Composite sports paddle including distal frame separation and method

Abstract

A composite sports paddle with distal frame separation addresses the need to separate the performance characteristics of the front face and back face structures, even when the ball strikes only one face. It introduces a separation of the face plies to act independently and separates the distal frame while maintaining rigidity along the paddle's distal portion. By focusing on these independent structures, the overall performance of the paddle is enhanced and paddle meets the demands of today's players.

Description

114564-0005W001COMPOSITE SPORTS PADDLE INCLUDING DISTAL FRAME SEPARATION AND METHODField of the Invention

[0001] The subject matter herein relates generally to composite sports paddles, wherein the manipulation at impact of the ball and paddle produces beneficial outcomes depending on the style of play of the individual striking the ball. Players may focus on power, control, or the amount of spin they produce over the ball at impact, with many seeking a combination of all three attributes. Additionally, the tactile feedback or "feel" of the paddle during play and the exit velocity of the ball post-impact are critical factors that influence performance and player preference.Background

[0002] Originally, paddles were constructed from wood, which had significant performance limitations due to their heavy weight and lack of advanced performance characteristics. The performance of these wooden paddles was restricted by their inherent material properties, which did not allow for the optimization of factors such as stiffness, weight distribution, and vibration control.

[0003] In more recent times, the introduction of honeycomb cores with a sandwich type structure made from materials such as aluminum, Nomex, PPE plastics, and hybrids of these materials has significantly advanced paddle design. These honeycomb-sandwich structures improved to provide a lighter weight structure, compared to wood, a strong face laminate bonded to a honeycomb core thus enhancing the overall performance of the paddle. However, these honeycomb structures still have significant limitation. The cores are typically combined with face-bonded structures made from high-performance fibrous materials such as fiberglass, Nomex, or carbon fiber. These face materials offer superior strength, stiffness, and impact resistance compared to traditional wood, however the PPE, Nomex, and Aluminum cores still have significant limitation to strength, bending, compression and performance.

[0004] Further advancements have led to the development of more sophisticated core structures using fibrous unidirectional carbon fiber, glass fiber, or similar materials. These new core structures are internally pressurized and molded with the handle, face plies, core, and distal frame structures, all integrated into a single, cohesive unit. This innovation provides several key advantages:114564-0005W001 / 9803171.1114564-0005W001Higher Performance: The integration of advanced materials and pressurized core structures enhances the paddle's responsiveness and energy transfer capabilities, resulting in better ball control and increased power.Improved Strength-to-Weight Ratios: The use of lightweight, high-strength materials allows for the creation of paddles that are both strong and easy to handle, reducing player fatigue during extended play.Extended Paddle Lifespan: The durability of advanced composite materials extends the useful life of the paddle, providing players with a longer-lasting piece of equipment.Precise Engineering: The ability to mold all structures together into a single unit enables precise control over the paddle's mechanical properties, allowing for the optimization of specific attributes tailored to each paddle's intended use and aid to improve or more efficiently control Coefficient of Restitution ratios between ball and paddle collision.

[0005] Players today demand high-performance equipment that meets their specific needs. Even with advancements in performance, durability, and manufacturing consistency, challenges remain in satisfying all players' performance requirements.Summary

[0006] An aspect of the present disclosure introduces a new level of sophistication by focusing on the performance of each independent structure within the paddle, including the core, handle, face, distal frame, and the transition between the handle and paddle face. Each of these structures significantly influences the overall performance, feel, and style of play.

[0007] The distal frame structure, which connects the handle to the face and links the front and back faces of the paddle around the perimeter, contributes to the paddle's torsional and bending stiffness. Modem players seek longer dwell times between the ball and paddle while maintaining the power and energy transfer, requiring specific stiffness from the distal structure, core structure, and transition between the face and handle.

[0008] The aspect of the present disclosure addresses the need to separate the performance characteristics of the front face and back face structures, even when the ball strikes only one face. It introduces a separation of the face plies to act independently and separates the distal frame while maintaining rigidity along the paddle's distal portion. By focusing on these- 2 -114564-0005W001 / 9803171.1114564-0005W001 independent structures, the overall performance of the paddle is enhanced and paddle meets the demands of today's players. The distal frame structure may be applied to fully molded structures with Solid Span Technology (SST®) (e.g., solid carbon-fiber ribbed) composite structure as shown and described in U.S. Pat. No. 10,377,093 (EXHIBIT A), which is incorporated herein, honeycomb core, close-cell foam core, or a combination of these. The distal frame structure may include a damper and / or a perimeter weight system.

[0009] Another aspect of the disclosure involves a composite sports paddle comprising a handle; a transition section; and a composite paddle head coupled to the handle through the transition section, the composite paddle head including a distal frame with an edge, the edge of the distal frame including two sections and a gap between the two sections, creating distal frame separation, allowing the two sections to act independently while maintaining rigidity along the distal frame.

[0010] One or more implementation of the above aspect of the disclosure includes one or more of the following: an elastomeric material in the gap to absorb impact to the distal frame; the elastomeric material extends outside of the gap; the elastomeric material partially covers the edge; the elastomeric material is an edge guard that covers the edge; the elastomeric material of the edge guard is thinner in the gap compared to outside of the gap, creating a thin flex area in the gap that allows more flex than thicker areas of the edge guard outside of the gap; the composite paddle head include a solid carbon-fiber ribbed core, a honeycomb core, and / or closed-cell foam core; a method of using the composite sports paddle comprising striking a ball with the composite paddle head of the composite sports paddle in the distal frame with one of the two sections; and inhibiting vibrations in the one of the two sections created from striking the ball from passing to an other of the two sections with the gap between the two sections; and / or the composite sports paddle further includes an elastomeric material in the gap, and inhibiting vibrations includes absorbing vibrations in the one of the two sections created from striking the ball with the elastomeric material in the gap between the two sections.Brief Description of Drawings

[0011] The accompanying drawings, which are incorporated in and form a part of this specification illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention.

[0012] FIG. 1 is a side view of a composite sports paddle with distal frame separation;- 3 -114564-0005W001 / 9803171.1114564-0005W001

[0013] FIG. 2 is a front view of the composite sports paddle of FIG. 1 with distal frame separation;

[0014] FIG. 3A is a side view of a frame edge with distal frame separation similar to that shown in the composite sports paddle of FIGS. 1 and 2;

[0015] FIG. 3B is a side view of a frame edge similar to that shown in FIG. 3A, but with a rubber-like membrane shown incorporated in the frame edge;

[0016] FIG. 4 is a side view of a frame edge similar to that shown in the composite sports paddle of FIGS. 1-3B, but with a rubber protective edge guard (or Bumper with Flex Zone) shown incorporated in the frame edge.

[0017] FIG. 5 illustrates example core structures that may used in the composite sports paddle with distal frame separation.Description of Embodiment of the Invention

[0018] With reference to FIGS. 1-5, embodiments of a composite sports paddle 100 with distal frame separation 110 will be described.

[0019] The composite sports paddle(s) 100 with distal frame separation (or a split frame) 110 shown in FIGS. 1-4 address the need to separate the performance characteristics of a front face structure 120 and a back face structure 130, even when the ball strikes only one face 120, 130. It introduces a separation of face plies 140 to act independently and separates a distal frame 150 into segmented tubular sections 190 while maintaining rigidity along a distal portion 160 of the paddle 100. By focusing on these independent structures, the overall performance of the paddle 100 is enhanced and the paddle 100 meets the demands of today's players.

[0020] The distal frame 150 has an internal tubular structure made from carbon fiber that is pressurized using either a chemical expansion system or air pressure. Traditionally, the distal frame structure is designed with various curvatures to create strength and rigidity. This structure not only provides overall strength to the paddle but also connects the front face and back face ofthe paddle, thereby increasing stiffness and limiting bending ortorsional moments. Additionally, the distal frame acts as a pathway for sound and vibration and, thus, separating the frame into two sections allows for further manipulation of frequencies to customize feel on a paddle’s design to meet a tailored feel.- 4 -114564-0005W001 / 9803171.1114564-0005W001

[0021] By breaking up the distal frame structure into segmented tubular sections 190, more flex and disruption of the pathway for unwanted vibrations is introduced, thereby minimizing or altering frequency or sound waves. This disruption leads to improved control over the bending and torsional stiffness of the paddle 100, resulting in a more accurate and controllable ball response upon impact. Segmenting the distal frame 150 can also provide a customized feel while maintaining a desired Coefficient of Restitution (COR) upon the ball and paddle strike.

[0022] Specifically, when the ball strikes a center 170 of the paddle 100, the rigidity and stiffness of the original design are retained. However, when the ball is struck closer to edge(s) 180 of the paddle 100, separating the tubular sections 190 of the distal frame 150 with a separation (e.g., space, gap, channel) 200 becomes more beneficial. This segmentation / separation 200 allows for more flex and vibration control near the edges 180, enhancing the performance of the paddle 100 in off-center hits and providing a more forgiving and responsive play experience.

[0023] Further, as shown in FIG. 3B, an elastomeric (e.g., rubber-like) membrane 210 may be introduced between the segmented / spaced tubular sections 190. This membrane 210 serves multiple purposes: it enhances the aesthetics of the paddle 100, provides additional protection to the distal frame 150, allows for finer control over stiffness, contributes to damping unwanted vibrations, and utilizes the elastomeric membrane 210 to manipulate perimeter weighting to improve swing speed and twist weight. The membrane 210 can be a continuous piece or segments to target specific areas to customize perimeter weight.

[0024] Still further, as shown in another embodiment in FIG. 4, an elastomeric (e.g., rubber) protective edge guard or bumper 220 with flex zone / thin flex area 230 be introduced between segmented tubular sections 240 of a split distal frame 250 of a paddle 260. Compared to FIG. 3, an edge 270 of the split distal frame 250 of FIG. 4 is more rectangular to accept the bumper 220, which may be an adhesive that is bonded to carbon fiber wall 280 of the edge 270, forming the elastomeric protective edge guard or bumper 220. The elastomeric protective edge guard or bumper 220 allows the carbon fiber wall 280 of the split distal frame 250 to be generally thinner because, more of the elastomeric edge guard or bumper 220 is used to absorb impact rather than the carbon fiber. The flex zone / thin flex area 230 of the elastomeric protective edge guard or bumper 220 has a thin curved section (or thin flex area) to allow for the bumper to flex as the split distal frame 250 is compressed upon ball impact at a face 290, 300 of the paddle 260. In embodiments where an inside edge 310 of the paddle 260 is filled- 5 -114564-0005W001 / 9803171.1114564-0005W001 with a soft EVA foam 320, the paddle face 290, 300 is allowed to flex at the edge 270. With the elastomeric rubber protective edge guard or bumper 220 introduced in a separation (e.g., space, gap, channel) 330 between segmented tubular sections 240 of the split distal frame 250, the edge guard / bumper 220 is designed to also flex, in a controlled manner, with the face 290, 300 of the paddle 260 upon ball impact. The thin curved section (or thin flex area) creates the flex zone 230 in the edge guard / bumper to help separate the load when the ball impacts the paddle face 290, 300. In contrast, if the edge guard / bumper 220 remained rigid (no elastomeric protective edge guard), the load would transfer to the opposite face 290, 300 and, thus, limit the intended technology of the paddle 260, cause additional stress on the edge guard / bumper 220, and possibly cause premature separation of the edge guard / bumper 220 and split distal frame 250.

[0025] As shown in FIG. 5, in alternative embodiments including the rubber protective edge guard / bumper 220, the paddle 100, 260 is constructed with a core 350 that is one or more of a solid carbon-fiber ribbed (e.g., SST) core 360, a honeycomb core 370, and / or close-cell foam core 380.

[0026] Additionally, a handle 400 and transition section 410 between the handle 400 and head 420 is maintained closed to retain stiffness and torsional rigidity. This design ensures that the paddle remains robust and stable during play. Opening mostly the distal portion of the paddle 100, 260 allows for better performance by optimizing flexibility and vibration control where it is most needed.

[0027] Alternative embodiments include fully or partially opened sections to further enhance performance and customization options for different play styles and preferences. Advanced composite materials and hybrid constructions may be used to improve the paddle's mechanical properties and durability.

[0028] Advantages of the segmented distal frame structure include:Enhanced Flexibility: By breaking up the traditional continuous distal frame, we can introduce controlled flex points that enhance the paddle’s responsiveness and provide better control over the ball's trajectory.- 6 -114564-0005W001 / 9803171.1114564-0005W001Vibration and Sound Management: The segmentation disrupts the direct pathway for vibrations, reducing unwanted vibrations and minimizing noise. This can lead to a more comfortable playing experience and potentially a more desirable acoustic profde.Precision in Stiffness Control: We can precisely control the bending and torsional stiffness of the paddle, tailoring it to provide the ideal balance of power and control for the player.Optimized Ball Response: Maintaining the COR while introducing a segmented structure ensures that the paddle remains efficient in energy transfer, delivering a consistent and predictable response upon ball impact.Rubber-like Membrane Benefits: The introduction of a rubber-like membrane between the segmented sections improves aesthetics, offers additional frame protection, allows for nuanced stiffness adjustments, and enhances vibration damping. Retention of Core Stiffness: By keeping the handle and transition sections closed, we retain essential stiffness and torsional rigidity, ensuring overall structural integrity and stability.

[0029] The figures may depict exemplary configurations for the invention, which is done to aid in understanding the features and functionality that can be included in the invention. The invention is not restricted to the illustrated architectures or configurations, but can be implemented using a variety of alternative architectures and configurations. Additionally, although the invention is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features and functionality described in one or more of the individual embodiments with which they are described, but instead can be applied, alone or in some combination, to one or more of the other embodiments of the invention, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus, the breadth and scope of the present invention, especially in the following claims, should not be limited by any of the abovedescribed exemplary embodiments.

[0030] Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as mean “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; and adjectives such as “conventional,” “traditional,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item- 7 -114564-0005W001 / 9803171.1114564-0005W001 described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, a group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and / or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and / or” unless expressly stated otherwise. Furthermore, although item, elements or components of the disclosure may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated. The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent.114564-0005W001 / 9803171.1

Claims

114564-0005W001CLAIMS1. A composite sports paddle, comprising: a handle; a transition section; and a composite paddle head coupled to the handle through the transition section, the composite paddle head including a distal frame with an edge, the edge of the distal frame including two sections and a gap between the two sections, creating distal frame separation, allowing the two sections to act independently while maintaining rigidity along the distal frame.

2. The composite sports paddle of claim 1, further including an elastomeric material in the gap to absorb impact to the distal frame.

3. The composite sports paddle of claim 2, wherein the elastomeric material extends outside of the gap.

4. The composite sports paddle of claim 3, wherein the elastomeric material partially covers the edge.

5. The composite sports paddle of claim 3, wherein the elastomeric material is an edge guard that covers the edge.

6. The composite sports paddle of claim 5, wherein the elastomeric material of the edge guard is thinner in the gap compared to outside of the gap, creating a thin flex area in the gap that allows more flex than thicker areas of the edge guard outside of the gap.

7. The composite sports paddle of claim 1, wherein the composite paddle head include a solid carbon-fiber ribbed core, a honeycomb core, and / or closed-cell foam core.

8. A method of using the composite sports paddle of claim 1, comprising: striking a ball with the composite paddle head of the composite sports paddle in the distal frame with one of the two sections;- 9 -114564-0005W001 / 9803171.1114564-0005W001 inhibiting vibrations in the one of the two sections created from striking the ball from passing to an other of the two sections with the gap between the two sections.

9. The method of claim 8, wherein the composite sports paddle further includes an elastomeric material in the gap, and inhibiting vibrations includes absorbing vibrations in the one of the two sections created from striking the ball with the elastomeric material in the gap between the two sections.- 10 -114564-0005W001 / 9803171.1

Images