proximal side of the stepped structure; The second portion defines the second width adjacent to and located on the distal side of the step structure; and The first width is smaller than the second width.

2. The racket of claim 1, wherein the core is formed of a plurality of units arranged in a honeycomb pattern; wherein the core is shaped by cutting the core from a material larger than itself; and wherein one or more units along the periphery of the core are destroyed.

3. The racket of claim 2, wherein the core comprises foam within a unit along the periphery of the core.

4. The racket of claim 1, wherein the first portion defines a first pair of parallel edges located on the first side and the second side, the first pair of parallel edges extending along the length of the core; The first portion defines the first width between the first pair of parallel edges; The second portion defines a second pair of parallel edges located on the first side and the second side, the second pair of parallel edges extending along the length of the core; and The second portion defines the second width between the second pair of parallel edges.

5. The racket of claim 4, wherein the first pair of parallel edges extends to a length between one-fifth and one-quarter of the length of the core.

6. The racket according to claim 1, characterized in that, Also includes: A frame attached to the core, the frame being positioned near the proximal end of the racket, wherein the frame is positioned adjacent to the first portion of the core and extends to the stepped structure of the core; The frame and the core define the framed portion of the racket, including the first portion of the frame and the core; and The second portion of the core defines a frameless portion of the racket, the frameless portion extending toward the distal end of the racket and beyond the frame.

7. The racket according to claim 6, characterized in that, Also includes: An edge protector attached to the racket face, wherein the edge protector extends along the frameless portion and surrounds the second portion of the core.

8. The racket of claim 7, wherein the frame defines a frame thickness, the step structure defines a step width, and the edge protector defines an edge protector thickness. The frame thickness is approximately the combination of the step width and the edge protection thickness, and the difference between the two is less than one percent of the total width of the finished racket.

9. A Peak racket, characterized in that, include: The core of the racket face, the core extending through the racket face, wherein the core defines a core periphery and has a first portion and a second portion; as well as A frame, wherein the frame extends toward the proximal end of the racket into the handle of the racket and partially into the racket face, and wherein the frame is attached to the core along the periphery of the core at the first portion of the core; The frame defines the framed portion of the racket, including the frame and the area of ​​the racket located between the frame; and The frameless portion of the racket extends toward the distal end of the racket and beyond the frame, the frameless portion including the remainder of the racket other than the framed portion, and the frameless portion including the second portion of the core.

10. The racket of claim 9, wherein the core defines a first width at the first portion and a second width at the second portion; and wherein the first width is smaller than the second width.

11. The racket of claim 10, wherein the core includes a stepped structure at the boundary between the first portion and the second portion; wherein the stepped structure defines a stepped width; wherein the frame defines a frame thickness; and wherein the stepped width is approximately equal to the frame thickness, and the difference between the two is within one percent of the total width of the finished racket.

12. The racket according to claim 9, characterized in that, Includes an edge protector, wherein the edge protector is attached to the second portion of the core and positioned along the frameless portion of the racket.

13. The racket according to claim 9, wherein, With the handle positioned at a reference point at 6 o'clock, the frame extends to the circumferential positions at 3 o'clock and 9 o'clock around the core.

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